Near Infrared Spectroscopy for fast process measurement

Infrared spectroscopy could be used in numerous process control for a fast and reliable quality control inspection, analysis and verification.

Clay dryers face two challenges that are now solved by the use of near-infrared (NIR) spectrometers in manufacturing plants: measuring moisture content to sell by actual weight and managing drying time to control energy consumption.

1. Measuring moisture content and optimizing the production process

The NIR spectrometer offers a fast and accurate method for measuring moisture content. By using the absorption of infrared radiation by the water present in the clay, it allows direct quantification of moisture without the need for destructive sampling or long waiting times (as with gravimetric methods).

Installing several measuring heads in different areas of the dryer provides accurate measurements, and using a centralized monitoring system allows sensor data to be collected and analyzed in real time. This makes it possible to track moisture variations and adjust the dryer settings accordingly.

2. Manage drying time and control energy consumption

Drying time in a dryer is closely related to the initial water content and the final moisture target. NIR allows the drying process to be dynamically regulated by automatically adjusting the duration and intensity of drying to avoid overheating or unnecessarily prolonging the cycle, thereby minimizing energy consumption.

By optimizing dryer settings (such as temperature, air flow, or time) and improving drying management, it is possible to reduce the factory's carbon footprint by limiting the excessive use of fossil fuels to heat the dryers. Precise humidity control also prevents deformation or cracking caused by improper drying, limiting scrap and, by extension, waste of resources.

With continuous, real-time measurements, it becomes possible to immediately adapt the drying process to variations in environmental conditions (ambient humidity, temperature).

By reducing unnecessary energy consumption and CO₂ emissions, the integration of a near-infrared spectrometer to control humidity in a clay dryer directly contributes to the decarbonization of the industry and improved competitiveness in the face of increasing environmental regulations.