Drying, Curing and UV
Automated In-Line Moisture Monitoring Increases Productivity: Reduces waste and energy costs and improves process eff iciency By Sarah Hammond, MoistTech
I
ncorporating the right combination of automation tools can help production facilities overcome challenges posed by outdated machinery and labour-intensive procedures that hinder overall productivity. One key example is automated moisture monitoring, where the “steel collar” worker automates mundane, repetitive and time-consuming tasks, allowing valuable human resources to focus on more critical jobs and eliminate ineffi ciencies that hinder peak production. When installed directly on production lines, automated moisture monitoring reduces human error inherent in time consuming and outdated manual processes. Incorporating moisture measurement during production allows the user to create a closed-loop process and have full control over the production line. While several methods are available, the use of near-infrared (NIR) technology can produce a high return on investment (ROI).
BENEFITS OF MOISTURE CONTENT MEASUREMENT EQUIPMENT AND PROCESSES
Moisture measurements are used throughout many manufacturing processes, from examining incoming raw materials, to ensuring fi nal product quality and shipping weight. Moisture ranges outside of tolerance can inhibit the production process and even create wear and tear on other equipment. In the past, many fi rms have relied on manual moisture testing and measurement methods, but these old school methods are notoriously subject to errors and are a known primary cause of many production issues. Manual moisture monitoring essentially requires a laboratory setup in a controlled environment. Samples need to be immediately sealed in plastic or glass jars once taken from the production line for testing. The moisture content will naturally change every minute that passes once the sample is removed from the production line, throwing off the fi nal results. Older manual testing methods often lose the ability to test samples accurately. Moisture control systems automate and
controlled using real-time measurements, in-line systems in feedback-loops often produce a high return on investment (ROI).
accelerate many of these mundane inspection-based quality tasks. Adding the automation of moisture detection throughout the production process can eliminate frequent mistakes and allow for a closed loop process when tied directly into a programmable logic control (PLC) system. With critical points of production being monitored for moisture content, everything from the raw material to the fi nished product can be precisely monitored for accuracy and quality. In addition, moisture measurement systems tied into the process controller can easily detect out of spec products so they can be dealt with immediately, ensuring additional product is not aff ected. When issues are identifi ed early, corrections can be made long before an imperfect or contaminated product reaches consumers. Real-time process control with moisture detection provides true product data that can be used to improve operation effi ciency. This reduces wasted eff ort and materials, and decreases the frequency of downtime, manual intervention and defective goods. Real-time control of moisture leads to signifi cant cost savings, in terms of energy, spoilage, down time, quality control rejects and customer complaints. For processes that can be closely
AUTOMATED IN-LINE MOISTURE MEASUREMENT TECHNOLOGIES Several technologies are available for automated in-line moisture measurement. One such method that greatly improves quality is near-infrared (NIR) technology, which uses a simple light source for measurement. NIR moisture measurement is a fast, non-destructive, non-contact method of measuring and controlling moisture content that off ers clear advantages over the traditional methods, including ease-of-use, elimination of hazardous chemicals and increased effi ciency of product testing. With NIR analysis, all manual steps of collecting, drying and accurately weighing samples are eliminated. When incorporated throughout the production process, NIR technology greatly improves quality. NIR moisture sensors give manufacturers the ability to adjust moisture levels on real-time information, lowering raw material and fuel costs, higher yields and more uniform products. Allowing the moisture measurement to be automated with high and low alarms built into the system allows for personnel to focus on other aspects of the process while maintaining accuracy in moisture control. It reduces human error, increases plant effi ciency from the automated process and frees up man hours for other tasks that cannot be automated.
IMPROVE QUALITY BY INCORPORATING AUTOMATED MOISTURE MEASUREMENT Quality and consistency are crucial when it comes to maintaining a manufacturing line. Implementing an automated moisture control sensor instantly reduces waste and energy costs as well as improves the effi ciency of the line. In many cases, manufacturers can achieve a very favourable ROI. For more information, visit
https://www.moisttech.com
30
February 2025
www.convertermag.com
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