Simplify plant operation

The following operational benefits have been reported using the Malvern Insitec on-line particle sizer in toner manufacture:

• easy routine maintenance
• high up-time thanks to very high hardware and process reliability
• reduced time for product campaign changeover
• "safe" start-up - easy to start up confidently, with just a simple comparison required to reference steady-state product runs
• fast reactivity of measurement after a process change
• real-time optimization of the process - for example, changing parameters during a product campaign to optimize the process while staying within specification
• Multiple real-time measurements on the same production line - at mill exit for example, and on final grade - have generally proved to be advantageous for improved quality and increased yield together with a cost reduction.

The installation of two Insitec analyzers per line has now become the standard within the toner industry, given that the extra cost is justified in the ROI estimation.

Intelligent process operation

The Insitec has been used in a number of studies to improve the operation of the grinding/classification process, notably in data mining.

NexPress (data mining):
NexPress data mining - download a paper (requires free login)