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FTIR NIR Raman UV-Vis Mass Spec LIF Fluorescence PAT Process Spectroscopy
Registered in England 2919549
Spectroscopy from Lab to Line - since 1994

PAT case studies

Process Analytical Technology, PAT, has been used by the most

progressive companies for decades. Measuring and controlling

critical parameters while you manufacture your product rather than

after completion of the process enables you to enhance quality, cut

costs and often improve safety and environmental performance.

PAT measurements can be on-line (in the reactor or pipe) or at-line

(measured by the operator at the point and time of need rather

than waiting for a remote laboratory.

Here are some case studies:

 
on-line UV-Vis for PAT on-line spectroscopy for process control Clairet Scientific PAT spectroscopy, process analystical technology
01604 494411
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Dryer monitoring with NIR
Drying:   A large pharma company installed FT-NIR probes to monitor several fluidised bed dryers. Their old procedure involved drying the product for 36 hours, but the results from the NIR showed that the product reached the specification for residual water after 9 hours. A system was implemented where the plant operators recieved a signal via a pager when a batch was dried to spec. The result was a massive saving in energy costs, a dramatic improvement in plant throuput and an improvement in product quality since the previous procedure had always resulted in the product being over-dried.
polymer blend monitoring with NIR and other types of spectroscopy
Polymer Blending:   This polymer product was manufactured by blending two viscous, sticky liquids in a semi-continuous process. Ensuring that the mixture contained the correct ratio of the two components was a critical quality parameter which the manufacturer needed to monitor and control in real time. Our solution used a non-invasive NIR  sampling accessory to make the measurement, which overcame problems of product build-up on a probe and cleaning during product changeovers. The NIR measured the blend to a high level of accuracy and generates an output of the blend ratio  be used to control the ratio of the components in the blend.
batch end-point monitoring with spectroscopy
Batch end point:   We were approached by company who wanted to determine the end-point of a batch production process.  If the reaction was allowed to continue beyond the end point it resulted in the build-up of unwanted by- products.They had tried UV-Vis spectroscopy without success. We investigated Mid-IR, Raman, NIR and UV-Vis on their products. It emerged that UV-Vis was in fact the best technique for this application but the sampling technque that they had tried was well suited to the product. We introduced the new sampling technology, implemented the spectrometer and reaction monitoring model resulting in a successful on-line application. The results were higher plant throughput and better quality product .
Raman process control, NIR process control
Process Control:   This process used toxic gases to  produce an intermediate in aqueous solution. There was a potential risk of explosion from an unwanted by- product. The risk was mitigated by keeping one component in excess and a technique was required to monitor and confirm that the excess was being maintained. Raman spectroscopy proved to be an ideal solution - the materials all had good Raman signatures and the water solvent has a weak Raman signature, minimising interference. A system was implemented that monitored the reaction and sent an alarm signal if the amount of the material required to be in excess started to reduce.The hazardous by- product could also be measured with Raman and a second, back-up alarm was set up should this material ever be detected.
For a full list of Apps Notes, click to visit our library
Registeed in England 2919549 

PAT case studies

Process Analytical Technology, PAT, has been

used by the most progressive companies for

decades. Measuring and controlling critical

parameters while you manufacture your

product rather than after completion of the

process enables you to enhance quality, cut

costs and often improve safety and

environmental performance.

PAT measurements can be on-line (in the

reactor or pipe) or at-line (measured by the

operator at the point and time of need

rather than waiting for a remote laboratory.

Here are some case studies:

 
Clairet Scientific on-line spectroscopy
Process Control:   This process used toxic gases to  produce an intermediate in aqueous solution. There was a potential risk of explosion from an unwanted by-product. The risk was mitigated by keeping one component in excess and a technique was required to monitor and confirm that the excess was being maintained. Raman spectroscopy proved to be an ideal solution - the materials all had good Raman signatures and the water solvent has a weak Raman signature, minimising interference. A system was implemented that monitored the reaction and sent an alarm signal if the amount of the material required to be in excess started to reduce.The hazardous by-product could also be measured with Raman and a second, back-up alarm was set up should this material ever be detected.
Drying:   A large pharma company installed FT-NIR  probes to monitor several fluidised bed dryers. Their old procedure involved drying the product for 36 hours, but the results from the NIR showed that the product reached the specification for residual water after 9 hours. A system was implemented where the plant operators recieved a signal via a pager when a batch was dried to spec. The result was a massive saving in energy costs, a dramatic improvement in plant throuput and an improvement in product quality since the previous procedure had always resulted in the product being over-dried.
Batch end point:   We were approached by company who wanted to determine the end-point of a batch production process.  If the reaction was allowed to continue beyond the end point it resulted in the build-up of unwanted by- products.They had tried UV-Vis spectroscopy without success. We investigated Mid-IR, Raman, NIR and UV-Vis on their products. It emerged that UV-Vis was in fact the best technique for this application but the sampling technque that they had tried was well suited to the product. We introduced the new sampling technology, implemented the spectrometer and reaction monitoring model resulting in a successful on-line application. The results were higher plant throughput and better quality product .
Polymer Blending:   This polymer product was manufactured by blending two viscous, sticky liquids in a semi- continuous process. Ensuring that the mixture contained the correct ratio of the two components was a critical quality parameter which the manufacturer needed to monitor and control in real time. Our solution used a non- invasive NIR sampling accessory to make the measurement, which overcame problems of product build-up on a probe and cleaning during product changeovers. The NIR measured the blend to a high level of accuracy and generates an output of the blend ratio  be used to control the ratio of the components in the blend.