How Moisture Analysis Improves Quality Control in Manufacturing

In a conversation with Industry Outlook, Tapash Paul, Business Head of MM Automation, talks about how accurate moisture analysis is revolutionizing quality control in manufacturing. He describes how real-time monitoring of moisture protects manufacturers from defects, reduces wastage, and improves product life extension. With increased production requirements and demands for more efficiency, Tapash underscores the importance of accurate moisture control as a key factor in ensuring consistent product quality and enhancing operational results in a wide range of industries.

How does precise moisture control prevent defects and inconsistencies in sensitive manufacturing processes, ensuring consistent product quality and performance?

Moisture is an inherent property of the atmosphere. Whatever is in the atmosphere, the air and all have an indirect effect on the moisture of any field unit. For example, in the daily market, products such as corn or cotton prices will vary depending on the daily level of moisture. If it has moisture, the weight will increase, and the rate will change.

Also in industries such as medical sector, power generation plants, or any product, everywhere moisture presence makes the loss. Recently we have developed and supplied to cold drinks company.  They reduce the moisture content or the oxygen content in that. This is the way the quality differs from the moisture. This is the way moisture affects every field in its way, not the environment.

What challenges do manufacturers encounter in maintaining ideal moisture levels during high-volume production without compromising product quality?

Maintaining an ideal moisture level becomes a challenge, especially in high-volume production. It is easier to maintain the desired level of moisture in monoprocess productions, rather than individual small products like food packs, medicine bottles, medicine syringe packs, soap cakes, etc., because the moisture affects everywhere.

In the continuous process, to measure gas quality, they set up an online monitor and keep measuring the level; in between they take and check the records. Also, there is an alarm system, it goes down or changes as per the set level and the records maintain the things. However, the challenge lies in the mass products and individual products such as small products, and small packs. While packing, if the moisture, oxygen, or atmosphere level is there, it spoils the products. So in the packing atmosphere, monitoring is challenging and expensive. Technologies are there to keep an extra consciousness on processing the moisture rate.

This process should start with the packaging, processing, and ingredients. It is important to do studies during the process such as production, packaging, and dispatch. So that's why companies mention expiry dates in the food products because the products hold only limited dates. The customers or the manufacturers, whoever made the product, face challenges of maintaining this in every activity.

How does moisture variation affect packaging integrity and product durability, potentially leading to reduced shelf life and customer dissatisfaction?

There is a special package material known as moisture barrier bags. These moisture barrier bags are used in packing tea leaves, sweets, large instruments, and other materials across different fields. In our electronics field, including sensors and other electronics, this type of packaging plays a crucial role. They do packaging in a moisture-free atmosphere. Then they will use good-quality materials which are used to limit moisture diffusion. However, regardless of the material used, over time, a certain amount of moisture can still enter and diffuse through the packaging.

Aluminum fossil fuel packages are used commonly to further reduce moisture entry. Also, we are keeping some moisture absorbent in that package and exporting it. While exporting there is a chance that the internal moisture goes down or goes high. So we keep an indicator called a lock key. There is one ring that color indication will change like litmus paper which indicates moisture levels. Moreover, there are multiple spots, for example, six spots, five spots, and three spots which represent moisture levels such as 10%, 20%, and so on. While seeing that they can understand the moisture is protected up to this level. It will ensure that internal products are the same. If any moisture diffuses in that, products get discarded which will lead to huge loss.

What emerging technologies are enhancing moisture analysis accuracy, enabling manufacturers to improve quality control and reduce errors?

We are using moisture monitoring technologies range from minimum seven to eight types. These technologies are nothing but the type of sensors and each sensor works on some basic technologies. In the Chilled Mirror Hygrometer, the mirror is placed in front of the temperature sensor or thermometer, and the air or gas substances pumped into the device as it passes through the mirror will frost, and mirror frostiness comes. So where the frostiness comes, it measures the temperature. Loss of Drying / Loss of Weight technologies are mostly used for grains. Halogen Moisture Analysis is used for drying the moisture, so you find the weight difference and all.

In our field, we are mostly using capacitive sensors that we are manufacturing. The capacitive sensor gives direct output and measures while inserting into gas media. Neutron Probes are used to measure water content. Infrared is used in medical biotechnology systems and Radio Frequency or Infrared Frequency is used in the production of the medicine. These are the major technologies we use for bulk processing.

How can real-time moisture data help manufacturers respond quickly to process changes and maintain consistent quality standards?

Real-time data provides immediate insights, which enables clarity and leads to quick decision-making. Also, we can know about the fault, the day and time it happened. This is made possible through moisture monitoring. Same as in the power plant, the process plant, and the food packaging plants where moisture issues are common concerns. Moreover in the gas field, moisture levels are measured batch by batch while filling the gas cylinders. Batch by batch they keep records. If customers complain about the product then they take out the readings, review the readings, and verify the issue. It also enhances productivity.

Real-time monitoring improves operational efficiency by increasing the speed of operations, which naturally enhances overall performance. Also real time data helps in the selection and modification of the ingredients. By getting real time data they can change and adjust the quality of the ingredients that they use and it gives real visibility and control.

What role does moisture analysis play in preventing costly rework, minimizing waste, and avoiding product recalls?

Moisture analysis helps to detect the issues in the product processes and prevent defect that leads to costly reworks, capping, and all. If it goes bad, then instead of further processing, it is better to stop there. Moisture monitoring is essential at every step.  The sweet packages, dairy, these all big dairies, nowadays, they're packaging the sweets in a vacuum container or nitrogen-filled packages. During packaging, the producers make sure that the products are dried properly within the production process and packaged in controlled environments. This entails moisture creep management that incorporates vacuum and nitrogen cleaning and product processing for quality purposes. Consequently, they can export products successfully without major complications.

Naturally, anything in the world, whatever you do, there is corruption. So here we are calling as corruption, like moisture infiltration, or oxygen infiltration. Infiltration of ambient air is an inevitable process that takes place day to day. Its effects are reduced by placing a time limit on the products. Sweets, for instance, expire after one month, and packing can maintain the quality of the product for that duration only. After this period, the product spoils naturally.

We have developed machines and supplied them to several companies to optimize their packaging processes. In the current competitive market, companies that supply efficiently have an added competitive advantage, which in turn increases market reputation, market value, and market share. Ultimately, this leads to profitability. It's a very essential thing to minimize the cost. If much of the product is lost to corruption or otherwise, this has a direct effect on the bottom line. As we grow throughout the country, wastage continues to reduce, which not only saves us money but also increases overall production efficiency.