Drysdale & Associates, Inc. can provide technical assistance to help you in many ways. The following examples illustrate some of the breadth of our expertise and capabilities...

A particular client manufactures saltine crackers. In the manufacturing process for saltine crackers (and other baked and fried foods), we provide on-line infrared analyzers to monitor moisture content, oil content and various other constituents. The traditional method for monitoring moisture content of saltine crackers is for the QC technician to periodically take product samples from the line to the laboratory. The samples are crushed, precisely weighed, thoroughly dried, and then weighed again to calculate the exact moisture content of the product as it is being produced. Naturally this procedure takes time and the manufacturing line is running continuously, so by the time the laboratory reading is determined, a great deal of product has already been produced, often out of spec and resulting in scrap and lost production.

After installing infrared moisture analyzers from Process Sensors, our client observed that there was frequently a significant discrepancy between the on-line moisture analyzer readings and the laboratory readings. Obviously, since the laboratory method is known to be precise, the immediate conclusion was that the moisture analyzers were erroneous, and they challenged the validity of the analyzer readings.

We conducted extensive research into understanding the manufacturing process for saltine crackers. (Click here to download and view an exciting video of the results of the research. The video is about 4 meg.). As part of the research we conducted an infrared thermal analysis of the saltine crackers. Crackers exit the oven at a fairly uniform temperature near 400F. Upon exiting the oven, they immediately begin to cool towards ambient. Since the crackers are fairly uniform in mass, the most significant variable tends to be their moisture content. Crackers that are higher in moisture have more mass and cool more slowly, while crackers that are lower in moisture have less mass and cool more quickly. Therefore, by thermally profiling the crackers just downstream of the oven exit, the thermal profile offers a direct "view" of the moisture distribution of the product.

After viewing the infrared video analysis, a detailed cracker by cracker laboratory moisture analysis was then conducted. The QC lab confirmed exactly what the infrared thermal imaging illustrated, that the product was in fact not uniform at all in moisture content across their web. The discrepancy between the laboratory and infrared analyzer readings was entirely a result of poor sampling techniques a significant mis-understanding of the actual characteristics of the product. This research lead to a greater understanding of their product, and eventually resulted in significant quality improvements and cost savings to the client.

As a result, the client has since installed Process Sensors infrared moisture analyzers on all of their baked and fried product manufacturing lines. The analyzers provide instantaneous monitoring for both moisture and oil content, and allow the operators to take corrective action before the product parameters go out of limit, thus saving hundreds of thousands of dollars per year.

Drysdale & Associates, Inc., can assist you in analyzing the thermal and spectral characteristics of your product or process. More examples of our services are described further down this page. Please contact us for specific assistance.