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Improve Packaging Line Efficiency with Thermal Imaging

Improve Packaging Line Efficiency Using Thermal Inspection

Using Thermal Imaging to Improve Packaging Line Efficiency

Improving packaging line efficiency is essential for businesses that want to stay competitive and profitable. A more efficient packaging line can lead to reduced costs, improved productivity, and increased customer satisfaction. Adding an inspection system to your line is recommended as it can reduce bad seals and increase overall efficiency.

Thermal seal inspection (TSI) is a fully automated system that uses thermal cameras to inspect the seals on packaging materials. This method detects temperature differences that can indicate faulty seals, such as gaps or areas of weak adhesion. With a thermal inspection system, you can quickly identify any defective packaging that may cause product damage, contamination, or shipping delays.

Here are some ways a thermal inspection system can improve the efficiency of your packaging line:

Reduce Downtime

A thermal seal inspection system can quickly detect defective packaging before it goes down the production line. This helps reduce the likelihood of downtime caused by packaging failure.

Reduce Film Waste

Thermal seal inspection helps to identify faulty seals early, which in turn reduces the need for rework. This results in a significant reduction in the amount of film wasted during the packaging process.

Improve Quality of Packages

Thermal imaging can detect temperature differences on the surface of packaging, allowing for the identification of even minor seal defects. This improves the overall quality of your packaging, reducing the risk of product recalls or customer complaints.

Increase Throughput

Automated inspections are faster than manual inspections, allowing for higher throughput in your packaging line.

Minimize Waste

By reducing the amount of faulty seals and rework needed, businesses can minimize waste and improve sustainability in their packaging operations.

Reduce the Chance of Missed Defects

Automated inspections offer the advantage of being consistent and impartial, which greatly reduces the potential for human error. This reduces the chance of missed defects that can lead to product recalls or customer complaints.

Easy to Integrate

Thermal cameras can be easily installed at various points along the line to ensure consistent inspection of packaging seals. The system requires very little hardware, making installation a very straightforward process.

Good Return on Investment

Businesses can recoup their investment in thermal seal inspection systems quickly by saving money on waste and rework costs.

Preventative Maintenance

Detecting faulty seals before they cause issues downstream can help to prevent costly breakdowns or maintenance issues with packaging equipment.

Enhance Customer Satisfaction

Enhanced package quality and reduced defect risk can result in greater customer satisfaction, ultimately boosting brand reputation and fostering customer loyalty.

How does thermal seal inspection work?

Thermal cameras can be used to inspect heat-sealed packaging by detecting temperature differences on the surface of the packaging. Heat-sealed packages are formed by applying heat to the packaging material, which melts and fuses to create a seal. Thermal seal inspection systems work by using infrared cameras to “see” the residual heat from thermal-based sealing processes. Identifying a good seal by the temperature profile allows TSI to reliably detect good and bad seals.

TSI Software Display

A properly formed seal should be uniform, without any gaps or defects. However, issues with the seal, such as incomplete sealing, contamination, or defects, can affect the temperature distribution on the package’s surface. The thermal camera can quickly and non destructively identify any defects or anomalies in the seal.

Packages Suitable for Thermal Inspection

Thermal seal inspection can work for different types of packaging, such as:

  • Flexible Packaging – This includes pouches, bags, and sachets made from plastic films, aluminum foil, and paper.
  • Rigid Packaging – This includes trays, clamshells, and blisters made from plastic, glass, and metal materials.
  • Sealed Containers – This includes cans, jars, and bottles made from glass, plastic, and metal.
  • Pharmaceutical Packaging – This includes blister packs, pouches, and bottles used for medication.
  • Food Packaging – This includes trays, bags, and bottles used for food and beverage products.

Understanding the Impact of Packaging Materials on Thermal Imaging Inspection

To effectively use thermal imaging to inspect heat sealed packaging, it’s important to know how packaging materials look in infrared. The type of material used affects how well thermal imaging works for quality inspection.

Packaging materials have different emissivity levels that measure how well they emit thermal radiation. Materials with high emissivity are better at absorbing and emitting thermal radiation and are easier to detect using thermal imaging cameras. Materials with low emissivity, such as aluminum foil or metallicized films, can be challenging to inspect. This is because they reflect thermal radiation, making it difficult to obtain accurate temperature readings.

Visible and IR images of aluminum foil demonstrate how thermal reflections can interfere with temperature measurements. The IR image displays yellow and orange colors. These colors do not come from heat emitted by the foil. Instead, they are warm reflections from a hand placed over the foil.

Visible and IR images of aluminum foil demonstrate how thermal reflections can interfere with temperature measurements. The IR image displays yellow and orange colors. These colors do not come from heat emitted by the foil. Instead, they are warm reflections from a hand placed over the foil.

Additionally, some packaging materials, such as plastics, can be thermally transparent in certain infrared wavebands. Plastic materials make it difficult to detect temperature variations on the material’s surface.

Visible and IR images of a plastic bag demonstrating opacity in the visible spectrum and transparency in the infrared wavebands.

Visible and IR images of a plastic bag demonstrating opacity in the visible spectrum and transparency in the infrared wavebands.

To overcome these inspection challenges, infrared filters can be used to block out specific infrared wavelengths. Thermal camera wavebands can also be selected to improve the camera’s sensitivity to specific materials.

Conclusion

Thermal seal inspection can help businesses improve their packaging line by reducing downtime, waste, and missed defects. TSI systems can detect even minor seal defects, improving the quality of packaging and reducing the risk of product recalls. MoviTHERM’s thermal seal inspection is easy to integrate and offers a good return on investment. By detecting faulty seals early, businesses can avoid issues and enhance customer satisfaction.

2024-08-16T17:20:23-07:00Thursday, March 21, 2024|Blog|
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Understanding the Risks of Fire in Battery Storages

What are the Risks of Fire in Battery Storages & How to Prevent Them?

