Polymerization case studies
Client profile
The profile of a typical customer is a factory where polymerization processes are used. These processes are needed in almost every field of industry, from the production of plastics, resins and adhesives, household chemicals, oils, electroplating through the automotive, textile space or medical industries.
Client problem
Current industry methods for controlling polymerization are indirect and imprecise. They rely on infrequent lab tests, which focus on atoms rather than chemical bonds, failing to distinguish between monomers and polymers. This often involves problematic chemical preparations and results in high error rates by measuring reaction byproducts.
Our solution
We use a Spectrally X1 device with a fiber-optic probe to collect real-time process signals. Unlike traditional methods, our solution focuses on chemical bonds, accurately distinguishing between monomers and polymers, and monitors polymerization directly and automatically, eliminating the need for specialized personnel or extensive R&D.
What are the stages and what are the benefits?
Optimization of the polymerization process:
Process monitoring allows for continuous assessment of the content of polymers and monomers in the solution. Our solution allows to measure polymers and monomers in: powders, liquids, bulk and even in water solutions. Analysis of measurement data allows you to identify process areas requiring optimization or improvement, leading to increased efficiency and productivity.
Waste reduction:
By reacting quickly to an incorrectly performed process, it is possible to minimize the amount of waste, which translates into saving raw materials and resources. Waste disposal, especially nowadays (BAT directive), is very expensive and every kilogram of waste less translates into real savings for the industrial plant.
Improving product quality:
Constant monitoring of the process ensures stable production conditions, which translates into constant product quality. Eliminating fluctuations in process parameters such as chemical composition leads to the production of more uniform and expected products. This translates into a real increase in competitiveness.
Increasing profitability and profits:
Stages of implementing our services
Customer needs analysis (audit)
understand your needs; personalized measurement solutions; on-site assessments to gain a local perspective
Feasibility study and offer
determination: inline, online, offline, or a combination thereof; tests on client samples if necessary; implementation plan; ends with offer proposals
Agreement and start of cooperation
formalization of terms; negotiation and signing of the contract; starting off the collaboration
Implementation
developing the system; testing and calibration at the client's site; staff training; ongoing supervision