ColVisTec AG

Inline process monitoring opens the door for a lot advantages and benefits:

• In-situ application, non-destructive, no sampling, no material loss
• Real-time information about process stability & quality
• Impact of speed changes on the quality of the extrusion
• Determination of optimal extruder screw configuration
• Innovative residence time measurement and analysis
• Controlled color changes: start phase, end of run
• Detection of pulsing pumps/bridge building
• Avoid off-specification batches & waste production
• Detection of dosage elevations
• Optimized recipe formulation & processes design
• Comprehensive quality - Documentation of the quality of the delivered product
• Reduced costs results in higher ROI

Extrusion is a very complex process subject to influence by various factors. Such factors can be process parameters e.g. temperature, pressure, production speed, etc. the extruder and its components i.e. pumps, feeders, blenders, combination of the screws, cooling, vacuum etc. In addition, raw material can influence the result, reflecting different lots, ratio of mixture etc. All these factors, either singly or in combination result in modification to the color of the produced material during the extrusion process.   Color measurement is a well-accepted technology to check the quality of the color values in the produc­tion process. Usually these measurements are performed ‘off-line’. The time between sampling and obtaining the results from the laboratory can take several hours. A sig­nificant disad­vantage is that only a single measure­ment is gener­ated in this time period and the quality of the color during before and after the sam­pling point is unknown.   With the inline process monitoring by measuring the color taking place directly in the melt is not only complete documentation possible, but when color variations occur, immediate intervention can take place. With our method are the measured results available in real time.   Color values not only are an indicator for product quality but also useful as an excellent insight for process monitoring in the extrusion stage. All parameters in the production process (temperature, pressure, production speed, feeders, pumps etc.) have an impact directly on the color values. It is now possible to make measurements directly in the melt without the need for sampling. Immediate adjustments of the process parameters are therefore possible through immediate ‘off-specification’ detection.

Detected information is the spectra in the molten polymer during the process. Calculated, displayed in real-time and stored data for the analysis are: L*, a*, b*, C*, h, dE*, YI, WI, selected spectral range etc.


The “InSpectro X” technology deploys a probe directly in the extruder. The Reflection Polymer Melt Probe (RPMP) is installed on the exit of the extruder by using ½”-20 UNF thread (typ. Dynisco®).  It is screwed into posi­tion on the exit of the extruder. The RPMP consists of the threaded sleeve and fiber optics. A sapphire on the tip of the probe is the observation window and is very well suited to the harsh conditions in the extruder (temperature, pressure, and friction through flowing material).   The melt stream must completely cover the sapphire sur­face. The self-cleaning function of the sapphire is ensured by the shear force of the material flow. Ideal installation is directly into the melt stream at the die-plate, in an adapter or flange. Measurements are performed on opaque as well on transparent materials.   The UV-VIS spectrophotometer “InSpectro X” is integrated in a NEMA4 box (equal to IP55) with a panel PC and touchscreen. The appropriate spectral range is 220 through 820 nm (resolution 1 nm). “InSpectro X” comes in a stainless steel box, designed and equipped spe­cifically for this applica­tion in the production environment where the ambient conditions can be dusty, vary in tem­perature, subject to vibration etc. The box also contains a thermoelectric cool­ing and heating device to eliminate the influences from ambient temperature by keeping the tem­perature inside the box at a constant level.

ColVisTec proudly presents "GiANT" world’s first triple "3 in 1" inline spectrophotometer platform including UV-VIS + NIR + Raman spectrophotometers in one rack as PAT system e.g. for pharma applications (hot melt extrusion), chemicals, polymers etc.

The combination of all three spectrophotometers enables a lot of opportunities in the monitoring of processes from many directions. This new combination of spectrophotometer combination opens new ways for the understanding of processed materials - especially pharma applications - and extrusion processes.

For more information, please download the brochures below and/or meet us in hall 16, booth A42 (ENTEX booth).

ColVisTec proudly launces the world's first combined "UV-VIS + NIR" inline fiber optic probe made for all type of extruder applications e.g. polymer extrusion, hot melt extrusion, reactive extrusion, chemicals, powder coatings (in mixers and extruders), food extrusion, pet food extrusion etc.

Both fibers for UV-VIS and NIR range are assembled in one probe. This gives the chance to measure in sequence both optical information via a single probe.

Advantages are:

• only one free 1/2"-20UNF bore is needed in the extruder die-plate
• both information are made at the same position in the process and
• nearly at the same time

The FSMA connectors allow to connect the combined probe to an UV-VIS and NIR spectrophotometer in parallel. The advantages are to gather the process and processed material information at the same position by using only one free 1/2"-20UNF hole in the extruder.
 
This combined "UV-VIS + NIR" probe in combination with the "InSpectro X" of ColVisTec is a perfect tool for the inline monitoring of extrusion processes.