Understanding the Risks and Ensuring Safety

As the demand for renewable energy sources continues to rise, battery storage technology has become a critical component in the transition to a more sustainable future. While li-ion batteries are known for their high energy density and rechargeable capabilities, they also pose significant safety risks, including the potential for fires. The importance of fire protection for lithium battery storage is ever increasing. Fire protection systems can ensure the safety of people and property.

In this article, we will explore the various fire protection strategies and technologies used in battery storage systems to prevent, detect, and mitigate the impact of fires.

The Fire Hazards of Lithium-ion Batteries

In recent years, there has been a significant increase in fires related to Battery Energy Storage Systems (BESS). While BESS offers a viable solution for energy storage, the associated fire risks cannot be ignored. The fires related to BESS can be attributed to various factors such as thermal runaway, manufacturing defects, battery damage, and improper installation.

Thermal Runaway: What It Is and How to Prevent It

Lithium-ion batteries pose significant fire hazards when stored improperly. They contain flammable electrolytes that can ignite and create a fire that can quickly spread, leading to property damage, injuries, and even fatalities. When lithium-ion batteries are stored together, there is a risk of a chain reaction where a single battery’s thermal runaway can cause other batteries to catch fire.

Battery Thermal Runaway Cycle Initiation EventsThermal runaway is a dangerous chain reaction that can occur in lithium-ion batteries, leading to overheating, gas generation, and even explosions. It can happen when a cell’s temperature rises above a critical threshold due to overcharging, high ambient temperature, or internal short circuits.

Once initiated, thermal runaway can spread to other cells, leading to a cascading failure that can be hard to control. To prevent thermal runaway in battery storage, it is essential to monitor the temperature of the batteries, limit the charging rate, avoid overcharging, and keep the ambient temperature within a safe range. Proper ventilation, early detection systems, and emergency response plans can also help mitigate the consequences of thermal runaway if it occurs.

Thermal imaging can be a useful tool to monitor the temperature of battery cells and prevent thermal runaway. By using thermal cameras, operators can detect temperature changes in real-time and quickly identify any hotspots or abnormal heat signatures.

This allows them to take immediate action to cool down the affected cells and prevent a potential thermal runaway event. Thermal imaging can also help identify any defective cells that may be generating excess heat and remove them from service before they pose a risk of starting a fire.

Manufacturing Defects

Manufacturing defects in lithium-ion batteries can be a significant fire hazard. These defects can cause short circuits or other malfunctions that can lead to thermal runaway and ultimately a fire.

For example, if the separator that keeps the positive and negative electrodes apart is defective, it can cause the electrodes to touch. This would result in a short circuit and overheat the battery. Additionally, if the anode or cathode is contaminated during manufacturing, it can lead to a buildup of gas, which can rupture the cell and cause a fire.

battery that has been destroyed due to fire explosion

Thermal imaging can be an effective tool for detecting manufacturing defects in lithium-ion batteries. Thermal imaging cameras can detect temperature anomalies in the battery cells, which can indicate defects or other issues that could potentially lead to thermal runaway.

For example, a hotspot in the battery cell may indicate a manufacturing defect that is causing the battery to generate excess heat. By identifying these defects early on, manufacturers can take corrective action to prevent potential fires or other hazards. Thermal imaging can also be used during the testing phase of battery development to detect defects before the batteries are put into use.

Improper Installation

Improper installation of battery energy storage systems can create fire hazards. If the BESS is not installed properly, it can lead to incorrect wiring, overloading of circuits, or improper ventilation, all of which can cause overheating and thermal runaway. If the storage system is not installed in a location with appropriate fire protection measures, a fire can spread quickly and cause significant damage. It is important to ensure that BESS installations are conducted by qualified professionals following manufacturer’s guidelines and local codes and regulations.

In addition, it is also important to install an early fire detection (EFD) system. These early warning systems help ensure safety of all equipment and individuals. EFD systems can detect potential fires in their early stages, allowing for prompt response and mitigation.

EFD systems use various methods, including thermal imaging cameras, to detect the first signs of a fire. By installing an early fire detection system, the risk of a BESS fire can be greatly reduced, and the potential damage can be minimized.

Ensuring Safety with Thermal Imaging

As previously mentioned, thermal imaging is an important tool for ensuring safety in lithium ion battery energy storage systems. Thermal cameras can help detect defects or early signs of thermal runaway at all stages of the battery lifecycle. This includes manufacturing, operation, and storage.

A fire protection system that leverages thermal cameras, such as EFD, are a must for energy storage systems (ESS). By installing an early fire detection system in battery storage facilities, any potential fires can be quickly detected and contained.

MoviTHERM iEFD System

The MoviTHERM iEFD system has been proven highly effective in preventing and detecting li-ion battery fires. It addresses the unique challenges of battery storage facilities, including the risk of thermal runaway and potential for fire to rapidly spread through numerous batteries.

One of the key advantages of the iEFD system is its real-time temperature monitoring of individual battery cells. With real-time monitoring, the potential of thermal runaway or other fire hazards can be detected early. This allows facility managers to take immediate action to prevent fires from spreading.

The system incorporates smart thermal imaging and intelligent alarm management features for maximum safety and reliability. The iEFD system is flexible and scalable, suitable for use in a broad range of battery storage applications. It can be customized to meet specific requirements, providing peace of mind that facilities are protected.

early fire detection system for battery storage facilities

Contact us today to discuss how the MoviTHERM iEFD can help keep your storage safe and secure.

2024-08-16T17:20:32-07:00Thursday, March 21, 2024|Blog|
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How to Prevent Lithium Battery Fire in Energy Storage Facilities

How to Prevent Lithium Battery Fire

Safeguard Your Energy Storage Facility from Lithium Battery Fires

Energy storage facilities are at a heightened risk for fire due to the nature of lithium-ion batteries. These batteries are widely used in electric vehicles, personal electronic devices, and energy storage systems. Once a fire starts in a battery storage, it can quickly escalate and become difficult to extinguish. A spontaneous fire can lead to significant property damage, environmental pollution, and potential harm to personnel.

