The Importance of DDGS (moisture Control)
Distillers Dried Grains with Solubles (DDGS) is a by-product of bioethanol production and is widely used as livestock feed because it is rich in protein, fat, fiber, etc. Proper moisture management is essential to maintain the quality of DDGS and ensure the health of livestock.
High moisture content in DDGS can lead to problems during transportation and storage due to mold growth, deterioration in quality, and poor flowability. In particular, strict moisture control is required to prevent quality deterioration, as the Maillard reaction can adversely affect the digestibility of amino acids.
Intended audience and purpose of this article
This article assumes that the quality control personnel of feed manufacturers are the main readers. The aim is to provide a detailed explanation of how infrared moisture meters can help in process management and trend management in DDGS production process and to provide specific information for selecting the most suitable moisture meter.
Applications and Challenges of moisture Measurement in DDGS
moisture measurement in production process control
In the DDGS manufacturing process, corn starch is fermented to produce ethanol, and the remaining solids are then dried. Proper moisture control during this drying process is directly linked to product quality. Insufficient drying increases the risk of microbial growth, while excessive drying can cause amino acid denaturation and reduce nutritional value. Using an infrared moisture analyzer makes it possible to monitor moisture content in real time and optimize the drying process.
Moisture monitoring for quality maintenance and trend management
DDGS has a higher fat content than corn, and if it is transported without being cooled sufficiently, it can experience problems with caking. Additionally, DDGS produced from corn contaminated with the mycotoxin deoxynivalenol carries the risk of the mycotoxin also becoming concentrated. To avoid these problems, continuous moisture monitoring is important for maintaining quality. Infrared moisture analyzers are suitable for product trend management because they provide fast, non-destructive measurements.
Characteristics of moisture measurement required at various sites
Moisture measurement of DDGS is required in various fields, including process control within production plants, quality inspection before shipment, and research development. Accurate and fast moisture measurement is particularly essential for feed manufacturers to ensure stable quality DDGS and maintain consistent quality in the manufacture of compound feed. Ease of use and maintenance at the work site are also important factors.
Comparison of moisture measurement principles and advantages of infrared moisture analyzers
Overview of major moisture measurement methods (infrared, heat drying, electrical resistance, etc.)
The main methods for measuring moisture are:
Heating drying method (loss on drying method)
- This method involves heating the sample and determining moisture content from the change in mass before and after moisture evaporates. This is a widely adopted official method and allows for high accuracy measurements, but it takes a long time to complete.
- These are equipped with high accuracy balances and offer a variety of measurement modes.
Infrared (near-infrared spectroscopy)
- Moisture content is calculated by irradiating the sample with infrared light and measuring the amount of absorption of specific wavelengths by moisture non-contact, rapid measurement is possible, making it suitable for real-time process management.
Electrical resistance type/electrical capacitance type
- Moisture content is measured by passing current through the sample and observing the change in electrical resistance and capacitance. This method is non-destructive and quick, but may be easily affected by the specific gravity and thickness.
- It is mainly used to measure moisture of wood and building materials, and is not suitable for powders such as DDGS.
Karl Fischer titration
- This method utilizes the principle of the quantitative reaction between water and iodine to accurately measure trace amounts of moisture. Because it reacts specifically to water, it is suitable for cases where extremely high accuracy is required, but it requires the use of reagents and is time-consuming to measure.
Why choose an infrared moisture analyzer for DDGS?
The primary reasons infrared moisture analyzers are chosen for DDGS are their non-contact, fast, and high accuracy. DDGS is often handled as a powder or granule, and non-contact infrared moisture analyzers reduce the risk of sample contamination or physical damage and enable continuous online measurement.
In particular, real-time monitoring of moisture content on the production line enables quick adjustments to the drying process, contributing to maintaining consistent product quality. Another major advantage is that measurement time is shorter than with the heat drying method, and large volumes of samples can be processed efficiently.
