Online Particle
Size Measurement
MYTA Online PSM
Josef Reiser
Intelligent process optimization with sensor technology.
Benefits of process optimization.
Production and availability
■ Process stabilization
■ Reduced down times
■ Increase of plant availability
Quality of final products
■ Higher reproducibility
■ Higher product consistency
■ Higher product quality
Productivity and economic efficiency
■ Higher yield and throughput
■ Maximum use of capacity, increased capacity
■ Optimization of cost drivers
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Cost
Profit
Earnings
Online particle size measurement
Marked demands
 Consistent product quality
first break
 Monitoring of product specifications
 Ongoing automatic process optimization
semolina
flour
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MYTA Online PSM
Product concept
MEAG control
Product sampler
Software
Wide range particle
size measurement
Connection to
gravity spouting
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MYTA Online PSM
Technology
main product flow
 Online detection of small particles
between10-165 μm with laser
 Online detection of coarse particles of
105-5000 μm with digital camera
product sampling
(volume opens
periodically)
deceleration
of probe
 MEAG Control
 Stand-alone and/or WinCos software
measurement
of single
particles
acceleration
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compressed
air, 0.5 bar
MYTA Online PSM
Animation
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Online particle size measurement
Customer Benefit
 Online information about granulation:
 Continuous process monitoring and traceability
100
143 m
90
107 m
81 m
80
52 m
34 m
70
60
3
through, Q (x) (%)
 Deviations from the target granulation:
 Enabling fast response, high process stability
 Wide range measurement with high resolution:
 More information than with sieve analysis
50
40
30
20
 Complete solution with sampler and sensor:
 High reproducibility
 Data visualization and storage:
 Quality control and traceability
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10
0
02:24
04:48
07:12
09:36
12:00
14:24
time (hh:mm)
16:48
19:12
21:36
Online PSM
Installation
- Compact design
- Directly on gravity spouting
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Online PSM
Installation
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Online PSM
Example of installations
Final product monitoring
of semolina based on soft
wheat
(very fine products)
Process optimization of
maize grits
(before flaking)
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MYTA Online PSM
Installation examples
F1
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F2
F3
Comparison: new sensor versus lab sieve method
(Soft wheat grist: B1)
Sieve
Sensor
100
100
gap 6:25
70
70
through, Q (x) (%)
80
60
2 625
3 615
1 600
7 600
6 548
4 545
5 530
40
30
20
50
40
30
20
10
10
0
3000
2500
2000
1500
1000
particle size (m)
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gap 5:30
60
3
gap 5:30
50
gap 6:25
90
80
3
through, Q (x) (%)
90
500
0
0
3000
2S
3S
1S
7S
6S
4S
5S
2500
625
615
600
600
548
545
530
2000
1500
1000
particle size (m)
500
0
Installation examples Online PSM
Online flour-monitoring regarding screen damage in milling
Example:
Continuous monitoring of
particle size in flour
F1
In case of larger particles:
Alarm
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F2
F3
Installation examples Online PSM
Online Durum semolina monitoring in milling
Example:
Continuous
monitoring of
semolina
granulation
In case of a
granulation shift:
Alarm
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Installation examples with Online PSM
Validation method
Example:
Flour monitoring after control sifting.
Detection of larger particles in the final
product (screen damage).
To be used as validation method.
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Online particle size measurement with MYTA Online PSM
Summary
 Max. operation reliability based on
active process optimization
during grinding process.
 Monitoring of finished products
for consistent particle size
distribution.
 Monitoring of intermediate/final
granulation.
 Validation methods.
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New Bühler
Online NIR
Generation
NIR Multi Online Analyzer
Josef Reiser
Principle of NIR Spectroscopy
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Actual OnlineNIR Concept
Today (at Bühler and all competitors)
NIR
Spectrometer
wheat
NIR
Spectrometer
Semolina
Flour
NIR
Spectrometer
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Every new application or measurement
point, needs a completely new NIR unit.
Intelligent process optimization with sensor technology
NIR Multi Online Analyzer MYRG, the new Bühler NIR generation
Wheat 1
One single spectrometer for
up to 6 measurement points.
Wheat 2
PC SW
NIR Spectrometer
Multiplexer
Flour 1
Flour 2
Semolina 1
Semolina 2
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Calibration packages
Included in standard package
- Moisture
- Protein
- Ash
Flour Parameter
Moisture
Range
7 – 16 %
Protein
8 – 17 %
Ash
0.35 – 1.8 %
Wheat Parameter
Additional calibration package available
- Starch damage
- Falling number
- Water absorption
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Moisture
7 – 19 %
Protein
8 – 17 %
Semolina Parameter
Moisture
8 – 17 %
Protein
11 – 17 %
Ash
0.6 – 1.8 %
Parameter
Starch Damage
Range
13 – 31 UCD
Falling Number
Water Absorption
200 – 600
52 – 67 %
Elements of the new Bühler Online NIR MYRG
NIR Spectrometer
with calibration
models
Multiplexer
Optical
fibres
probes
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Hardware
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Signal: Measurement section with screw – versus down pipe
Produkt 1
Produkt 2
Produkt 3
HWM 679
HWM 625 Biscuit
Haushaltmehl 455
Probe 1
m.section with screw
Probe 2
down pipe
This comparsion shows: It is possilbe to get the
same quality of signal either using a probe directly
connected on a down pipe.
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Examples of customer test installations
Customer 1: Measurement point 1
Measurement section using a screw
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Customer 1: Measurement point 2
measurement section installed on tubing
Examples of customer test installations
Customer 2: Measurement point 1
before Control sifter
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Customer 2: on balances where the
the product is accumulated (e.g.
MWBO)
Examples of customer test installations
Customer 3: Measurement point 1 for whole grain
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Examples of customer test installations
Customer 4:
Measurement of flour on MSDL dump scale
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Consequences of system interventions
Change of light bulb
. The measurement values in the graphs
do not alter more than the usual NIRmeasurement inaccuracy.
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Consequences of system interventions
Change of ambient temperature
Inside the calibration range, the prediction values
are stable against temperature changes.
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Intelligent process optimization with sensor technology
Customer benefits new NIR Multi Online Analyzer MYRG
Up to 6 measurement
points
Several measurement points and products
with one single spectrometer
Loops possible
Ensuring a consistent finished product
Short pay back period
For applications with more than one
measurement point
All from a single source
Calibration, spectroscopy, integration in the
customer mill, after sales service is provided
by Bühler
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www.buhlergroup.com
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