In this article, we discuss how to prevent lithium battery fire in energy storage facilities with the help of thermal imaging.

Lithium-ion Battery Fires Are on the Rise

According to data from the National Fire Protection Association (NFPA), there were an estimated 3,050 fires in battery storage and charging areas in the US between 2012 and 2016. Of these fires, 739 were reported in 2016 alone. In addition, several high-profile incidents of lithium-ion battery fires have occurred recently, including the 2013 fire at the Boeing 787 Dreamliner’s battery compartment and the 2016 Samsung Galaxy Note 7 battery explosions.

Why do lithium batteries catch fire?

Lithium batteries can catch fire due to a process called thermal runaway. This happens when the battery gets too hot, causing a chain reaction that raises the temperature even more. This can cause the flammable electrolyte inside the battery to ignite, leading to a fire that can spread rapidly. Thermal runaway can be triggered by various factors, including overcharging, physical damage, manufacturing defects, or exposure to high temperatures.

Battery Thermal Runaway Cycle Initiation EventsDetect Overheating of Lithium Batteries

One of the most effective ways to prevent battery fires is through early detection of hotspots in battery cells. Thermal imaging cameras can detect hotspots in battery cells caused by factors such as overcharging, damaged cells, or other issues that could lead to thermal runaway.

The cameras can detect temperature changes that are invisible to the naked eye and can quickly identify potential fire hazards. This allows operators to take appropriate measures to prevent a fire from starting or spreading. For instance, if a hotspot is detected, the operator can immediately shut down the affected battery or move it to a safe location for cooling. Additionally, thermal imaging can be integrated with other monitoring systems to provide a more comprehensive view of battery health and reduce the risk of fires.

There are various ways to implement thermal imaging technology for monitoring lithium-ion battery storage. For example, early fire detection systems use cameras to detect overheating in lithium-ion batteries. These systems monitor the temperature of the batteries and detect any anomalies or hotspots in real time. The early detection provided by these systems allows operators to take preventative measures to mitigate fire risk.

lithium ion battery that has been over heated and caught fire

Early Fire Detection Systems

MoviTHERM has developed iEFD, a system that uses smart thermal cameras and cloud connectivity to detect hotspots in lithium-ion batteries. The iEFD system is strategically installed and can monitor specific battery cells or charging stations. The system continuously monitors the temperature of the batteries and compares the readings to historical data to detect any anomalies. If a hotspot is detected, the system automatically sends an alert to the operator, who can properly mitigate the fire risk.

early fire detection system for battery storage facilities

Detect Hotspots Early

The iEFD system offers several benefits in preventing lithium-ion battery fires. The system detects hotspots early, allowing operators to take preventative measures to mitigate the fire risk. This early detection can significantly reduce the risk of damage, preventing downtime and potential loss of revenue.

Improve Emergency Planning

The iEFD system improves emergency planning by providing a map feature that can locate the hotspot and notify relevant personnel. The map feature helps track the fire’s movement, allowing emergency responders to quickly locate and respond to the affected area. This increases their response time and keeps personnel safe. The map feature is also useful for training purposes, allowing personnel to visualize the potential spread of a fire and understand how to respond effectively.

Easy Integration

The iEFD system can be integrated with fire suppression systems to provide a more robust solution. In the event of a fire, the system can trigger the fire suppression system to suppress the fire before it spreads. This integrated approach can reduce the risk of damage to property.

Following Safety Measures

Thermal cameras and other early detection systems are important in preventing fires in storage facilities, but they are only a warning system. They can detect hotspots in batteries and alert operators to take action, but they can’t put out the fire by themselves. To prevent fires, it’s essential to take additional safety measures such as proper battery storage and charging protocols, regular maintenance, and training staff to handle potential fires.

Finally, it is essential to have a plan in place for responding to battery fires. It’s important to be prepared in case of a fire by having emergency contact information readily available. Including the fire department and other relevant authorities. Additionally, clear evacuation procedures should be established for all employees and other occupants of the facility.

Conclusion

Overall, preventing lithium battery fires in battery storage facilities requires a multi faceted approach. This includes a combination of technology, proper handling and storage, regular maintenance and inspections, fire suppression systems, and emergency response planning.

By combining early fire detection systems with other safety measures, facility operators can minimize the risk of battery fires and ensure the safe and reliable operation of battery energy storage systems.

2024-08-16T17:20:41-07:00Thursday, March 21, 2024|Blog|
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Optimizing Infrared Viewing Windows with Materials and Coatings

Optimize Infrared Viewing Windows with Materials and Coatings

Infrared viewing windows are critical components of thermal imaging systems that play a significant role in transmitting infrared radiation from an object to the detector without compromising the integrity of the system. In harsh environments, where high temperatures, pressures, and contaminants can damage the optical system, these windows are especially important.

This article explores the various exotic optical materials used for infrared viewing windows, including their unique properties and limitations. It also covers the different types of coatings applied to these windows, their impact on performance, and the factors to consider when selecting the appropriate material and coating for an infrared viewing window. The crucial role these windows play in thermal imaging systems, allow for high-quality image capture in harsh environments.

Infrared Viewing Windows

Infrared viewing windows can operate in two different spectral ranges: midwave infrared (MWIR) and longwave infrared (LWIR). MWIR is generally defined as the wavelength range of 3-5 µm, while LWIR is defined as the wavelength range of 8-14 µm. Different materials are used for MWIR and LWIR windows due to the differences in their transmission properties.

