Digital Re-print - January | February 2012

The Benefits of using Digital Microwave Moisture Measurement

Grain & Feed Milling Technology is published six times a year by Perendale Publishers Ltd of the United Kingdom. All data is published in good faith, based on information received, and while every care is taken to prevent inaccuracies, the publishers accept no liability for any errors or omissions or for the consequences of action taken on the basis of information published. Copyright 2010 Perendale Publishers Ltd. All rights reserved. No part of this publication may be reproduced in any form or by any means without prior permission of the copyright owner. Printed by Perendale Publishers Ltd. ISSN: 1466-3872

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FEATURE

FEATURE

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Hydronix digital, microwave moisture sensors provide accurate and cost effective moisture control in feed meals and pellets, grain, cereal and pulses

The benefits of using

Digital microwave moisture measurement

by Jason Laffan, Managing Director, Hydronix Limited, UK
eed and grain producers will be familiar with the benefits of being able to control moisture during the various stages of the production process. Monitoring the moisture in the raw materials, controlling the water addition during the mixing/blending process and finally checking the moisture in the final product will enable substantial savings to be made. Product yields may be maximised, ingredients efficiently utilised, energy consumption reduced and a quality finished product ensured. For these reasons it is becoming more common for producers to start considering installing moisture control systems and they therefore need to look for solutions that offer the best accuracy and flexibility at the most competitive price. There is an increasingly wide choice of moisture measurement systems available that all claim to have the best and latest technology, but how does the producer, whose area of expertise lies in other technologies, know which system to choose? There are five main technologies available on the market, although their degree of accuracy and their ability to solve the problem varies considerably. There is the option of resistive, capacitive, infrared, nuclear or microwave techniques. The first four all have their limitations: resistive and capacitive are susceptible to impurities that may lead to erroneous results; infrared tends to be relatively expensive and can be affected by dust and vapour and therefore typically lends itself to dry, clean, controlled environments; nuclear systems are very expensive, and although very accurate in certain applications can be difficult to maintain.
18 | January - february 2012

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However, microwave sensors are not affected by dust, vapour or colour and have proved overall to be the best option in terms of ease of use, reliability, accuracy and cost effectiveness, usually covering the capital expenditure in a matter of months. Having settled on the microwave measurement method, choosing the right sensor technology now starts to become more involved. There are microwave sensors that are purely analogue, those that are analogue but output their results in a digital format, and those that actually use a digital measuring technique.

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The Hydro-Probe III is the latest release in the Hydronix range of sensors specifically designed to measure in organic materials. Using an existing and proven design, the Hydro-Probe III now includes the measurement modes which are already being used successfully in the grain industry in the Hydro-Mix VII.

Measurement technique
There are various methods of using microwaves to measure moisture. One of the most common methods used is the resonant cavity technique. In the past, an analogue microwave sensor would measure moisture through a combination of frequency shift (the left to right movement of the response) and amplitude attenuation (the change in the height of the response) of the resonator, see Figure 1. This combination was measured as a single analogue response and therefore frequency shift and attenuation could not be separated. In the 1980s, Hydronix, a leading manufacturer of microwave moisture measurement systems introduced the worlds first digital microwave sensor. This broke new ground, for the first time enabling the frequency shift component to be accurately measured using digital techniques. This development resulted in two significant improvements in the sensors, an improvement in accuracy and also a very significant extension of the moisture range for which the sensor would give a true linear response as moisture levels increased. Every material will have a different effect on the microwave field generated by the sensor. As moisture increases the response will shift and reduce in amplitude.

Figure 1: Moisture causes a change in the dielectric property of a material resulting in frequency shift and amplitude attenuation

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Hydronix sensors include: Figure 2: The Measurement Less advanced sensors simply measure a change in amplitude at a fixed frequency. Measuring across a custom frequency range gives more accurate results than those sensors that work within the confines of a single frequency using an open band such as those used by Burglar Alarm Systems or Wi-Fi (433MHz or 2.4GHz). The components required to manufacture a sensor that measures a frequency shift as opposed to a change in amplitude at a fixed frequency are more complex but provide a superior
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Digital technology with precise linear output Wide moisture measurement range Suitable for chutes, silos, mixers or conveyors Choice of measurement modes Not affected by dust or colour Different installation options Temperature stable

enquiries@hydronix.com

www.hydronix.com
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FEATURE nique requires the sensor reading to undergo significant mathematical manipulation in order to output what appears to be a linear response to changes in moisture. A digital multifrequency measurement has the ability to measure from 0 percent moisture through to material saturation while maintaining senFigure 3: The effects of a non-linear measurement technique sitivity and precision across the full result. The reason for this is demonstrated in working range. This also highlights a key Figures 2 and 3. difference between an analogue sensor As the moisture increases the frequency that claims to be digital because it can shifts from f1 to f2, f3 and then f4. The shift process the signal and output a seemingly between each is similar in magnitude. A sen- linear measurement and a sensor that uses sor with a digital measurement technique will a digital microwave moisture measurement continually scan the frequency response and technique that is inherently linear. will track the equal changes in frequency as The latter will overlay the linear response the material becomes wetter. with subsequent processing to fine tune the For the same moisture changes, a sin- curve and incorporate features such as ongle frequency sensor simply measuring the board signal smoothing, alarms and averaging change in the amplitude at frequency f1 will functions. measure the changes from A1 to A2, A3 and then A4. It can be seen that the sensor Accuracy requires calibration progressively loses the ability to register a Calibration is the process of defining the change in reading as the material becomes relationship between the changes in the senwetter. sor response with the change in the moisture Typically, a good analogue sensor will lose content of the material. This is required the ability to register additional changes in because each material will have its own moisture from about 12 percent onwards. electrical properties (dielectric properties), This not only effects the sensors ability to which affect the microwave field differently. register changes in moisture above this level A good sensor should only require calibut it also means that the entire moisture brating once for a given material. A poor curve lacks linearity as shown in Figure 3. quality sensor will require continual recaliUtilising a non-linear measurement tech- brating due to errors. When well calibrated, an accurate and temperature stable moisture sensor should glide up and down the linear moisture line all year round. However, a good sensor that is poorly added. For a relatively small capital outlay, both labour and energy costs as well as the amount of material spoilt are reduced, potentially saving the producer many 10s of thousands of pounds over the year.

