Category: Innovation

Industry-4-0, Innovation 25 January 2024

Plastic identification, verification and classification using Visum Palm™

identificación, verificación y clasificación
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Plastic identification, verification and classification using Visum Palm™

In this article we will address the problem of classification and plastic identification using the Visum Palm™ handheld NIR analyser as an agile, real-time and non-destructive technique useful in different processes, whether in the recycling of post-industrial plastic, in the analysis and classification of post-consumer plastic, in the identification of polymeric raw materials for their industrialisation, or even in areas of research and development of new plastic.

In all these cases, near infrared spectroscopy is presented as a valuable tool used for the characterisation of plastic compared to traditional methods of analysis.

Identification and sorting is important in plastic recycling and in manufacturing when using recycled plastic, as in both cases it must be ensured that the plastic materials are as pure and clean as possible because low levels of impurities can significantly affect the quality and performance of a recycled batch.

Although there are several portable NIR analyzers on the market, it is important to consider the spectral range that the equipment works with, the size of the measurement area (spectrum acquisition) and the spectral resolution (the quality of the spectrum obtained). The new Visum Palm™ analyser has a measuring area of 10 mm diameter, operates in the spectral range 900-1700 nm with a resolution of only 3 nm (↓ nm = ↑ spectral resolution). It is a self-contained device with an embedded computer and touchscreen and therefore does not need to be connected to a computer or smartphone to work with it.

Análise de forragens e espectroscopia nir

The new Visum Palm™, which includes a polymers library, allows readings and determinations to be made at the line without the need for sample preparation in less than 3 seconds. It is also possible to use it as a laboratory device as it has a support base that allows the attachment of different sample holders for the analysis of pellets, flakes or plastic up to 2 mm.

The factory library included in the analyser has the following classes: PMMA, PE, PC, PETG, EVA, PVC, PET, PU, PS, ABS, PA, PP, VIN, PLA, PBT, PMP, POMC, PPS, PVA, PPSU, EMA, PHBV, PAEK, PBAT, PBS, TPES, TPS, MABS, HIPS, MBS, SBC, PCL, PEEK, PHB, SAN, PI, PB.

Extend and develop your own library with Visum Master™

Visum Master™ is a computer software that allows the end user to create, extend and strengthen their own identification, classification and quantification methods or libraries without the need for a specialist or technical knowledge of spectroscopy, making the analyser a truly open system to meet present and future analysis needs (new polymer classes, new suppliers, etc.).

As shown below, it is possible to incorporate spectra of new samples within an existing class or to incorporate new classes and thus keep the library as robust and up-to-date as possible in order to be able to classify or identify plastic.

plastics

Plastic identification

It is a working method that allows the plastic identification analysed within the library available in the analyser. The result obtained, as can be seen below, is the type of polymer with the highest similarity and the following (from highest to lowest similarity).

Image 1: Visum Palm™ screen performing plastic identification

Plastic identification screen visum palm polymers identification

Polymer Verification

As with plastic identification, it is based on a mathematical procedure of similarity but it allows choosing a type of material to be analysed within the identification library to confirm its identity. The result of the verification analysis is PASS / FAIL. In case of a negative result (FAIL), it provides the class corresponding to the type of plastic analysed. Both cases are shown below.

polymers_identification

Plastic classification

In contrast to plastic identification analysis, classification uses machine learning algorithms to accurately analyse and classify samples that are spectrally very similar to each other, where a double check is necessary to determine the polymer class (PET/PETG, for example). Through the Visum Master™ software, the user can create his own classification libraries for the most problematic cases.

As a result of the analysis, the user obtains the corresponding class.

In conclusion, NIR spectroscopy is a very valuable and effective tool for plastic identification or classification and, although not covered in this article, it is also useful for manufacturers of plastic and new formulations to quantify blends. The open nature of the analyser through the Visum Master™ software makes the Visum Palm™ analyser an open, self-contained system that can continuously introduce new samples, spectra and generate different libraries without the need for a specialist.

By IRIS Technology Solutions
Industry-4-0, Innovation 10 October 2023

IRIS Technology Solutions at Alimentaria FoodTech 2023

FoodTech trade show
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IRIS Technology Solutions at Alimentaria FoodTech 2023

At the end of September, IRIS Technology Solutions presented at Alimentaria FoodTech trade show 2023 Barcelona the various real-time quality and process control solutions for the industry that the Catalan company manufactures and markets under the Visum® brand.

Alimentaria-FoodTech is the machinery, technology and ingredients show that integrates the food processing and preservation value chain. It is a transversal fair that serves the food and beverage production industry from raw materials to commercial distribution.