Exotic Optical Materials

Exotic optical materials are often used for infrared viewing windows because of their unique properties that make them ideal for certain applications. These materials include:

  1. Germanium (Ge): Germanium is a popular material for MWIR and LWIR windows due to its high refractive index, high thermal conductivity, and excellent transmission properties in the infrared range. However, it is relatively soft and can be easily scratched or damaged, so it requires a protective coating.
  2. Zinc Selenide (ZnSe): ZnSe is another popular material for infrared viewing windows due to its excellent transmission properties in the MWIR and LWIR ranges. It also has a low absorption coefficient and is highly resistant to thermal shock. However, it is relatively soft and can be easily scratched or damaged, so it requires a protective coating.
  3. Sapphire (Al2O3): Sapphire is a material that is highly resistant to abrasion, erosion, and thermal shock, making it an ideal material for harsh environments. It has excellent transmission properties in the MWIR and LWIR ranges, but its high refractive index can cause problems with image distortion.
  4. Calcium Fluoride (CaF2): CaF2 is a material with excellent transmission properties in the MWIR and LWIR ranges. It has a low absorption coefficient and is highly resistant to thermal shock. However, it is relatively soft and can be easily scratched or damaged, so it requires a protective coating.
  5. Silicon (Si): Silicon is a common material for visible-light windows, but it is also transparent in the MWIR range. It has a low refractive index, which can reduce reflection losses, but it is also more brittle than Germanium and can suffer from thermal stress in high-temperature applications.

Coatings

Coatings are often applied to infrared viewing windows to improve their performance. The four most common types of coatings are anti-reflective (AR) coatings, protective coatings, DLC coatings and wavelength specific coatings aka. Bandpass coatings.

  1. Anti-Reflective (AR) Coatings: AR coatings are used to minimize reflections and increase the transmission of infrared radiation through the window. These coatings are typically made of multiple layers of dielectric materials with different refractive indices.
  2. Protective Coatings: Protective coatings are used to protect the infrared viewing window from scratches, abrasions, and other forms of damage. These coatings are typically made of hard materials, such as diamond-like carbon (DLC) or silicon carbide (SiC).
  3. Diamond-Like Carbon (DLC) Coatings: DLC coatings are extremely hard and durable, making them ideal for use in harsh environments. They can also reduce reflection losses and improve transmission in the LWIR range.
  4. Wavelength Region Specific Coating: This coating is typically applied based on the intended application of the window. For example, a Germanium window may have a broadband coating, allowing wavelengths from 3 µm to 14 µm to pass through. A window made for a LWIR – Long Wave Infrared application may be a coating favoring 8 µm to 14 µm.

Impact on Performance

The choice of material and coating for an infrared viewing window can have a significant impact on its performance. The following factors should be considered when selecting a material and coating:

  1. Transmission: The transmission of infrared radiation through the window is the most important factor to consider. The material and coating should have high transmission properties in the desired spectral range.
  2. Durability: The material and coating should be durable enough to withstand the harsh conditions of the environment in which they will be used. They should be resistant to scratches, abrasions, thermal shock, and other forms of damage.
  3. Image Quality: The material and coating should not cause image distortion or reduce the clarity of the image.
  4. Cost: The cost of the material and coating should be considered, as some exotic materials and coatings can be expensive.

Conclusion

Infrared viewing windows are essential components of thermal imaging systems that enable the capture of high-quality images in harsh environments. The choice of material and coating for these windows plays a crucial role in their performance, considering factors such as transmission, durability, image quality, and cost. In this article we provided an overview of the various exotic optical materials and coatings used for infrared viewing windows, highlighting their unique properties and limitations.

Ultimately, selecting the appropriate material and coating for an infrared viewing window is essential in ensuring optimal performance and maximizing the system’s lifespan. With ongoing advancements in technology and materials, it is likely that the use of infrared viewing windows will continue to play a vital role in the evolution of thermal imaging systems in various applications, from military and aerospace to medical and industrial.

2024-08-16T17:20:49-07:00Thursday, March 21, 2024|Blog|
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What types of packages can be inspected with thermal imaging?

Types of Packages That Can Be Inspected Using Thermal Imaging

What types of packages can be inspected with thermal imaging technology? The answer to this question is crucial to ensuring the quality and safety of products within the packaging. Traditionally, inspecting the quality of seals in packaging has been a time-consuming and inefficient process. However, with technological advancements, thermal imaging has emerged as a reliable and efficient way of inspecting seal quality in packaging.

In this article, we will explore the different types of packaging that can be inspected with thermal imaging for seal quality, and how this technology is helping companies ensure the safety and quality of their products while improving efficiency and reducing costs.

types of packages that can be detected using thermal imaging

Flexible Packaging

Flexible packaging is popular in the food industry because it protects products from external factors such as moisture, air, and light. However, seal integrity is critical in maintaining product quality and safety. Thermal imaging can detect defects such as wrinkles, misaligned seals, and weak seals in flexible packaging.

rigid packaging can be inspected using thermal imaging

Rigid Packaging

Rigid packaging is commonly used for products that require more protection, such as pharmaceuticals and medical devices. The integrity of the seals in this type of packaging is critical in maintaining product sterility and preventing contamination. Thermal imaging can detect defects such as incomplete seals, leaks, and contamination in rigid packaging.

blister packaging can be inspected using thermal imaging

Blister Packaging

Blister packaging is commonly used in the pharmaceutical and medical industries to package pills and other small products. The seal quality of blister packaging is critical in maintaining the efficacy and safety of the products. Thermal imaging can detect defects in blister packaging, such as weak seals, punctures, and incomplete seals.

bottles can be inspected using infrared thermography

Bottles and Cans

Bottles and cans are commonly used for beverages, food, and pharmaceutical products. The integrity of the seals in these containers is critical in maintaining the quality and freshness of the products. Thermal imaging can detect defects such as leaks, weak seals, and contamination in bottles and cans.

Conclusion

Thermal imaging has revolutionized the way companies inspect the seal quality of their packaging. With its ability to detect defects such as weak seals, incomplete seals, leaks, and contamination in various types of packaging, including flexible, rigid, blister, and bottles and cans, thermal imaging has become a reliable and efficient method of ensuring the safety and quality of products.

