Nowadays, a majority of the manufactured products are combinations of many elements. Normally, the individual components in a mixture will move apart (segregate) during the manufacturing process, which gives rise to an inconsistent final product. Separation or segregation of granular powder materials is one of the major reasons for process failure in systems that deal with powder materials. Conservative estimations report that up to 30% of all unscheduled downtimes are because of segregation and quality problems.
With modern spectroscopic technology, the new SPECTester has the capability to analyze a sample consisting of up to six individual components and offers a simple report denoting why and how much the sample material is separating. The instrument is completely automated and offers data about product uniformity, particle size differences, and component concentrations. The SPECTester can measure segregation by sifting, particle size, angle of repose, fluidization, air entrainment, and chemical component. It has full potential to identify both primary and secondary segregation mechanisms. The SPECTester can be used in R&D environments to study properties of materials before entering into production, and also in production plants for real-time quality control.
- Completely automated operation with reports of how much the material mixture is separating
- Measurement of combinations with up to six components
- Offers data on changes in product uniformity, particle size, and component concentration
- Optional fluidization module measures the segregation potential of fluidized beds
- Simulates process conditions to spot segregation by fluidization, sifting, air entrapment, and angle of repose
- 50 segregation points measured across the sample bed
- Offers uniformity index for sample and segregation variance data
- Points out product quality control problems
- Rapid analysis—10 to 30 minutes to complete a run based on the sample and application
- Data can be exported to PDF and Excel formats
- CE compliant
- USB Interface
Data Generated by the SPECTester
The SPECTester offers three important tools to the user:
- Segregation intensity number
- Uniformity number
- Excel-ready database explaining the segregation behavior of the mixture as well as the individual components as they undergo a process
The segregation intensity number for each individual component shows how much that component is contributing to the overall segregation that takes place within the material mixture. The segregation intensity number can be used to determine the challenging component and/or components in the mixture. This number ranges from 0 to 1. A segregation intensity number greater than around 0.25 implies that a particular component is contributing considerably to the segregation problem.
The inverse of the segregation intensity number is the uniformity number, which is also in the range of 0 to 1. The uniformity number indicates the overall uniformity in the concentration of each specific component within the mixture. A larger uniformity number denotes that the ingredient appears quite uniformly through the mixture. A smaller uniformity number denotes that the ingredient reappears in the mixture pile to a non-uniform degree.
The Excel-ready database (.csv format) can be used to make charts, tables, and graphs that define the segregation behavior (or lack therefore) of the individual components and the material mixture in presentations and reports.