Sample volume, measurement range, measurement speed, and on-site suitability
When measuring moisture in DDGS, it is important to:
Sample volume
- Generally, infrared moisture analyzers can measure samples weighing a few grams to a few tens of grams. Models with larger sample pans can accommodate more sample, improving sample representativeness and drying efficiency.
Measurement range
- The moisture range for DDGS is about 10-12% for dry types, but can be as high as 70% high moisture type for wet types. moisture The meter must be able to handle these broad moisture ranges. Many infrared moisture meters have a measurement range of 0-100% (wet base solids) and can handle a wide variety of DDGS conditions.
Measurement Speed
- Rapid measurement results are essential for process control. Infrared moisture analyzers provide real-time measurements, which means the results can be reflected immediately in production line adjustments.
Suitable for the site
- When considering that quality control personnel at feed manufacturers will be using the instrument on-site at factories, ease of operation, ease of maintenance, and durability are important. moisture meters with simple operation panels and structure that are easy to clean are suitable for on-site use.
Key points for selecting an infrared moisture analyzer for DDGS
Accuracy and measurement speed
In DDGS quality control, the accuracy of moisture quantity is very important. In particular, it is desirable to choose a model that can achieve the same accuracy as the measurement results in accordance with official law. Some infrared moisture meters have high accuracy models with a minimum moisture display of 0.01% or a mass display of 1mg.
Measurement speed is also an important selection point for process control and trend management in the production process. Rapid results allow for timely adjustments to manufacturing conditions and reduce product quality variations.
Operation, maintainability, and cost
When considering ease of use in the field, ease operation is also important. moisture analyzers with an intuitive interface, measurement condition registration functions, data memory functions, etc. will improve work efficiency.
Regarding maintainability, ease of removal and cleaning are key points. Because the nature of samples makes them prone to dust and adhesion, it is desirable to choose a model with structure that can be kept clean.
The balance between installation costs and running costs must also be considered. It is important to understand not only the initial investment, but also the costs of consumables and regular calibration and maintenance.
Installation location and operation image
Infrared moisture meters for DDGS are mainly expected to be used in feed manufacturers' factories and quality control departments. The installation location could be near the production line or in the inspection room. Models that can be measured online in real-time can be integrated into production lines for a higher level of process control.
The operational image is to measure moisture by taking regular samples, or continuously measuring the moisture of DDGS on the production line, and recording and analyzing the data to help manage quality trends and detect problems early.
Specific checklist for model selection
Below is a specific checklist for selecting an infrared moisture analyzer for DDGS:
- Measurement method: Infrared method
- Measurement accuracy: Does it meet the required accuracy, such as a minimum moisture display of 0.01%?
- Measurement speed: Can measurements be made inline, such as in real time?
- Measurement range: Does it cover the expected moisture range of DDGS (e.g., 0-100% wet basis)?
- Sample volume: Can measurements be performed with an appropriate sample volume?
- operation: Is display easy to see and is it easy operation?
- Maintenance: Is structure easy to clean? Are consumables easily available?
- Durability: Is the design robust to withstand use in a factory environment?
- data management: Is it possible to save and output measurement data (RS-485, LAN, etc.)?
- Support system: Does the manufacturer offer sufficient support for calibration, maintenance, and troubleshooting?
Popular infrared moisture meter models and feature comparison
Chino IRMA Infrared Moisture and Thickness Meter
The Chino IRMA Infrared Moisture and Thickness Meter uses infrared light to simultaneously measure moisture and thickness without contact. It is particularly suitable for online measurement in continuous production lines, contributing to real-time process management. For powders such as DDGS, the reflective method allows you to measure the surface moisture and determine the dryness state.
Key points for introducing a near-infrared moisture meter
When introducing a near-infrared moisture analyzer, it is important to consider the following points:
- Selecting the wavelength range: Choose a model that can effectively measure the specific wavelengths absorption by moisture (e.g., 1450 nm or 1940 nm).
- Data management function: Measurement data can be graphed in real time on a PC or managed by a PLC, which helps analyze quality trends and ensure traceability.