At MoviTHERM, we offer a turnkey Thermal Seal Inspection solution, MoviTHERM TSI, that leverages thermal imaging technology to provide 100% quality inspection of heat-based sealing. Our system is designed to adapt to various seal inspection applications, helping companies improve efficiency, reduce costs, and ensure the safety and quality of their products. With MoviTHERM TSI, companies can have peace of mind knowing that their products are packaged safely and securely.

2024-08-16T17:21:10-07:00Thursday, March 21, 2024|Blog|
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Condition Monitoring Modalities for Predictive Maintenance

Condition Monitoring Methods for Predictive Maintenance

Using the correct modality of condition monitoring is critical to ensure an asset or process’s complete condition health assessment. Sometimes, feedback from multiple testing modalities is essential for accurate condition valuation. A multi-inspection approach to condition monitoring increases the chances of discovering multiple failure modes and detecting them early enough to make the necessary repairs before they become catastrophic.

Predictive Maintenance

The sweet spot for a maintenance program falls between the “degradation start” point and the “potential failure” point of an asset’s life (see chart below). Work performed on the equipment during the “normal state” period might be effective for asset health and facility uptime, producing the desired outcome. However, it is less efficient because maintenance resources are consumed on equipment that may not require upkeep or repair. Any work or investment in healthy machines in the “normal state” produces a certain amount of waste.

Alternatively, maintenance efforts and costs become reactive if the machine asset condition is allowed to degrade beyond the “potential failure” point. In this stage, maintenance professionals chase problems with machine performance severely compromised and facility downtime highly probable. Maintenance costs in this phase can accelerate rapidly with additional company losses due to lost output and production.

Maintenance Mode Curve

Maintenance Modes, Asset Condition vs Time to Failure

Identifying equipment degradation at the earliest stage beyond the “normal state” is optimal for predictive maintenance. Maintenance professionals can be alerted at the earliest signs of failure by monitoring asset conditions with oil analysis, ultrasound, vibration, and infrared thermography. When equipment failure is predicted to occur, condition-based maintenance can be carried out with repairs made according to the priority of equipment needs. Maintenance and repair costs can be optimized by eliminating rush orders for parts and conducting services during planned outages and turnarounds.

Infrared Thermography Inspection

Infrared Thermography

Infrared Thermography

Infrared (IR) cameras operate on the heat transfer principle of radiation. The infrared camera has a focal plane array of detector elements that sense infrared light from object surfaces. The radiation captured by the infrared camera detector is digitized, converted to data, and displayed as a viewable image. Calibrated IR cameras can report temperature measurements from specific spots, lines, and areas on live or recorded images.

Infrared Thermography is a proven and effective way to monitor machine health and detect potential failure points before a failure can occur. Critical in-service health and wear characteristics of electrical, mechanical, hydraulic, and steam equipment can be assessed using thermal imaging, and temperature data is valuable to predictive maintenance programs.

Infrared Thermography is the easiest non-contact temperature measurement method available. Monitoring mechanical components such as motors, bearings, heat exchangers, cooling fans, exhaust vents, pipes, and more for “hot spots” can alert of possible future fail points. In addition, thermal scans of electrical components, such as cables, wiring, terminals, and control panels, can quickly reveal problems such as load imbalance, current overload, loose wires, corroded terminals, or heat management issues. Thermal imaging makes these otherwise invisible problems visible so corrective action can be taken before catastrophic failure. Deploying IR cameras to monitor critical equipment can be a very effective first line of defense against unexpected and unplanned downtime.

Vibration Analysis

Mechanical engineer use vibration meter to measurement of centrifugal pump vibration and electric motor at oil and gas plant or chemical factory.

Vibration Analysis

Anytime a piece of machinery is running it is making vibrations. Vibration analysis is a condition monitoring technique for measuring machinery vibration levels and frequencies and then using that information to analyze how healthy the machines and their components are.

A vibration sensor is a device used to assess the amount and frequency of vibration in a mechanical system. The most common vibration sensor is an accelerometer. Accelerometers are mounted directly on the machine for measurement. Signal data from the accelerometer is recorded by connecting a data collector. The recorded signal data is then analyzed by a computer program and trained vibration analysts to determine the machine’s health and identify possible impending problems.

Vibration analysis is an effective evaluation method for detecting mechanical imbalance, misalignment, looseness, and late-stage bearing wear.

Ultrasound Inspection

Ultrasonic Imaging

Ultrasonic Inspection

Ultrasonic sensors detect airborne and structure-borne ultrasounds inaudible to the human ear and convert them into audible and viewable signals. Ultrasound is a proven technology that detects specific mechanical, electrical, and other faults much sooner than other technologies. For instance, ultrasound monitoring can detect the most subtle ultrasonic noise from the friction of poorly lubricated or failing bearings before an infrared camera will see the resulting heat. Additional applications for ultrasound inspection include the detection of leaks, blockage, stuck valves, and failed traps in steam systems. Or identifying anomalies like corona, arcing, and tracking in electrical systems.

A recent development in ultrasound inspection is the release of ultrasonic imagers. These imagers collect ultrasonic sound signals and superimpose them on a corresponding visible image of the target area. Ultrasonic imagers simplify the analysis process by creating a visible ultrasound image. Ultrasonic imagers are available in portable hand-help and fixed-mounted configurations.

Oil Analysis

several sample oil to analysis and tribology test

Oil Analysis

Sampling and examining the lubrication oil of a machine can give clues to the machine’s health. For example, understanding particulate matter’s quantity, composition, and size in a machine’s lubricating oil can indicate machine wear. A typical machine will have low levels of solids with a size of less than 10 microns. As the machine components wear, the size and amount of particulate will increase. Oil analysis can also reveal oil health and identify the presence of contaminants that compromise lubrication efficiency.

