Incorporating moisture measurement during production reduces waste and energy costs and improves process efficiency.
By Sarah Hammond
Incorporating the right combination of automation tools can help waste production facilities overcome challenges posed by outdated machinery and labor-intensive procedures that hinder overall productivity. One key example is automated moisture monitoring, where the 鈥渟teel collar鈥� worker automates mundane, repetitive, and time-consuming tasks, allowing valuable human resources to focus on more critical jobs and eliminate inefficiencies that hinder peak production. When installed directly on the production line, automated moisture monitoring significantly reduces human error inherent in time consuming and out-of-date manual processes.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 final product quality and shipping weight. Moisture ranges outside of tolerance can inhibit the production process and even create wear and tear on other equipment. Each phase of the manufacturing process runs more efficiently and profitably with accurate moisture content.
In the waste industry, moisture content plays a critical role in various processes, making moisture monitoring essential for optimizing operations, reducing costs, and improving environmental compliance. Moisture affects multiple aspects of waste management: in landfill operations, it influences waste compaction, decomposition rates, and leachate generation, allowing for better space utilization and reduced environmental impacts when properly controlled. For composting, maintaining optimal moisture levels is crucial for efficient decomposition and producing high-quality compost. In waste-to-energy plants, the moisture content of waste directly impacts its calorific value, which in turn affects energy production efficiency.
Moisture also plays a significant role in recycling processes, influencing the quality and recyclability of materials such as paper, cardboard, and certain plastics. Additionally, excess moisture in waste can increase transportation costs and potentially lead to weight regulation violations. By implementing moisture monitoring systems, waste management facilities can effectively address these challenges across their operations.
In the past, many firms 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 and taken for testing. The moisture content will naturally change every minute that passes once the sample is removed from the production line, throwing off the final results. Older manual testing methods (for example, ovens) often lose the ability to test samples accurately.
Moisture control systems automate and accelerate many of these mundane inspection-based quality tasks. Adding the automation of moisture detection throughout the production process can eliminate the 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 finished 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 that they can be dealt with immediately to ensure additional product is not affected. When issues are identified 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 efficiency. This reduces wasted effort and materials, and decreases the frequency of downtime, manual intervention, and defective goods. Real-time control of moisture leads to significant cost savings, in terms of energy, spoilage, down time, quality control rejects, and customer complaints. For processes that can be closely controlled using real-time measurements, in-line systems in feedback-loops often produce a high ROI.
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 offers clear advantages over the traditional methods, including ease-of-use, elimination of hazardous chemicals, and increased efficiency 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 efficiency from the automated process, and frees up man hours for other tasks that cannot be automated.
Since NIR depends on light reflection, its one key disadvantage associated with its use are with products that are largely or completely carbon black. The technology still works, but may require tweaking or adjustments.
In addition to NIR, other automated technologies are available. For example, microwave technology sensors are often used, but they tend to lose accuracy quickly and may not give the same results every time. Those reliant on accuracy to a specific percentage must steer away from microwave technology. Another option is nuclear technology. While extremely accurate, cost is a major disadvantage; nuclear options may be four to five times the cost of NIR technology.
efficiency of the waste processing line.
(SRF) processing.
Improve Quality by Incorporating Automated Moisture Measurement
Quality and consistency are crucial when it comes to maintaining efficient waste management operations. Implementing an automated moisture control sensor instantly reduces waste and energy costs as well as improves the efficiency of the waste processing line. In landfills, real-time moisture data can help operators optimize waste placement and compaction, potentially extending the life of the landfill. In recycling facilities, automated moisture measurement can improve the quality of sorted materials, potentially increasing their market value. In many cases, waste management facilities can achieve a very favorable ROI by implementing automated moisture measurement systems, while also contributing to more sustainable and efficient waste handling practices.
Long-Term Sustainability
Incorporating automated moisture measurement systems in waste management operations provides significant benefits鈥攆rom reducing energy costs and minimizing waste to improving overall process efficiency. By leveraging technologies like NIR moisture sensors, facilities can enhance real-time process control, ensuring higher product quality and regulatory compliance while optimizing resource utilization. As automation continues to advance, waste management facilities that integrate these solutions will be better positioned for long-term sustainability, cost savings, and operational excellence. | WA
Sarah Hammond is a recognized expert in moisture measurement, serving as the Marketing Manager at MoistTech Corp. in Sarasota, Florida. Sarah is skilled at understanding the critical role moisture control plays in manufacturing processes, ensuring product consistency and quality while helping clients optimize efficiency and reduce waste. She can be reached at [email protected].