Induction Heating Applications

After unsatisfactory experiences with competitive pyrometers, this nationally known manufacturer of fasteners for aerospace applications recently installed fifteen Model PSC Sirius SI16 pyrometers on their Inductoheat, Ameritherm, and Tocco induction heating machines.

The machines pre-heat high-duty alloy blanks that are then forged into fasteners used in aircraft and space module construction.? The accuracy, precision adjustable focus and laser aiming of the Sirius pyrometer is critical to ensure correct temperature and heat distribution in the blanks.? This is essential to avoid post-forging stresses that could give rise to fastener failure in use.

A company spokesman, who selected the PSC? Sirius SI16?s over the competition, stated that ?The Process Sensors product was the only one that met or? ? exceeded our rigid requirements in the manufacturing environment.? All the pyrometers have performed flawlessly.?

The Application

Induction heating uses high frequency electromagnetic energy to rapidly heat metals. Application constraints typically include confined sighting paths, small targets, variable emissivity surfaces, smoke in the sight path and strong magnetic fields.

The design features of the Sirius pyrometers are aimed at eliminating or minimizing the impact of these factors on the measurement.? The narrow, short wavelength spectral response reduces errors due to variable emissivity.? Adjustable focusing and laser aiming simplify sighting on specific areas of the product, while avoiding partial obstructions in the sight path.? Digital signal processing and careful electronic design minimize magnetic interference.

The Market

Induction heating machines are common across manufacturing industries wherever metals are heat treated or formed.? The fastener industry, auto and aircraft components manufacturing, tool making and
pipe forming, as examples, all use a multiplicity of induction heating systems.

This processing method is also found in less obvious applications such as rebar coating and bearing manufacturing.

Many induction heating OEM?s have traditionally used competitive IR sensors, but it is clear that the high accuracy SI16 with wide temperature range, small spot size, adjustable focus laser aiming, standard analog and digital output capabilities make this the preferred sensor of choice in the induction heating marketplace.

Model No.: PSC?s Sirius SI16-0300-1300-1-2-2-5-1-A

Temperature range: 572?F to 2372?F ( 300 to 1300?F )

Process Sensors Attends SNAXPO 2009

Process Sensors attended the SNAXPO 2009 Show held March 29-April 1 in Orlando, FL to demonstrate instruments showing the importance of measuring moisture and oil in snack food manufacturing environments.  According to the Snack Food Association, ?More than 100 exhibitors filled the SNAXPO show floor offering new ideas, products and services for snack food company decision makers seeking to build their businesses.?

An application sheet explaining the importance of measuring moisture and oil in potato chips follows.

Measuring Moisture & Oil in Potato Chips

The continuous measurement of moisture prior to packaging is a key consideration in the production of potato chips.? The proper moisture level of finished chips helps guarantee taste, texture and shelf life.

The use of NIR (Near Infrared Reflection) moisture gauges in snack food manufacturing environments has become an accepted technology for monitoring and control.? The on-line measurements are instantaneous and non-contact.? Any change in moisture level can be immediately recognized by the use of a Process Recorder, eliminating the potential for customer quality complaints or waste.

NIR can also be used to measure oil content, along with moisture.? The oil measurement is most often done at-line as a quality indication prior to packaging.

Chip Manufacturing Process
Potatoes are peeled, sliced and de-starched prior to Frying and Seasoning. Measurements of oil and moisture are typically made shortly after the exit of the Fryer. Moisture measurement at the exit of the Fryer can be used to optimize moisture %, this results in greater product consistency, longer shelf-life and less waste material.

Transmitter Installation
PSC moisture transmitters should be located after the fryer outlet, over the vibrating conveyor.? The transmitter should be mounted 10? from the surface of the potato chips.? Heat at the fryer outlet can create very high temperatures.? If the transmitter must be located close to the outlet of the fryer, it is important to consider cooling.

The MCT330SF moisture transmitter is designed to measure moisture, oil and product temperature in a food processing environment. The transmitter is housed in a stainless steel enclosure and employs a food grade optical window. The MCT is optimized with filter combinations to measure moisture and oil at the same time.? The viewing window in the sensor is a food grade polymer.? The stainless steel housing is sealed so that the NIR sensor can tolerate a wash-down environment.

The MCT-330SF is fitted with an air purge assembly to prevent oil or moisture from depositing on the sensor?s lens.? The Stainless Steel Enclosure can also be fitted with a Vortex cooler in the event of a very elevated temperature environment.

Measurement Performance
Moisture measurement in potato chips is a very well understood and documented application. NIR wavelengths, algorithms, and sensor optical parameters are pre-set at the PSC factory.

A calibration is entered into the MCT-330SF at the PSC factory.? There is no calibration required after installation on the processing line.

It is important to locate the MCT so that there is always product beneath the NIR sensor.? The measurement works by detecting reflected light.? The light must be reflected off of the product, not the vibrating conveyor!

Breakfast Cereal Applications

Knowledge of the moisture content at the exit of the cooker, cooker extruder and exit of the

toaster, yields important information which can be utilized to maintain the consistent form,

taste and texture of the cereal in addition to optimizing product yield, reducing scrap and

saving on energy costs. On-line measurements give instantaneous information, enabling

tighter process control than can be obtained through lab analyzed data.

Cereal Production Process

Processes vary, but one such example might contain: a Mixing stage where dry and liquid

ingredients are mixed, Cooker, Extruder or Former, Cutter, Cooler, Flaking Roll,

Dryer-Toaster, Froster-Sprayer and Dryer.

Measurement Location

Moisture measurement at the exit of the Cooker, prior to the Former, reduces the quantity

of misshapes through product sticking or disintegrating in the flaking process. Moisture

measurement post Toaster enables maximization of final moisture, this optimizes yield,

without compromising taste, texture and shelf life characteristics.

Gauge Installation

Typically the gauge is installed over a conveyor, approximately 8? from the product. It is

important to maintain sufficient product bed depth to cover the conveyor, and continuous

product flow, especially if the gauge is used in closed loop control of the toaster or dryer.

The gauge is best positioned at a location several feet from the exit of the toaster/dryer as

this gives the product a chance to reach a degree of equilibration. If possible

measurement should be made on well mixed product; an ideal location is after a short drop

from one conveyor onto another.

The Food Grade MCT300 incorporates a food grade electro less nickel enclosure and either

a kel F polymeric, or sapphire viewing window. An optional water/air cooling panel or vortec

cooler are available if the ambient temperature exceeds 55?C.

Measurement Performance

Application Notes

Moisture in Breakfast Cereals

www.processsensors.com | ?2005 Process Sensors Corp.

Measurement Location Target % Typical Accuracy %

Moisture Exit Cooker 20-30% 0.4%

Moisture Exit Toaster/Dryer 2-8% 0.15%