As the equipment required to conduct oil analysis can be expensive and require extensive operator training, most companies will collect samples on a routine basis and submit them to a lab for analysis. These labs will analyze the samples and provide test reports, helping clients understand if the lubrication oil needs replacement or if a mechanical system should be serviced.

A well-implemented oil analysis program provides a window into lubricated mechanical equipment to help identify and resolve problems early, mitigating unrecoverable downtime.

Other Methods

Other condition-monitoring modalities include motor circuit analysis, radiography, laser interferometry, electrical monitoring, and electromagnetic measurement.

Buyer’s Guide for Condition Monitoring

Find All Your Answers in Our Guide

condition monitoring buyer's guide download

  • What types of sensors can I connect to the system?

  • How does the system keep my data safe from hackers?

  • Does the system alert of potential failures?

  • Does the system automatically save historical data?

  • Which type of system will save you money in the long run?

2024-08-16T17:21:18-07:00Thursday, March 21, 2024|Blog|
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How does a fire prevention plan benefit your workplace?

How does a fire prevention plan benefit your workplace?

A fire prevention plan can benefit your workplace by reducing the risks of fires and putting the safety of all employees first.

What is a fire prevention plan?

A fire prevention plan is a written document that outlines the procedures and actions that a business or organization should take to prevent fires from occurring and to protect employees, customers, and other stakeholders in the event that a fire does occur. A fire prevention plan typically includes information on the types of fires that may occur in the workplace, the steps that should be taken to prevent those fires from occurring, and the procedures that should be followed in the event of a fire.

What are the benefits?

Here are some specific benefits of having a fire prevention plan in place:

Reduced risk of fire

By taking steps to prevent fires from occurring, a fire prevention plan can help to reduce the risk of fires in the workplace. This can help to protect employees, customers, and other stakeholders, as well as the business itself.

Enhanced safety

A fire prevention plan can help to ensure that employees are aware of the risks of fire and the steps they should take to prevent fires from occurring. This can help to create a safer work environment for all employees.

Protects property and assets

A fire can cause significant damage to a business’s property and assets, including equipment, inventory, and documents. By having a fire prevention plan in place, a business can take steps to protect its property and assets from damage in the event of a fire.

Minimizes disruption to business operations

If a fire does occur, it can disrupt business operations and cause significant losses. A fire prevention plan can help to minimize the disruption to business operations and help the business to recover more quickly in the event of a fire.

Protects reputation

A fire can also damage a business’s reputation, particularly if it is not adequately prepared to prevent fires or respond to them. Having a fire prevention plan in place can help to protect a business’s reputation by demonstrating that the business is taking steps to ensure the safety of its employees and stakeholders.

What are some common components of a fire prevention plan?

Fire safety policies and procedures

A fire prevention plan should outline the policies and procedures that are in place to prevent fires from occurring in the workplace. This may include information on the use of open flames, electrical equipment, and other potential fire hazards.

Evacuation procedures

A fire prevention plan should include information on how to evacuate the workplace in the event of a fire, including the location of exits, the use of emergency alarms, and the designated assembly areas.

Emergency response plan

A fire prevention plan should outline the procedures that should be followed in the event of a fire, including who is responsible for calling the fire department, activating the alarm system, and evacuating the building.

Employee training

A fire prevention plan should include information on the training that employees should receive to help them understand the risks of fire and how to prevent fires from occurring. This may include training on how to use fire extinguishers, evacuation procedures, and other safety measures.

Maintenance and inspection

A fire prevention plan should outline the procedures for maintaining and inspecting the workplace to identify and address any potential fire hazards. This may include regular inspections of electrical equipment, heating and ventilation systems, and other potential fire hazards.

Early Fire Detection Systems Make Fire Prevention Planning Easy

Early fire detection systems can play a crucial role in fire prevention planning by helping to identify potential fires before they become a major threat. These systems can detect the presence of smoke or other indicators of a fire and trigger an alarm, alerting employees and emergency responders to the potential danger.

By providing early warning of a potential fire, early fire detection systems can help to prevent the spread of fire and minimize the potential damage and disruption caused by a fire. This can make fire prevention planning much easier, as it allows businesses and organizations to take proactive measures to prevent fires from occurring and to respond quickly in the event of a fire.

Learn more about early fire detection systems.

20+ Page Guide to Fire Detection Systems

Find All Your Answers in Our Guide

Infrared Non-destructive Testing Guide
  • Find a reliable fire detection system.

  • Save money in the long run.

  • Know the must-have features.

  • Find a system that adapts to your business needs.

  • Understand the importance of safety and security.
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2024-08-16T17:21:27-07:00Thursday, March 21, 2024|Blog|
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Induction Seal vs Heat Seal: What’s the difference?

What is the Difference Between Induction Seal vs Heat Seal?

The main difference between an induction seal and a heat seal is the way in which the seal is created. Induction sealing uses electromagnetic induction to generate heat and create a tamper-evident seal, while heat sealing uses heat to bond two materials together. In this article, we break things down to compare the benefits and challenges of an induction seal vs a heat seal.

Induction Seals

An induction seal is a type of closure that is applied to the top of a container. It is made of a layer of material that is bonded to the top of the container and creates a tamper-evident seal when it is heated by induction.

Induction sealing is a non-contact sealing process that uses electromagnetic induction to generate heat in a conductive material. This heat is used to seal the top of a container, such as a bottle or jar, in order to preserve the freshness and quality of the product inside.

Benefits of Using an Induction Seal Machine

There are several benefits to using an induction seal machine:

  1. Tamper-evident: Induction sealing creates a tamper-evident seal that is difficult to remove or break without leaving evidence of tampering. This helps to ensure the integrity of the product inside the container and can provide peace of mind for consumers.
  2. Preservation: Induction sealing helps to preserve the freshness and quality of the product inside the container. The seal helps to prevent contamination and can extend the shelf life of the product.
  3. Customization: Induction sealing equipment can be customized to work with a wide range of container sizes and shapes, making it suitable for a variety of applications.
  4. Efficiency: Induction sealing is a fast and efficient sealing process that can be easily integrated into a production line. It can seal containers at a high speed, which can help to increase productivity.
  5. Versatility: Induction sealing can be used with a variety of container materials, including plastic, glass, and metal. It can also be used with a wide range of products, including food, beverages, pharmaceuticals, and personal care products.

