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:

The ability to monitor the amount of monomers and polymers on an ongoing basis makes it possible to shorten the production process time and thus increase efficiency or increase savings in the consumption of raw materials, electricity and the involvement of specialized staff.
Reducing production costs and minimizing losses contribute to increasing operational profitability, which leads to an increase in company profits.
Reduction of material losses
0 %
Optimization of energy consumption
0 %
Increasing production efficiency
0 %
Reduction of production time
0 %
Relieving the laboratory load
0 %
Reduction of pollutant emissions
0 %

Stages of implementing our services

Stage 1

Customer needs analysis (audit)

understand your needs; personalized measurement solutions; on-site assessments to gain a local perspective

Stage 2

Feasibility study and offer

determination: inline, online, offline, or a combination thereof; tests on client samples if necessary; implementation plan; ends with offer proposals

Stage 3

Agreement and start of cooperation

formalization of terms; negotiation and signing of the contract; starting off the collaboration

Stage 4

Implementation

developing the system; testing and calibration at the client's site; staff training; ongoing supervision

Polymerization control

creating a protective coating on the galvanized element

automotive electroplating

Better control of wastewater quality, reduction of disposal costs

Manufacturer of specialty chemicals

Real-time control of chemical processes

Manufacturer of specialty chemicals

A system for interpreting spectroscopic results