The case describes continuous measurement results and moisture-trend displays
The challenge
Moisture Control Blind Spot Leads to Batch Rework
Traditional manual sampling and lab testing are delayed, failing to capture real-time changes in resin drying water content.
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Liquid resin drying requires water content to be controlled between 0.5%-1%. In conventional methods, samples are taken manually every two hours, with lab testing taking 40 minutes, resulting in data feedback nearly three hours after the drying process continues. For example, during one batch, water content rose to 1.2%, but delayed test results meant the issue was only detected after two hours, requiring 500kg of resin to be reworked due to excessive moisture.
Manual sampling involves contact with the production process, posing both operational safety and sample contamination risks.
Read background
The drying equipment outlet reaches temperatures of 80-100°C, and opening the sealed dryer for sampling risks burns from splashing hot resin. Additionally, sampling tools exposed to ambient air may introduce dust or impurities, contaminating samples and skewing test results. In one case, a factory's sample was contaminated with impurities during sampling, leading to a false passing result for water content, resulting in cured resin with bubbles.
Excessive water content reduces cured resin strength, while overly low levels lead to brittle cracking. In traditional monitoring, water content fluctuates between 0.3%-1.5%, with a finished product qualification rate of only 78%. In one instance, delayed monitoring allowed water content to drop below 0.3%, causing an entire 2-ton batch to be scrapped due to brittleness, incurring losses exceeding $10000.
How it works
Corrosion- and Heat-Resistant Process Integration
This solution is applied to the liquid resin drying process, replacing traditional manual sampling and lab testing. The equipment features a high-temperature, corrosion-resistant design and can be installed directly at the dryer's outlet pipeline. Using non-contact spectral detection technology, it collects data without interrupting the production process, adapting to both batch and continuous drying methods.
Seconds-Level Moisture Tracking with Dynamic Alerts
Enables real-time quantitative monitoring of water content in resin drying, capturing moisture changes instantly. High-precision moisture sensors generate results every 20 seconds, with data transmitted synchronously to the production monitoring system. The interface displays real-time water content curves and values, automatically highlighting warning lines when approaching critical thresholds of 0.5% or 1%.
Self-Optimizing Process Parameter Decisions
Provides precise water content data to guide production parameter optimization. The system automatically recommends adjustments based on moisture changes: for instance, when water content rises to 0.9%, it suggests "Increase drying temperature by 2°C"; when it drops to 0.6%, it advises "Reduce hot air speed by 10%," assisting operators in achieving precise control.
What changed
Moisture Stability Control Redefines Quality Limits
Significantly improves resin yield by reducing non-compliant products due to abnormal water content. Real-time monitoring stabilizes water content at 0.5%-0.8%, with fluctuations reduced to ±0.1%, boosting the finished product qualification rate from 78% to over 95%. After implementation, there is a case that a company reduced defective products by approximately 3 tons monthly, saving over $12000 in losses.
Continuous Production Breaks the Downtime Curse
Replaces manual sampling, enhancing production plan execution efficiency and continuity. Eliminating the need for sampling stoppages every two hours extends the continuous operation time of the drying process, increasing daily capacity by 12%. By removing lab testing wait times, production adjustment response time is shortened from 3 hours to 5 minutes, improving production plan completion rates by 20%.
Zero-Contact Safety Through Human-Machine Interface
Reduces manual involvement in production monitoring, lowering operational risks and enhancing worker safety. Eliminating manual contact with high-temperature equipment and resin raw materials completely removes burn and sample contamination risks. Over six months of implementation, no safety incidents have occurred in related production stages, and worker satisfaction with operations has increased by 40%.
Reported results describe this project and its operating conditions. Suitability for your application requires evaluation of your sample and installation.
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