FEATURE nique that is capable of maintaining linearity from the absorption point (also known as S.S.D) to complete saturation by definition will give excellent accuracy limited only by the accuracy of the calibration. The Hydronix range of sensors is supported in over 65 countries worldwide and our team of engineers is backed-up by our free global exchange program. If you would like to know more about measuring moisture at your feed plant, or about using the latest microwave moisture measurement technology, contact Hydronix:

There are a variety of moisture measurement sensors available on the market, all of which claim to provide the best and most accurate results. It is well known that the microwave measurement technique provides the best results in the feed and grain industry

To conclude

Figure 5: A multi-point calibration technique is recommended

calibrated or an unreliable sensor that is well calibrated may, for a short period perform well when operating at or around the moisture range to which it was calibrated. As the sensor moves away from this moisture range the reading will exhibit an ever-increasing error. The same error will also exist for a sensor with an underlying non-linear measurement technique that is well calibrated. For the demanding end-user, even a small calibration error can lead to large errors as the moisture varies even with an accurate sensor as shown in Figure 4. As appealing as it may be, leading manufacturers would agree that any claim made by a sensor manufacturer that their equipment does not require calibrating will lead to sub-optimal results in the field regardless of technical claims concerning the measurement technique of the sensor. A well-calibrated sensor that operates with a different calibration slope with for example wheat and barley is likely to be more accurate than a sensor that claims one calibration fits all. Figure 4 shows the increasing inaccuracy arising from either a very small calibration error or the assumption of the gradient of the calibration slope. At the point of calibration, between 12.5 percent and 13.5 percent moisture the sensor is reasonably accurate but as the working moisture range moves away from this range, perhaps with a change of material from a different supplier, the error will progressively increase shown by the grey area which is the difference between the theoretically correct calibration and the one in use. It is usual for moisture sensors measuring in the silos to be calibrated to an absolute moisture percentage. Hydronix always recommends that the best and most failsafe method for calibrating a sensor is to use a multi-point technique such as that used in its free software, Hydro-Com, see Figure 5.
Grain

There are a variety of moisture measurement sensors available on the market, all of which claim to provide the best and most accurate results. It is well known that the microwave measurement technique provides the best results in the feed More inforMation: Figure 4: The effects of assuming and grain industry. When choosing Jason Laffan a calibration slope a sensor, you should ensure that Managing Director it is fully temperature stable and Hydronix Limited completely linear over the working range at Advances in technology Tel:+441483468900 More advanced microwave moisture which you wish to operate. A digital sensor Email:enquiries@hydronix.com Website:www.hydronix.com sensors, such as those manufactured by utilising an underlying measurement techHydronix now provide the Filip_Anzeige_130x180mm_GB_c_Filip_Anzeige_117x191mm_US_c 16.11.11 17:33 Seite 1 user with the ability to choose between different measurement modes, which is of particular interest to feed and grain producers. Different organic materials sieve cleaning brushes have their own distinct dielec sieve cleaners with studs tric property behaviour and bottom cleaners will therefore respond differ roller mill brushes ently to each of the underlying measurement modes. The best mode may now be selected for the material and the application to best account for the temperature range, precision required and bulk density changes over time. The new measurement modes were introduced into the Hydronix Hydro-Mix VII sensor for mixers and conveyors during 2010, and proved to be extremely successful Dynamic movement in the feed and grain indusand effective cleaning try providing producers with is achieved by combining more accurate results than the ideal shape, size ever before. and weight Slider knob, This new technology was tongue and then introduced in 2011 corner scrapers work into the new generation of together to provide Hydro-Probe sensor. Typically effective pan cleaning installed underneath silos or on conveyors, the new HydroStuds or bristles Probe III has proved to be arranged around even more successful than its the entire perimeter predecessor. Eliminating the produce exceptional need for continual and timesieve cleaning consuming manual moisture tests, the Hydro-Probe provides an instant and continual FILIP GmbH moisture level directly to the Tel: + 49 (0)52 41 - 2 93 30 Mill brush manufacturer control system. Fax: + 49 (0)52 41 - 2 03 21 Johann - Sewerin-Str. 8 This allows driers to be E-Mail: info@filip-gmbh.com D - 33330 Guetersloh adjusted immediately, or the Outside Germany: We will be glad to name our local representative! correct amount of additives, such as mould inhibitors to be

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