Why Moisture Variation Slows You Down

MoistTech Corp. manufactures the diamond standard in moisture measurement sensors, service, and support. With more than 40 years of experience, our equipment stands above the competition, providing continuous, reliable readings with zero maintenance, a one-time calibration with a non-drift optical design that allows operational personnel to confidently make line adjustments based on real-time measurements. Connected directly to a PLC if desired, a moisture control system creates a closed-loop process within your facility.

Moisture content in materials plays a crucial role in the quality and efficiency of production, but these levels can often vary from batch to batch. When moisture levels are not consistent, it can lead to product quality variations, even if the levels differ just slightly. Inconsistent product quality can lead to necessary rework that disrupts throughput, throwing off the rhythm of the production line. If you have noticed irregularities in product quality or an increase in unplanned line downtime, moisture variation could be the hidden culprit. Implementing an on-line moisture sensor from MoistTech allows for real-time data collection so moisture variations can be addressed before product quality is affected. 

Compare MoistTech’s technology to others in one minute:

Effects of moisture variations

Even minimal variations in moisture levels can have lasting effects on products. Minor moisture changes can lead to differences in texture, weight or chemical properties of the final product, resulting in batches that do not meet quality standards. Customers trust products to consistently meet their quality expectations and variations in quality can contribute to a dip in sales. Rework may be necessary if the materials are too compromised to be salvaged. This, in turn, leads to product waste, excessive energy consumption and schedule delays. When the schedule is thrown off, it can affect your ability to meet delivery deadlines and customer expectations.

Moisture variations can cause issues with both products and equipment, including:

• Decreased material quality
• Diminished equipment performance
• Product quality defects
• Increased downtime
• Process instability

How online moisture monitoring solves the problem

A fail proof solution for the production line is a near-infrared (NIR) moisture measurement solution that allows for full monitoring. With the ability to be read on an external display or tie back into a PLC system, users can create a closed loop process and ensure safety and quality control during production. MoistTech’s NIR system is developed to stay consistently calibrated, giving you trustworthy moisture readings throughout the process.

By continuously monitoring moisture on the production line, moisture variations can be detected before they morph into a larger problem. With MoistTech’s moisture sensors, data are constantly available for review. This allows operators to quickly notice any variations and make the necessary adjustments to prevent diminished product quality. While other moisture measurement methods can take time to retrieve data, MoistTech’s sensors provide real-time results so adjustments can be made immediately. Moisture monitoring helps keep production throughput on track, as well as reducing unplanned downtime.

Additional benefits of moisture sensors

MoistTech’s moisture sensors utilize near infrared (NIR) technology. This allows for no-contact moisture measurement. The production line does not need to be stopped to gather data and there is no waste from collecting samples. Our sensors are low maintenance and shipped pre-calibrated from the factory to eliminate the need for future recalibration. Thanks to the plug-and-play design, sensors can be installed almost anywhere on the production line. Popular installation locations include belts, conveyors, bins and cyclones. Each of our sensors comes standard with the Windows software needed for basic operation and they do not require any external hardware. Instead of guessing about the moisture content of materials, you can depend on accurate, repeatable data from a MoistTech moisture monitoring sensor.

High potential ROI

Improve production efficiency by 400 per cent or more with a MoistTech sensor. The best value for your money comes when you can control the moisture in the process through an automatic, feed-back-loop control system that changes the process based on the in-line measurement. When compared to the savings from reduced product loss and decreased work stoppages, the system has a high potential ROI.

Plug-and-play system

MoistTech sensors come pre-calibrated to fit your exact application like a glove, eliminating the need for constant recalibration. Think of them as the superheroes of moisture measurement, tuned to your specific needs and continuously monitoring to ensure they stay on point. This not only guarantees accuracy but also extends the life of your sensors. MoistTech’s moisture sensors automatically adapt to changing conditions, maintaining peak performance without the need for constant attention. No babysitting required — these sensors are on top of their game, giving you reliable results without the headache of drifting calibration.

The ability to reduce waste and keep the production line moving is essential to plant operators. Moisture measurement and control play a large role in the process and catching out of tolerance readings as quickly as possible on the line allows for increased plant efficiency and product quality. 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. Increased plant efficiency, lower energy costs, higher accuracy, instant return on investment (ROI) and low to zero maintenance are just a handful of benefits seen when implementing a moisture control system.