Visum® Solutions

Visum® solutions optimize and digitize quality control on different production lines. They operate on the basis of NIR, Raman, Hyperspectral and Machine Vision spectroscopy, providing real-time information for decision making and rectification of production processes. In addition, trade show participants were able to see first-hand the new Visum Palm™ handheld NIR analyser.

handheld nir analyser

The new Visum Palm™ analyzer has an innovative and ergonomic design, as well as the possibility to perform analysis at any time and place without the need to connect it to any external electronic device. This is possible because it incorporates an embedded touch screen and computer, which allow all the routine functionalities of the device.

In addition, it has the Visum Master™, this software, unlike the most common modeling and calibration software on the market, with which the user has to have certain technical knowledge about chemometrics or entrust such a task to a third party.

It allows to perform calibrations in an automated and agile way only by incorporating spectra and references (quantitative or qualitative), in addition to other functionalities.

Shealthy Project

shealthy

IRIS Technology Solutions has also presented at FoodTech the European SHEALTHY project, which seeks to evaluate and develop an optimal combination of non-thermal sanitization, preservation and stabilization methods to improve safety (inactivation of pathogens and spoilage microorganisms) while preserving nutritional quality (up to 30%) and extending shelf life (up to 50%) of F&V products. By combining and modulating non-thermal technologies with minimal processing operations, SHEALTHY’s approach will finally be able to meet today’s growing consumer demand for healthy food.

By IRIS Technology Solutions
Ai, Digitalization, Industry-4-0, Innovation, Pharma-4-0 5 September 2023

New Visum Palm™ AI-assisted handheld NIR analyser

handheld nir analyser
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New Visum Palm™ AI-assisted handheld NIR analyser

IRIS Technology Solutions introduces the latest version of its Visum Palm™ portable NIR analyser to complement its Visum® range of real-time process analysers for industry.

The new Visum Palm™ is a fully portable NIR spectrophotometer that allows real-time analysis of different substances, products or mixtures, without the need for traditional laboratory and sampling techniques, allowing industry to obtain results on the spot to make decisions or correct production process parameters.

The new generation Visum Palm™ brings with it an innovative design and a radical change in the way users experience NIR technology, now assisted by AI with the Visum Master™ software, so that each manufacturer can automatically create their own predictive models or calibrations according to their control and analysis needs.

 

Design, autonomy and robustness

The Visum Palm™ analyser offers an innovative and ergonomic design, as well as the possibility to perform analysis at any time and place without having to connect it to any external electronic device. This is possible because it incorporates an embedded touch screen and computer, which enable all the routine functionalities of the device.

The Visum Palm™ operates in the 900 to 1700 nm range, as this is the band that best combines availability of chemical information with price and technological maturity. It operates mainly in diffuse reflectance mode, for which it has specially designed and patented optics to extract as much information as possible from the sample. Specifically, it has a large illumination area (50 mm diameter) and a collection area of 10 mm. These features differentiate it from similar analysers in terms of its suitability for analysing heterogeneous samples, which is most often the case in real working conditions. In cases where heterogeneity is more evident, the device is configurable to calculate and report the average of a given number of repetitions.

The Visum Palm™ analyser is IP65 compliant, making it resistant to dust, moisture and water. It is also rugged enough to be carried and tested almost anywhere indoors or outdoors and even comes with a stand for desktop or tabletop use.

 

A new AI-assisted user experience

Unlike most common modelling and calibration software on the market, which requires the user to have some technical knowledge of chemometrics or entrust the task to a third party, Visum Master™ PC-based software makes NIR technology even more accessible by automating pre-processing, multivariate analysis algorithm selection and validation. This allows any user to generate models by simply inputting spectra and references (quantitative or qualitative) for routine real-time analysis to replace traditional analysis.

The new software also allows to extend and edit pre-existing models, synchronise with the portable analyser to import spectra, export models, download measurement results, automatically generate analytical method validation reports and audit reports for GMP environments, and to check the metrological performance of the device in a guided manner when needed.

 

For industry and GMP environments

While NIR technology has a myriad of applications in numerous industries such as plastics, food, chemical, agribusiness, wood, biofuels, to mention the most relevant but not the only ones; it is for the pharmaceutical industry and GMP environments where the new Visum Palm™ device introduces significant novelties at the level of usability and functionality. It is 21 CFR Part 11 compliant, allowing the generation and display of an automatic Audit Trail report, the record of all device activity, where comments and observations can be incorporated. It also allows the user to automatically generate the analytical method validations developed and perform metrological checks of the device when required and download the results at a later date.