RPMP (Reflection Polymer Melt Probe) is a inline fiber optic probe made for all type of extruder applications e.g. polymer extrusion, hot melt extrusion, reactive extrusion, chemicals, powder coatings (in mixers and extruders), food extrusion, pet food extrusion etc.

The body of the probe is made of stainless steel with a sapphire tip embedded in Hastelloy®. Only the sapphire window and Hastelloy® have contact with the processed media. The modeling of the RPMP probe body follows the 1/2"-20UNF design (typ. Dynisco), well known from temperature sensors and pressure transducers. 

For the measurement of opaque (colored) type of molten materials is only one free 1/2"-20UNF hole needed at the die-plate position, between screen changer and the die-plate etc.

Since the tip of the probe penetrates the barrel by 5 mm we select a position, where no rotating parts are. Attached picture shows some examples of RPMP installation in different type of extruders from different brands (single screw, twin screw, planetary roller extruder of ENTEX etc.).

The probe body with the sapphire window withstands temperatures of 350-400 degree Celsius and 200 bar pressure.

The fiber optic itself comes with 5 meter fiber length and can be extended for longer distances with extension fibers.

The RPMP in combination with the "InSpectro X" of ColVisTec is a perfect tool for the inline monitoring of extrusion processes.

TPMP (Transmission Polymer Melt Probe) is an inline fiber optic probe made for all type of extruder applications on transparent/clear type of molten media e.g. polymer extrusion, hot melt extrusion, reactive extrusion, chemicals etc.

The setup is so, that two probes are positioned opposite to each other (e.g. 3-9-o'clock) in the melt stream. One probe sends the light through the transparent media and the opposite positioned probe detects the light, which came through the processed transparent material. With that, TPMP guarantees to detect and display in real-time any change in the processed material inline in real-time during the process run.

The bodies of both probes are made of stainless steel with a sapphire tip embedded in Hastelloy®. Only the sapphire window and Hastelloy® have contact with the processed media. The modeling of the TPMP probe body follows the 1/2"-20UNF design (typ. Dynisco), well known from temperature sensors and pressure transducers.

For the measurement of transparent type of molten media are needed two free 1/2"-20UNF opposite positioned holes. Since the tip of the probes penetrates the barrel by 5 mm. We select a position, where no rotating parts are present. Attached picture shows an example of TPMP installation in an extruder.

The probe body with the sapphire window withstands temperatures of 350-400 degree Celsius and 200 bar pressure.

The fiber optic itself comes with 5 meter fiber length and can be extended for longer distances with extension fibers.

The TPMP in combination with the "InSpectro X" of ColVisTec is a perfect tool for the inline monitoring of extrusion processes.

CP (Color Probe) is an immersion fiber optic probe made for all type of applications in batch and continuous processes, where liquid, paste or powder type of media are processed. Typical applications are e.g. paints and coatings, chemicals, cosmetics, food etc.

Probes body is made of stainless steel with a sapphire window. The diameter of the body is 3/4" (19.05 mm) and comes with a length of 256 mm. The fiber length is 5 meter (standard version), if necessary it can be extended up to 20 meter. CP is made for temperatures up to 100 °C and 10 bar pressure.

Prozessüberwachung inline - Process monitoring inline
24/7 Prozessüberwachung - 24/7 process control
Prozessanalyse - Process analysis
kontinuierliche und Batch Anwendungen-  Continuous and batch application
Extruder und Mischer Anwedungen - Extruder and mixer application
Reaktive Extrusion - reactive extrusion
chemische Prozesse - Chemical processes
Tauchsonden - Immersion probes
Extruder Messsonden - Probes for extruder application
Rezepturentwicklung - Recipe/Formulation development
F&E Anwendungen - R&D application
Verweilzeit Messungen und sofortige Analyse - Residence time distribution and immediate analysis
Prozesscharakterisierung - Process characterization
Extruder Charakterisierung - Extruder characterization
Extruder Anwendung - Extruder application
Farbmessung inline - Color measurement inline 
Spektralphotometer inline - spectrophotometer inline
Steady state
Dosierfehler - Feeder problems
Prozess Drift - Process drift 
Temperaturschwankungen - Temperature elevation
Drehzahländerungen - Speed change
Qualitätskontrolle inline 24/7 - Quality control 24/7
In-Situ System
PAT - Process Analytical Technology
HME - Hot Melt Extrusion
Messsonde für Farbmessung - Probes for color measurement
Messsonde für Extruder - Probes for extruder application
Glasfasersonde - Fiber optic probes
Degradation
Vergilbung - Yellowing
YI - Yellowness Index
WI - Whiteness Index
CIE-Lab, CIE-2000, HunterLab, L*, a*, b*, C*, h, dE*