SUCCESSFUL INSTALLATIONS of ON-LINE NIR MOISTURE GAUGES IN FOOD PROCESSES

Transcription

1 SUCCESSFUL INSTALLATIONS of ON-LINE NIR MOISTURE GAUGES IN FOOD PROCESSES Hartmut Federle Department ProductEngineering 1

2 Contents What means industry by successful installation s 5. Workshop Water in Food Lausanne

3 Examples of Moisture Measurement Snack Foods Milk Powder Coffee Flour Cereals Ingredients Sugar Chocolate Biscuits Breadcrumbs Milk Powder Tea Gluten meal Animal foods Potato flakes Noodles Cheese Starch Workshop Water in Food Lausanne

4 installation in industry quality assurance production efficiency low cost of ownership Workshop Water in Food Lausanne

5 Objectives - Quality Assurance High stability reading High accuracy at any time Low influence on changing environmental conditions Linearity over whole range High sensitivity to moisture Workshop Water in Food Lausanne

6 Objectives - Production Efficiency Reduced wastage Production running at set point Immediate process information Easy operating Savings in labour costs High reliability Workshop Water in Food Lausanne

7 Objectives - Low Cost of Owner Ship Simple and quick installation Easy set up Minimal service Plug and forget Robust system Low cost of spare parts Quick response on service demand Integration in existing field bus systems Low investment costs Workshop Water in Food Lausanne

8 Gauge 710 Light Path Source lamp Off-axis collecting mirror Outgoing beam Internal reference Collected light Filter wheel 130rps Segmented mirror Primary detector Secondary detector Lapdog beam splitter Source: NDC Infrared Engineering Workshop Water in Food Lausanne

9 Examples of Integrated Moisture Measurements PowderVision PV710 PharmaView PH710 Source: NDC Infrared Engineering Workshop Water in Food Lausanne

10 Examples of on-line s SPECTRA QUAD Powder sampler option Source: Thermo Electron Corporation PROCESS SENSORS CORP Workshop Water in Food Lausanne

11 Gauge Design - Quality Needs High speed of filter wheel Low noise High quality of filters Sophisticated algorithms Insensitive to path height changes Insensitive to ambient light Insensitive to product temperature Automatic compensation of source changes Workshop Water in Food Lausanne

12 System Design - Production Needs Correct product from start to stop Closed loop control Reduced routine quality checks Continuously monitoring the moisture Simple change of recipe parameters Operator information about problems Long life time of the lamp Workshop Water in Food Lausanne

13 System Design Owner Ship Needs Simple installation over conveyor belts Reliable sampling systems for powder application in tubes, fluid beds or closed conveyors Pre-calibrated to start immediately Improved calibration procedure Long life time of source lamp and motor Fast service on demand Housing protection IP 65/Nema 4 Interfaces available like Ethernet TCP/IP, Profibus, Modbus, Devicenet Workshop Water in Food Lausanne

14 Hard Environmental Conditions Workshop Water in Food Lausanne

15 Workshop Water in Food Lausanne

16 Calibration Why Results are different from lab values Product shows different behaviour New developed product Process changes Gauge problem Workshop Water in Food Lausanne

17 Different Methods for Calibration Pre-calibrated s by factory set up Calibrating by Trim adjustments manually and automatically (Autotrim) Full calibration Workshop Water in Food Lausanne

18 Calibrating by Trim adjustments Gauge reading Span Zero Reference value Workshop Water in Food Lausanne

19 Steps for Calibration Choose calibration function at the panel Start data acquisition and sampling Take samples - 5 times - plastic bag sealing Source: NDC Infrared Engineering Workshop Water in Food Lausanne

20 Steps for Calibration Samples over the full range ( % Standard deviation expected magnitude Apply laboratory reference method Transfer lab data to system Source: NDC Infrared Engineering Workshop Water in Food Lausanne

21 Calibrating Over Full Range [%] Gauge reading Moisture (oven) [%] Workshop Water in Food Lausanne

22 Calibration Cycle dryer Processed material Sampling Results Laboratory test - Sampling - Sample preparation - Oven test - Data evaluation Workshop Water in Food Lausanne

23 Calibration Cycle dryer Processed material Results Sampling Laboratory test - Take samples - Measurement in seconds - Data evaluation Workshop Water in Food Lausanne

24 moisture measurement results in - improved product quality and consistency - higher production efficiency - cost savings Avoid calibration hunting Increase process know how New tasks for Quality Department - control the on-line s Workshop Water in Food Lausanne