Usage and tips based on case studies
Infrared moisture meters are used to measure moisture of a wide range of samples, from powders and granules to pastes and liquids. For example, accurate moisture measurements can be achieved for light samples (such as feathers) or samples that burn easily (such as candy, caramel, and cream cheese) by adjusting the drying mode and temperature settings.
When measuring DDGS, spreading and plating the sample evenly affects the accuracy of the measurement. Proper plating promotes uniform heating and moisture evaporation, and is an important tip for obtaining reliable data. In addition, optimizing the measurement conditions by creating calibration curve tailored to characteristic of the sample will result in more stable measurement results.
Latest Case Studies of Infrared Moisture Meters for DDGS
Example of process management at a feed manufacturer
A feed manufacturer used to measure moisture in the drying process of DDGS by random inspection, but the long-term measurement time made it difficult to feedback in real time. Therefore, we installed an infrared moisture meter and installed it on the drying line to continuously monitor the moisture amount of DDGS.
This allows for real-time adjustment of the dryer's temperature and conveying speed, ensuring that the product's moisture content is always within the optimal range. It is especially effective as a moisture absorption measure during the rainy season, and greatly contributes to the stabilization of quality.
Actual results and feedback from the field
The following effects have been reported from introducing an infrared moisture meter:
- Stabilizing quality: Real-time moisture management reduces variations in product moisture content, stabilizing quality. This has also led to fewer customer complaints. Selection of wavelength range: Select a model that can effectively measure the specific wavelengths absorption by moisture (e.g., 1450 nm or 1940 nm).
- Improved production efficiency: Optimized drying process reduce over-drying and under-drying, resulting in lower energy costs and increased production throughput.
- Reduction of waste: By being able to detect defective products early and take prompt action, product waste has been significantly reduced.
- Reduced workload: Compared to conventional measurement methods, the workload for sampling and measurement has been reduced, reducing the workload for workers.
Comments from the field include, "When we first introduced the system, we had to go through a lot of trial and error to set the measurement conditions, but once we found the optimal conditions, we were able to obtain stable, high accuracy data," and "Because it is contactless, it can be used safely from a hygienic standpoint."
Best practices for strengthening quality control
In addition to implementing infrared moisture analyzers, best practices for enhancing DDGS quality control include:
- Multi-Point Measurement: By measuring moisture at different points along the production line, you can understand moisture fluctuations throughout process and identify bottlenecks.
- Regular calibration: Regular calibration is essential to maintain the measurement accuracy of your moisture analyzer. Calibration using saturated salt solutions or standard samples is recommended.
- Data integration and analysis: By centrally managing measurement data and performing trend analysis and statistical analyzing, we implement the PDCA cycle of quality control and strive for continuous improvement.
- Collaboration with external organizations: If necessary, it may be effective to collaborate with external specialist organizations to conduct more detailed constituent analysis and quality evaluation.
Summary and future trends
Prospects for advanced moisture management at production sites
The moisture management of feed ingredients, including DDGS, is a critical factor that significantly affects product quality, safety, and production efficiency. Infrared moisture meters are expected to play a central role in the advancement of moisture management at production sites in the future due to their characteristic non-contact, non-destructive, and high-speed measurement.
In the future, field of view the realization of a smart factory, in which real-time data obtained from moisture meters is automatically analyzing used to predict and control optimize drying conditions, in conjunction with AI and IoT technologies. This will minimize human error, further improving quality and reducing production costs.
Frequently asked questions about selection and implementation Q&A
Q: What is the most important thing to consider when measuring moisture in DDGS?
- A: When it comes to process control, trend management in the production process, accuracy, measurement speed, and ease of use in the field are particularly important. Infrared moisture meters are powerful tools that meet these requirements.
Q: Which should I choose, heat drying or infrared drying?
- A: The heat drying method is high accuracy but takes time to measure. The infrared method is non-contact and allows for quick measurement, making it suitable for real-time process control of powders and granules like DDGS.
Q: Are there any limitations on sample volume or moisture content?
- A: Most infrared moisture analyzers have a wide moisture range (0-100%) that is sufficient for measuring DDGS.
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