“NIR technology today must be easy to use and understand, and at the same time it must give the user the freedom and autonomy to exploit it to the full and facilitate their day-to-day work. Technology must be an enabler. We will continue to take further steps in terms of automation and new functionalities because we are convinced that this is the right way forward and what the industry and the people in it need”, says Oonagh Mc Nerney, Director of IRIS Technology Solutions, S.L.

 

The new Visum Palm™ handheld NIR analyser is now available here, where you can also find technical information about the device, videos and contact IRIS Technology Solutions, S.L. for a demonstration or specific enquiry.

 

By IRIS Technology Solutions
Innovation, Environment, Industry-4-0 15 December 2022

Recycling of multilayer and composite plastics

Recycling of multilayer plastics
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Plastics bring value as convenient, versatile and lightweight consumer products, as well as advanced performance in high-end applications such as automobiles. However, despite their usefulness, it is clear that linear, single-use consumption of plastics is incompatible with Europe’s transition to a circular economy. This model prioritises the reuse and recycling of resources, with the aim of reducing waste and retaining as much value as possible.

In terms of plastics recycling, some progress has been made. For example, 41.5% of the plastic packaging waste generated was recycled in 2018. This is still not enough to achieve full circularity, especially in the recycling of multilayer plastics that are difficult to separate. In addition, it is essential that recycling technologies keep up with new materials entering the market

Advanced plastics recycling

The EU-funded MultiCycle project aims to develop a pilot plant for industrial recycling and treatment of multilayer plastics. This plant focuses on two important industrial segments that pose a challenge for recyclers: multilayer packaging/flexible films and fibre-reinforced thermoplastic composites of the type used in the automotive sector.

Technology selection

NIR and HSI-NIR are the techniques conventionally used for container sorting. The former is suitable for individual pieces of packaging prior to shredding and can also provide an initial assessment of suitability before moving on to the latter, which provides a mode of imaging. In the MultiCycle project, packaging materials were fed onto a conveyor in the form of flakes up to 5 cm and therefore HSI was the target technique for final implementation in the prototype incoming control system. However, point NIR spectroscopy was the target technique used for monitoring dissolved and recovered plastics during and after the CreaSolv® process, where no imaging capability is required. Complementary techniques such as LIBS and FTIR have also been preliminarily tested to detect other fractions such as AlOx or to enable the detection of black containers, which could improve the accuracy of monitoring when a full system is implemented.

Near Infrared Spectroscopy (NIRS)

NIR spectroscopy is a vibrational spectroscopic technique. In this region, absorption spectra are composed of overtones and combination bands with respect to the fundamental modes of molecules in the mid-infrared region. NIR radiation has a wavelength range of 900 to 2500 nm. The absorption bands in this region are broad, due to the high degree of band overlap. In addition, due to the selection rules of the phenomena, the signal intensity is ten to a thousand times weaker than signals in the mid-infrared region. However, this lack of intensity and the high band overlap is compensated by its high specificity. The specificity of NIR spectroscopy is based on the fact that NH, OH and CH bonds strongly absorb radiation at these wavelengths, which makes it an optimal tool for the study of organic compounds and polymers. In addition, the use of multivariate methods for the analysis of spectral data has made it possible to exploit the full potential of the technique for identification, discrimination, classification and quantification purposes.

Hyperspectral imaging system in the shortwave infrared region (HSI-SWIR)

Current technologies for the monitoring and classification of solid plastic waste in the near-infrared region have incorporated hyperspectral cameras in their configuration. They allow, instead of collecting a single spectrum, to record a hyperspectral image (HSI) of the sample (hyperspectral cube), which contains not only the spatial location of the sample, but also its chemical composition and distribution. In this regard, several publications and technological developments have been made using HSI-SWIR for the classification and identification of plastics.

A basic hyperspectral imaging system, shown in Fig.3, includes in its configuration, a sensitive sensor (CCD camera); a broadband illumination source; a spectrometer, which separates the backscattered/transmitted light into its different wavelengths and, when required, a conveyor belt for sampling. In this case, it should be noted that the conveyor belt must be synchronised with the recording speed of the CCD sensor for proper image acquisition. A hyperspectral system provides a hypercube as output. A hypercube is a set of data arranged in three dimensions, two spatial (an XY plane) and one spectral (𝜆, wavelength), as depicted below.

