Instant Insights from Delivery to Dispatch: The Benefits of NIR-Online

Eggcule Poirot returns from his encounter with the forest spirits, and the detectives are keen to hear his tale. “Let’s just say that some things cannot be explained with words,” says Eggcule, only increasing the level of intrigue amongst the detectives who are desperate to know what had occurred by the mossy boulder deep in the lush forest of Dorset, England.

In an attempt to refocus the detectives' attention, Shallot Holmes tells them he has a task for them, as he has been contacted by a former client who needs further assistance. “Further assistance? Did we not manage to solve their case?” asks Cornlumbo. “Well, it appears that we started the client on a journey of discovery, and they now want further advice from us,” explains Holmes before describing the details of the case. 

“Do you remember the cheese producer who previously contacted us because his NIR equipment was outdated and no longer supported by the manufacturer?” asks Holmes. “Oh yes, he was worried about losing all the calibration data he had spent years creating. We told him how to preserve his precious calibrations if I remember correctly,” says Nancy Beef. “Exactly; well., the client started researching new NIR instruments and discovered NIR-Online process analyzers. He wants to know if his calibrations could be used on an NIR-Online system and whether his company would benefit from the switch to an on-line setup. It would be a larger investment than buying another standalone unit,” says Holmes.

“An online system, so it’s connected to the internet?” says Cornlumbo. “That’s not what the term on-line means here, Cornlumbo,” says Nancy. “On-line refers to the system being incorporated directly into the production process, functioning in real-time during manufacturing or processing activities. It's more about continuous, instantaneous analysis as part of an operational process than periodic testing, which the client currently does with their standalone unit. Periodic or batch testing would be referred to as off-line or at-line analysis,” explains Nancy.

“So, it’s not connected to the internet?” says Cornlumbo. "Well, the term – on-line – here relates specifically to its operational integration rather than its connectivity to the internet, though these systems can be integrated directly into the process control system via different connections, such as OPC or TCP/IP, to enhance overall process efficiency. Furthermore, remote access enables support and calibration development,” says Nancy Beef.

“Oh, I see; you sure do know a lot about NIR systems, Nancy. I’m sure you could make some great recommendations to the client, says Cornlumbo. “I could, but there are many different types of systems and sensors, and it would be hard to make a recommendation without seeing the processing facility,” says Nancy.

Holmes agrees with Cornlumbo that Nancy would be the ideal candidate to inspect and check out the facility and asks Nancy if she would be willing to visit the client to assess the viability of NIR-Online and perhaps make some recommendations. “I’d be glad to help,” says Nancy, who makes her way to the facility.

On arriving at the facility, the client immediately bombarded Nancy with questions. He is concerned about the cost of implementation, as it would be more expensive than buying another standalone unit. Nancy listed some of the benefits of on-line NIR that she had prepared on the way to the facility to gauge whether it sounds like something the client should consider.

• What are the benefits of NIR Online process analyzers?
• Realtime Monitoring and Control: Online NIR process analyzers provide immediate feedback on process conditions and product characteristics, allowing for real-time adjustments to ensure product quality and consistency.
• Increased Efficiency: Continuous monitoring of the process, rather than only testing specific batches or individual samples, optimizes the use of raw materials and energy, reduces waste, and improves throughput by minimizing downtime and errors.
• Cost Reductions: On-line systems reduce the need for laboratory testing and the associated delays. Process optimization and testing incoming raw materials allow out-of-spec goods to be immediately rejected before impacting the batch. Over time, NIR analysis can create a healthy return on investment.
• Versatility: The range of systems available allows for use by various industries and in many different types of facilities. Each application can be tailored to specific requirements, such as moisture content, protein levels, or fat amount. 
• Improved Safety: By providing continuous data on process parameters, these systems can help identify potentially hazardous out-of-spec conditions before they become critical. 
• Quality Assurance: Continuous monitoring helps maintain strict quality standards, consistently ensuring products meet regulatory requirements and consumer expectations.

“And what about the calibrations that we spent years creating on our old standalone unit? You said we use these on a modern standalone unit; can they also be used on an on-line system?” asks the client. “Yes, the NIR-Online process analyzers also benefit from AutoCal, which can update calibrations automatically without chemometrics knowledge,” explains Nancy. “Fantastic. So where can I get an on-line system?” asks the client. Nancy explains that many systems are available for different types of processing facilities, and the system that will be required depends on how the facility is set up. The client takes Nancy to the facility to determine what is needed. 

Nancy is immediately impressed by the size and layout of the processing facility. The first thing she noticed that would influence the type of system required was the massive belt-driven conveyor system used to transport the cheese within the facility. 

Nancy recommends two types of over-belt systems that the client could utilize. The first is an X-Beam system that benefits from being able to perform analysis over a larger distance (up to 20 cm) than regular NIR systems – its measurement spot is 4-10 cm. The second is the X-Light system, which has a larger measurement spot (up to 40 cm) and can measure at a distance of up to 50 cm. Given the variety of cheeses produced, Nancy and the client agree that the X-light system would be more beneficial. It would be able to monitor cheeses of different heights accurately, and the wide analysis area that measures the mean of the area covered would be ideal for inhomogeneous cheeses, such as blue cheeses. The X-Light system would calculate the mean over the moldy and the cheesy regions, giving an accurate analysis of the whole. 

The client is thrilled, thanks Nancy for her help, and asks if she would like anything as a reward for all her help. “Well, I know that Cornlumbo would be terribly disappointed if I didn’t bring him some cheese back from your fantastic facility,” says Nancy. “Ah, he’s a lover of cheese; what type of cheese does this Cornlumbo chap like?” asks the client. “Oh, he’s not fussy; I’m yet to hear of a food that he won't eat!” says Nancy, chuckling to herself. With that, the client fetches a selection of cheese for the detectives to enjoy, and Nancy makes her way back to the office.