Ensuring quality and consistency in plastic manufacturing and recycling, Coperion has introduced the DewTector®, an innovative device that measures surface moisture content in bulk materials, especially plastic pellets. This patent-pending system delivers reliable, automated online measurements while remaining economical and easy to use.
Moreover, the device helps plastic manufacturers and recyclers monitor moisture levels efficiently. As a result, it plays a critical role in maintaining product quality and ensuring compliance with industry standards.
How the DewTector® Works
The DewTector® operates using a simple yet effective method. First, it directs a partial flow of bulk material into a pressure-tight chamber. Then, it determines moisture content by analyzing the moisture released into the airflow.
As the air absorbs moisture, a hygrometer measures only the water content. Consequently, the system delivers precise and reliable results, unaffected by other substances or variations in material composition.
In addition, the device does not require extensive calibration or chemicals for different materials or formulations. This feature makes operation and maintenance straightforward. The system achieves an accuracy of +5% to −15% across moisture levels ranging from several thousand ppm to a few hundred ppm, while performing up to ten measurements per hour.
Challenges in Measuring Moisture in Plastics
Plastic manufacturers frequently encounter moisture-related issues in their final products. These issues can arise from insufficient drying, faulty water separators, leaking wash nozzles, or environmental factors such as rain and condensation.
If manufacturers fail to detect excess moisture, it can lead to costly product complaints and damage to brand reputation. Furthermore, processors must comply with strict moisture limits to ensure high-quality output. Similarly, recycling operations depend on dry input materials for efficient processing.
Limitations of Traditional Methods
Traditionally, operators have relied on labor-intensive and often inaccurate methods to measure moisture. For example, they conduct sporadic manual checks of relative humidity in bags and containers.
Although some automated techniques exist, such as capacitive and microwave resonance methods, they tend to be complex and expensive. Additionally, they require extensive calibration for different formulations, which makes them impractical for many users.
Improving Efficiency with DewTector®
By contrast, the DewTector® simplifies moisture measurement and significantly reduces the need for manual sampling and analysis. As per press release, this innovation enhances operational efficiency while delivering accurate, real-time data essential for process control.
Ultimately, the system enables manufacturers and recyclers to maintain consistent product quality, reduce risks, and optimize their production processes.
