Essential Quality Control: A Reference Guide to Increased Efficiency

Essential Quality Control: A Reference Guide to Increased Efficiency
Reducing front-end expenses and increasing quality and efficiency has always been a top priority for producers, highlighting the need for companies to thoroughly evaluate their current methods of reducing waste – wasted efforts, wasted energy, and wasted product.

Evaluating and implementing lean manufacturing principles assists in eliminating waste and improving overall plant production. With implemented moisture control, manufacturing plants can find large money savings in a short amount of time.

When considering the many challenges plant operators are tasked with, moisture control plays a large role. Moisture content can affect the product quality and equipment function, making it a crucial implementation in proactive avoidance of quality control issues. Dryer effectiveness is critical as they consume a large amount of energy to operate, the implementation of moisture measurement before and after the dryer provides immediate control over the temperature and operational efficiency.

Moisture measurement and control sensors are located in countless applications all over the world, savings manufacturers time and money by quickly detecting the variable manufacturing process, allowing corrections to be made in real-time. Near-Infrared (NIR) technology is best suited for instant on-line, off-line, and laboratory moisture instrumentation. Moisture levels in powder, bulk, and granular application production is a critical component during various stages of production as it can easily become too wet or dry, immediately causing production and quality issues.

Ideally, a moisture control system should be able to accurately detect moisture at different stages of the manufacturing process, be easy to maintain, and be tough enough to withstand the harsh, abrasive nature of the raw materials and production environment. The installation of a NIR moisture detection device prevents bad/out-of-spec products due to undesirable moisture levels, allowing the facility to fine-tune the setup to make sure a more consistent, higher quality product is being produced, which ultimately improves the bottom line. Save money, time and prevent negative results due to inconsistencies and human error.

Over-drying a product can result in a dusty, ambient environment that can also result in a fire or dust explosion. Significant cost savings and product quality, as well as plant safety, are achieved with a proper moisture measurement system. The overuse of dryers results in overpaying energy costs. By implementing a moisture detection process, producers can monitor 100% of their product quality instantly and consistently; active adjustments can continuously be made to the process, optimizing the outcome.

Preventing airborne dust and controlling the weight of the ash residue can be controlled by reading the moisture levels during processing. Data collection and analysis during the production process helps to determine the characteristics of the material prior to final processing which provides process efficiency and optimization. Regular measurements of moisture in manufacturing lines remain necessary for drying control, which reduces treatment costs.

NIR moisture control technology helps provide top-of-the-line equipment to manufacturing facilities in a multitude of applications. A ratio-based measurement with a prime beam eliminated sensitivity to distance, improved stability and accuracy and provides a non-drifting design. These features allow for extremely accurate measurements with high sensitivity. NIR technology is specific and stands out among others for its ability to never come in contact with the product, is non-destructive, and provides instant, repeatable results.

Benefits of a Moisture Control System

Manufacturers can see a multitude of benefits with a moisture control system suited for their application including:

  • Reduce dryer usage & energy costs
  • Proper control of the infeed & dryer exit
  • Better quality & consistency of final product
  • Dust & fire elimination
  • Reduced purchase costs from water weight
  • Reduced amount of wear & tear on equipment from ash & dust buildup
  • Prevent blockages on conveyor

Manufacturers can enjoy immediate adjustments to the process based on real-time measurements as the sensor reads and records hundreds of data points per second. Immediate changes can be made to the production line directly through the PLC I needed, to stop extra waste and keep the production line moving effectively.  Avoid costly downtime and excessive waste by catching any out-of-tolerance readings as quickly as possible. Connect the sensors to a computer network or production laptop for complete software control of the production line – creating a closed-loop process.

This article is published by

MoistTech Corp. is the original manufacturer of Near-Infrared (NIR) technology in the Industrial Moisture industry, manufacturing a range of on-line sensors & at-line instruments for moisture measurement and real-time moisture process control.

MoistTech Corp.