Measurement parameters:

The most relevant parameters for hyperspectral cube recording can be summarised as follows:

  • Camera frame rate (fps)
  • Transporter speed (m/s)
  • Camera-transporter distance (cm) and collection time (µs). These parameters are interrelated and must be optimised to obtain good quality recorded spectra.

The hyperspectral images were recorded with a SWIR camera operating in the range ∼900-1700 nm, at a frame rate of 214 fps, with an integration time of 350𝜇s and a transporter speed of 25m/min.

Recycling of multilayer plastics

Figure 1: (Left) Sample set no. 1. Includes flexible plastic films of PE, PP, PA and PET. Single and double combinations of these polymers (i.e. polymer A/polymer B) were included. (Right) Classification image made by a PLSDA model.

Project conclusions

The HSI monitoring system has been able to provide a good approximation of the percentage of polymer content in a multilayer polymer sample. In the worst case, the most abundant polymer present in the sample is predicted, so with large batches, the final percentages would be fairly accurate. In terms of monitoring the dissolution process, only 1 polymer and 1 solvent were provided for testing in IRIS. The results obtained with Visum Palm™ were as expected, but no process models were tested over time. The dissolution control was not performed due to problems with the viscometer installed in LOEMI. For this reason, there are no further results in this section.

For the monitoring of the automotive samples, the selected technique was LIBS. The optimisation of LIBS was complicated, as it was the first time it was used. Models were run by changing different parameters to select the best conditions. The PATbox tool for LIBS did not allow data acquisition at the same speed as the LIBS software, so the models had to be modified. Finally, the models were calibrated and tested to predict the type of fibres in the black plastics PP and PA. The results obtained in the 3 batches were satisfactory, as the predictions given by the models (chemometrics and machine learning) were close to the real content. Some tests were performed to differentiate between PP and PA, but the classification rate was around 80% of good predictions. In general, mislabelling and soiling of the samples were not very useful for the development of the prediction models.

By IRIS Technology Solutions
Environment, Innovation 3 August 2022

Circular Economy: Bioplastics vs. black plastics

bioplastics
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Circular Economy: Bioplastics vs. black plastics

By 2022, a significant share of used plastics – in some countries more than two thirds – will be incinerated or sent to landfill, and only a small share will be recycled (30%). In this context, there is an urgent need to find biodegradable substitute materials for black plastics that cannot be recovered today by traditional optical and sorting techniques, while maintaining their functional properties in industrial applications.

In this context, IRIS Technology presented last July at SIMULTECH 2022, its research “Biodegradation prediction and modelling for decision support”, a mathematical AI model that allows predicting the biodegradation of natural materials of food origin that are candidates to replace carbon compounds currently used in the automotive industry, electronics, plastic bags, among others.

Bioplastics and black plastics

The term bioplastic is a complex one, encompassing materials that come from renewable sources and materials that are biodegradable. While many plastics, under certain natural or man-made conditions, are degradable, not all are recoverable. In particular, black plastics, because of their pigment or colour, escape the traditional infrared systems used in the recycling industry for their separation.

BionTop

The work being carried out by IRIS Technology together with a dozen European entities falls under the umbrella of the European BIOnTop project, which aims to develop a range of bioplastics and complementary coatings and validate their use in food and personal care packaging, determining their environmental impact and the economic viability of an extended substitution project in the industry.

BionTop Project 2

Administrations and Companies participating in the project

  • Germany: European Bioplastics EV, Fachhochschule Albstadt-Sigmaringen
  • Belgium: Istrazivanjei Razvoj Centre Scientifique & Technique del’Industrie Textile Belge ASBL, Organic Waste Systems NV, Sioen Industries NV
  • Slovenia: BIO-Mi Drustvo S Ogranicenom Odgovornoscu za Proizvodnju
  • Spain: AIMPLAS, Cristobal Meseguer SA, Emsur Macdonell SA, IRIS Technology Solutions SL, Queserías Entrepinares SA, Ubesol SL
  • Estonia: Wearebio OU
  • Italy: Consorzio Interuniversitario Nazionale per la Scienza e Tecnologia dei Materiali, Enco SRL, Laboratori Archa SRL, Movimento Consumatori, Planet Bioplastics SRL, Romei SRL
  • Netherlands: Total Corbion PLA BV
  • Czech Republic: Silon SRO
By IRIS Technology Solutions
Industry-4-0, Innovation 24 January 2022

IRIS Technology develops the first industrial system for the chemical control and inspection of melamine boards

Image HyperSpectra
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IRIS Technology, a Spanish engineering company that manufactures photonic solutions for online quality control, has developed the first industrial system for real-time quality control of melamine or particle boards with NIR and hyperspectral technology.

