Quality is critical in producing metallic soaps. This is done by achieving the perfect particle size distribution, measured in sample testing during production, performed one to two times per shift. This only gave a delayed impression of the process. Operators were "flying blind," relying heavily on experience to manage critical steps in the process.
The Solution
To address this challenge, we recently introduced a real-time monitoring system based on the aixProM framework that continuously tracks product quality by providing minute-by-minute updates on the solid material's d50 value. This approach ensures minimal waste and optimizes process efficiency.
A simple, cost-effective acoustic sensor is welded externally onto the pipeline, collecting sound data. This data is combined with existing process information, and through machine learning, the software translates it into an accurate, up-to-the-minute d50 value. In other words, the system "listens" to the process and outputs the particle size distribution in real-time.
The Benefits
- Non-invasive and easy to install on existing equipment.
- No direct contact with the material, ensuring no contamination.
- Precise quality monitoring within a half micron, validated by lab measurements.
- Low maintenance is required.
Scalable and Adaptable
This system is not just a one-size-fits-all solution. It's designed to be adaptable and scalable, tailored to your specific needs and processes. It can be integrated with additional data, like mass flow rates, to optimize production further, giving you the power to control and improve your production processes with data-driven decisions.
This is just the beginning of what data-driven production can achieve!