Challenges in Induction Seals

There are a few challenges that can arise when using induction sealing:

  1. Conductive material: Induction sealing requires the use of a conductive material, such as aluminum foil, in order to create the seal. If the material is not properly applied or is not of sufficient quality, it may not create a proper seal.
  2. Container size and shape: Induction sealing equipment is typically designed to work with a specific range of container sizes and shapes. If the container is outside of this range, it may not be compatible with the sealing equipment.
  3. Container material: The material of the container can also affect the effectiveness of the induction seal. Some materials, such as glass or certain types of plastic, may not be suitable for induction sealing.

Heat Seals

A heat seal, on the other hand, is a type of sealing process that uses heat to bond two materials together. Heat sealing is often used in packaging to seal bags or pouches, or to seal the edges of plastic sheets or films. This type of sealing process can be done using a variety of methods, including hot bar sealing, impulse sealing, and continuous sealing.

Benefits of Using a Heat Seal Machine

There are several benefits to using a heat seal machine:

  1. Speed: Heat sealing is a fast and efficient sealing process that can be easily integrated into a production line. It can seal bags or pouches at a high speed, which can help to increase productivity.
  2. Customization: Heat sealing equipment can be customized to work with a wide range of materials and seal configurations, making it suitable for a variety of applications.
  3. Versatility: Heat sealing can be used with a variety of materials, including plastic films and bags, paper products, and foil-lined materials. It can also be used to seal a wide range of products, including food, beverages, pharmaceuticals, and personal care products.
  4. Reliability: Heat sealing is generally considered a reliable sealing method that can create strong, consistent seals that are resistant to tampering and can withstand exposure to a variety of environmental conditions.
  5. Ease of use: Heat sealing equipment is typically easy to operate and maintain, making it suitable for businesses of all sizes. Overall, the benefits of using a heat seal machine depend on the specific application and the materials being sealed.

Challenges in Heat Seals

There are a few challenges that can arise when using heat sealing:

  1. Material compatibility: Heat sealing requires the use of materials that are compatible with the sealing process. If the materials being sealed are not compatible, the seal may be weak or may not hold up over time.
  2. Temperature: Heat sealing requires a specific temperature in order to create a strong, reliable seal. If the temperature is too low, the seal may not be strong enough. If the temperature is too high, the materials being sealed may be damaged or may become too weak to hold up over time.
  3. Speed: Some heat sealing processes, such as continuous sealing, require a high level of speed and precision in order to be effective. If the sealing process is not fast enough, it may result in weak or inconsistent seals.
  4. Pressure: Heat sealing often requires the application of pressure in order to create a strong seal. If the pressure is not sufficient, the seal may be weak or may fail.

Add Quality Assurance to Your Sealing Method

Thermal seal inspection can be used for quality assurance in heat seals and induction seals by identifying any defects or inconsistencies in the sealing process. This can help to ensure that the seals are strong, consistent, and reliable, which is important for preserving the quality and integrity of the product inside the container.

In the case of heat seals, thermal seal inspection can be used to identify any defects or inconsistencies in the sealing process that may result in weak or broken seals. This can be particularly important for products that are sensitive to contamination or require a long shelf life.

In the case of induction seals, thermal seal inspection can be used to ensure that the seals are properly applied and are of sufficient quality to preserve the product inside the container. This can help to ensure that the product remains fresh and of high quality until it is opened by the consumer.

Overall, thermal seal inspection is an important quality assurance tool for both heat seals and induction seals, as it helps to ensure that the seals are strong and reliable, and that the product inside the container is protected from contamination and other environmental factors.

Learn more about thermal seal inspections for quality assurance.

 

2024-08-16T17:21:36-07:00Thursday, March 21, 2024|Blog|
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5 Benefits of a Fire Detection System

Top 5 Benefits of Having a Fire Detection System

We have compiled the top 5 benefits to having a fire detection system installed in your business building.

Early fire detection (EFD) systems can be a vital component to business facilities and places of employment. These systems are responsible for protecting lives and property while reducing the effects of a fire. By detecting the presence of a fire in its early stages, these smart EFD systems can alert building occupants and emergency responders with ample time to take appropriate action and extinguish the fire or evacuate the building.

The images provided below were taken from our very own MoviTHERM’s iEFD system to help better explain the benefits of having a fire detection system installed in your facility.

1) Early Warning

Early fire detection systems can detect the presence of a fire in its early stages. With the help of infrared cameras, early detection systems are able to see the warming up of materials before the appearance of smoke particles or flames. Infrared cameras are the only fire detection device that are able to distinguish signs of fire before becoming visible to the human eye.

End-users can monitor and access all connected cameras and sensors by logging into the iEFD application. However, the system does not require human monitoring. iEFD is an intelligent early fire detection system that works on its own.

Benefits of a Fire Detection System

Views of connected infrared cameras through the iEFD dashboard.

2) Property Protection

An EFD system can help to protect the building and its contents from damage by detecting a fire early and alerting the authorities so that they can respond quickly. It is an important safety measure that can help to protect assets and minimize the impact of a fire on a business or organization.

During an incident, MoviTHERM’s iEFD automatically sends out a map of the hazard to all building occupants and first responders. The map is able to detect the location of the fire in real time and help understand how quickly the fire is evolving. This helps optimize the quick response time and protect building assets while keeping others out of harm’s way.