 

The wood industry, and consequently the furniture and furnishing industry, is a sector that continues to grow by leaps and bounds worldwide, with a year-on-year increase of 6.5%, still boosted by the increase in consumption during the pandemic. So, not surprisingly, technology is accompanying the industry in this growth by combining production and operations techniques with smart technologies such as photonics, analytics and artificial intelligence brought about by Industry 4.0.

 

The new chemical vision industrial system, manufactured and patented by IRIS Technology, uses NIRS (Near Infrared Spectroscopy) technology and machine learning together with chemometric models to analyse the composition of each melamine board unit produced, non-invasively, It can quantitatively analyse the distribution of the moisture parameter on the impregnation line and classify the curing level of each board in order to detect defects early, correct factory processes and reject or remanufacture boards.

 

Until now, the control of this type of parameters in the melamine production process was only carried out through destructive laboratory methods and visual inspection, implying a high cost for the manufacturer and the difficult -if not impossible- inspection of all the units produced. This new technological application stands as a solution for the inspection of this type of boards, thus reducing defective units, losses, claims and consequently improving the brand image of the manufacturer.

 

For more information please contact IRIS Technology www.iris-eng.com

finsa
By IRIS Technology Solutions
Industry-4-0, Innovation, Pharma-4-0 27 October 2021

Pre-release: The new Visum Raman analyzer will go on pre-sale to a small number of pharmaceutical companies.

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IRIS Technology presents in the latest edition of Farmespaña Industrial Magazine – Farmaforum Special – its line of PAT analyzers for the pharmaceutical industry with a great novelty for the industry, the expectation for the launch of its Raman analyzer, which will be available both to work at-line or integrated to the line, for the beginning of next year, and whose official launch will begin with a pre-sale stage to a limited number of Spanish pharmaceutical companies.

 

“Our industry knowledge and PAT experience have led us to develop this new member of our Visum family of spectroscopic analyzers, mainly to meet many needs for in-line formulation control, where the particularities of each project and the chemometric modeling work behind each one of them is extremely complex,” said Alejandro Rosales, Science and Technology Manager at IRIS.

 

IRIS Technology’s technical teams are currently working on expanding Raman analyzer applications to processes at different stages of the drug manufacturing industry prior to launch, and invite pharma companies interested in particular applications to perform ad-hoc modeling at no cost.

 

Visum Raman achieves a signal-to-noise ratio far superior to its market competitors because, thanks to its temporal resolution, it physically mitigates the undesirable effects of fluorescence, making it possible to extend the range of applications in the pharmaceutical industry beyond identification.

 

“It is important to us that the Visum Raman, like its NIR siblings, is strongly oriented to the process and production industry, and helps operators and technicians in the factory to make technological decisions at the line and in real time. For this reason, we have already been collaborating with some companies in response to particular challenges, but with a strong transversality to other products and processes. In relation to the reasonable technological uncertainty that this type of industrial-scale projects always generate, at IRIS we work under the “proof of concept” scheme, i.e., we previously validate the success of the project on a reduced scale and in comparison with the criteria agreed with the client”, remarked the Deputy Director of IRIS, Joan Puig.

 

Do you have a challenge for our Raman analyzers? Do you want to participate in the pre-sale? Write to us here.

 

By IRIS Technology Solutions
Industry-4-0, Innovation 14 May 2021

IRIS Technology among the Top 10 Spanish mechanical engineering startups of 2021

ENGINEERING
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The company IRIS Technology, is awarded in the ranking “Top Mechanical Engineering Startups in Spain 2021”, elaborated by the British portal “startupill.com“, in the position Nº6 of the most innovative companies in the mechanical engineering industry and worth following this year.

Startupill.com bases its selection on the performance of companies in categories such as: innovation, innovative ideas, innovative route to market, innovative product, growth, exponential growth, exponential growth strategy, management and social impact. Look the entire publication here.

About IRIS Technology

IRIS (www.iris-eng.com) is an advanced engineering company that manufactures PAT systems for in-line process and quality control in the pharmaceutical, food and chemical industries with its own devices registered under the VISUM Devices trademark. As a manufacturer, it realizes tailor-made solutions and ad-hoc configurations for different processes and analytical or control needs, from the actual engineering development to the specific chemometric modeling. In addition, it actively collaborates in numerous EU innovation projects with international partners and has in its staff physicists, mathematicians, chemometricians, opticians, engineers, software developers and highly specialized profiles from the world of science and technology.

By IRIS Technology Solutions