Benefits of a Fire Detection System, Map Views

Map Views from MoviTHERM’s iEFD System

3) Life Safety

An early fire detection system can save lives by alerting building occupants to the presence of a fire and allowing them to evacuate safely. Early warning alerts can notify a select group of people of a potential issue in the making. This buys valuable time to act on safety protocols and extinguish the hot spot before turning into a threatening hazard.

MoviTHERM’s iEFD system allows for alerts to be sent via email, text messaging or voice call. Each message is fully customizable based on the location and severity of the issue. This eliminates surprise and prevents employees from being in the wrong place at the wrong time.

4) Legal and Insurance Requirements

In many cases, building codes and insurance policies require the installation of a fire detection and alarm system to help protect against the risk of fire. By requiring a fire detection system as a condition of coverage, insurance companies can reduce the risk of losses due to fire and, in turn, reduce the cost of insurance premiums for policyholders.

In addition, some building codes and regulations may require the installation of a fire detection system, and insurance companies may require this as a condition of coverage in order to ensure compliance with these regulations.

5) Cost Savings

A fire detection system can help to minimize the cost of damages caused by a fire by detecting it early and alerting the authorities so that they can respond quickly. The NFPA (National Fire Protection Association) found that the average property damage cost of a fire for industrial properties is $128,099. By warning earlier on the pathway to ignition, facility managers can avert costly and potentially life threatening fires before they are permitted to start and spread.

Conclusion

Modern technology has enabled the development of many newer and more efficient ways of detecting fires in buildings. It is important to note that early fire detection systems do not replace existing detection and response protocols. Instead, the system functions as an early warning system, detecting areas in the facility where ignition may occur.

Overall, a fire detection system is an important safety measure that can help protect lives, property, and financial assets. Industries including coal, biomass, industrial laundry, wood processing, trash bunkers, and metal recycling can benefit from a fire detection system.

20+ Page Guide to Fire Detection Systems

Find All Your Answers in Our Guide

Infrared Non-destructive Testing Guide
  • Find a reliable fire detection system.

  • Save money in the long run.

  • Know the must-have features.

  • Find a system that adapts to your business needs.

  • Understand the importance of safety and security.
2024-08-16T17:21:45-07:00Thursday, March 21, 2024|Blog|
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Battery Thermal Runaway Risk & Prevention

The Risk of Battery Thermal Runaway and How to Prevent It

Battery thermal runaway is becoming a huge liability to companies that store and handle battery products. In recent years, battery storage, charging, and recycling centers have experienced increased fire activity caused by lithium ion battery thermal runaway.

One solution to reducing the risk of a battery fire are infrared cameras. Infrared fire detection systems monitor large areas and are able to detect heat releasing from battery packs or single batteries. Infrared cameras are the only device that are able to detect early signs of fire formation.

Risk of Thermal Runaway

Thermal runaway occurs in lithium ion batteries. Manufacturing defects or external misuse like overcharging, overheating, puncturing, or being crushed can lead to thermal runaway in lithium ion batteries. Thermal runaway occurs when the temperature of the li-ion battery reaches a critical state.

Battery Thermal Runaway Cycle Initiation Events

Lithium-Ion Battery Thermal Runaway Initiation Events

Internal causes of spontaneous ignition include coating defects at the electrode surface, contamination particles, and poor welds. Typically, these defects cause electrical shorts during operation that generate heat.

External causes include:

  • Electrical abuse from overcharging.
  • Mechanical abuse via crushing or puncture.
  • Thermal abuse from exposure to high temperature environments.

External initiating events are related to each other. For example, mechanical abuse from a puncture of the battery cell causes a short circuit, which is electrical abuse. The electrical abuse creates heating, which increases the lithium ion cell temperature, causing thermal abuse, which can trigger thermal runaway.

Preventing Thermal Runaway With Infrared Cameras

Various fire detection sensors are available today that alert of fire formation. The following chart shows the relative detectability of fire detection devices at different stages of fire development with corresponding damage levels.

Infrared camera systems are the first to alert before a fire develops. They are able to “see” heat generated by batteries early in the fire development process. Thermal cameras detect “fire” before forming smoke particles or flames.

Correct sensor selection and placement for battery monitoring are critical to ensure optimum detection performance. For outdoor or high airflow installations, infrared sensors are best for detection.

Fire Detector Response Time and Fire Progression vs. Damage Severity

Fire Detector Response Time and Fire Progression vs. Damage Severity

Leveraging the Advantages of IoT

Fire safety for battery storage, charging, and handling is an area that realizes the benefits of IoT. With smart fire detection systems, potential fires can more readily be detected and prevented.

With IoT, facility managers can connect multiple facilities into a central monitoring and alarming dashboard. Understanding the situation at all facilities improves the oversight and management of multiple systems from a single control point.

Smart fire detection systems can improve emergency planning by using algorithms and analytics. For example, analytics can consider factors such as:

  • The number of people in the facility
  • Facility maps
  • Location of the fire
  • The rate at which the fire is spreading
Sample Map View display from a cloud-based IoT Early Fire Detection Program

Sample Map View display from a cloud-based IoT Early Fire Detection Program

Conclusion

It is important to note that infrared fire detection systems do not replace existing detection and response protocols. Instead, the system functions as an early warning system – detecting areas in the facility where ignition may occur. New detection methods for heat, smoke, and fire are frequently developing.

Many new detection devices include wireless capabilities that make integrating IoT to infrared cameras a straightforward exercise. Beyond alarms and notifications, IoT infrared fire detection systems can provide automation controls like initiating and directing an extinguishing system.

Fire detection systems that leverage cloud computing require less hardware with a reduced installation burden. Available communication technology can be added to existing detectors, making IoT retrofitting existing systems easy. By warning earlier on the pathway to ignition, managers of the battery chain avert costly and potentially life threatening fires. First responders can react before the fire is permitted to start and spread.

Learn more about infrared fire detection systems.

2024-08-16T17:21:53-07:00Thursday, March 21, 2024|Blog|
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