Multiplexed NIR spectrometer technology

NIR identification in sorting processes

Multiplexed NIR spectrometer are widly used for the identification of plastic material in recycling plants. Waste collections from e.g. household waste are identified and analysed by an optical spectrometer and can therefore be sorted out.

KUSTAx.xMPL-24V - Multiplexed NIR spectrometer for recycling

KUSTA1.9MPL-24V/KUSTA2.2MPL-24V - Multiplexed NIR spectrometer for material identification in sorting plants
KUSTAx.xMPL-24V - Multiplexed NIR spectrometer for material identification in sorting plants

Material identification in sorting plants

Multiplexed NIR spectrometer KUSTA1.9MPL-24V and KUSTA2.2MPL-24V (formerly KUSTA1.9MPL and KUSTA2.2MPL) are fast scanning near-infrared sensors, which are used for the identification of bulk solids in sorting plants. On a conveyor belt the singulated material is passed by under the illumination unit and the reflected radiation is transferred to the optical multiplexer via fiber cables. The multiplexed spectrometer scans the 64 measuring tracks at frequencies of up to 70 Hz and sends the identification results to the process control via an ethernet protocol.

KUSTA1.9MPL-24V is mainly used in plastic- and waste paper recycling, while KUSTA2.2MPL-24V with an extended wavelength range is designed for C&D recycling. Depending on the application certain standard identification routines are included, which enable to reject several material types referring to freely selectable criteria.

In the version “-24V”, which is available from January 2016, the optical multiplexer, the spectrometer and the RGB sensor come in a separate housing of protection degree IP65, which can be mounted directly at the probe. Due to the high scan rate, materials on even 2 to 3 m wide conveyor belts can be identified at speeds of up to 3 m/s. For the detection of smaller particles (< 30 mm in diameter) hyperspectral imaging cameras KUSTAx.xMSI are recommended.

Additional equipment is described below.
Suitable software for LLA NIR technology is described here.

Schematic illustration of a sorting plant based on KUSTAx.xMPL-24V

Schematic illustration of a sorting plant with KUSTAx.xMPL-24V

Technical specification KUSTAx.xMPL-24V

  KUSTA1.9MPL-24V KUSTA2.2MPL-24V
Method Non-contact and non-destructive testing (NDT) method based on NIR spectroscopy;
Detection of absolute remission as a function of the wavelength 
Wavelength range  1.36 µm - 1.94 µm 1.1 µm - 2.2 µm
Spectral resolution   < 8 nm
Dispersion per pixel 4 nm
Scan rate 30 Hz - 70 Hz
Number of measurement tracks Max. 64
16bit RGB sensor Integrated
Operating voltage optical unit 24V DC, max. 3,6A (without industrial PC and control cabinet heating)
Operating voltage industrial PC 24V DC, max. 4,8 A
Operating voltage control cabinet heating 24V DC, 7A, 150W
Voltage 24V
power supply
90…265 V AC, 50-60 Hz, fuse 20 A (T)
Input: 100 V ... 240 V AC; Output: 24V DC / 20A
Environmental operating temperature +5 °C to +45 °C
Environmental operating humidity In process: 5 % - 95 %
20 % - 95 % rel.
Weight 31 kg
Dimensions (LxWxH) 500 mm x 500 mm x 300 mm
Base device Optic module containing the spectrometer, optical multiplexer and control electronics in a housing of protection class IP65, external: industrial PC, 24V power adapter
PC configuration Operating system Windows® 7 Embedded, 1,7 GHz, 8 GByte RAM, Solid State Disk 80 GByte, conectivity: DVI, COM, USB, Ethernet
Software Control software KustaMPL, customer specific analysis routines
Optional: spectrometric development environment KustaSpec
Operation Process mode: the process unit interacts via Ethernet interface with the industrial PC, which evaluates the spectra. Controling the system with a TFT display, mouse and keyboard for service purposes is possible but is not included in the scope of delivery.
Probe lines PMAmpl (Remission) or PMT (Transmission)
Scope of delivery Multiplexed NIR spectrometer KUSTAx.xMPL-24V, industrial-PC, 24V power supply


Product picture

Setup KUSTAx.xMPL-24V and probe line PMAmpl

Download product brochure

KUSTA1.9MPL-24V (PDF)

uniSPECx.xMPL-24V - Multiplexed NIR spectrometer for science

uniSPECx.xMPL-24V - Multiplexed NIR spectrometer for laboratory usage
uniSPECx.xMPL-24V - Multiplexed NIR spectrometer for laboratory usage

NIR technology for quality control

Multiplexed NIR spectrometer uniSPEC1.9MPL-24V and uniSPEC2.2MPL-24V (former uniSPEC1.9MPL and uniSPEC2.2MPL) were developed for analytical evaluation of material in the production process. Due to the high spectral resolution, these NIR spectrometers are ideal tools for scientific applications. Additionally, a high luminous intensity and a large sensitivity of the spectrometers are perfect properties for the use in quantitative- and rapid analysis applications of material streams.

The spectrometer are widely used as online analytics in food industries, plastics- and paper industry, for thickness measurement in control of coatings, the quality control in mineral industry and many more. Depending on the application, uniSPEC1.9MPL-24V or uniSPEC2.2MPL-24V is utilised. LLA advises the best fitting device for the customised application.

For each application, customised analysis modules are developed. Additional control software for the NIR spectrometer is custom-built and scope of delivery. The user interface can be designed and customised. The software can be used to store measured information for a future analysis or to change parameters in working processes.

The multiplexed NIR spectrometer can be connected to probe lines (64 measurement tracks) via fiber cables. Thereby a spatially resolved recording of material streams is generated.

In real time, analytical results will be automatically forwarded to a subsequent control system (e.g. nozzle control system) by a standardised interface (e.g. Profibus, Ethernet). This ensures a reliable identification and ejection of defective material (impurities, rejects, extraneous material).

Additional equipment is described below.
Suitable software for LLA NIR technology is described here.

Qualitative and quantitative analysis in the plastic industry
Analytical evaluation of industrial minerals
Evaluation of layers in the printing industry
Analytical evaluation in the food industry


Technical specification uniSPEC1.9MPL-24V / uniSPEC2.2MPL-24V

  uniSPEC1.9MPL-24V uniSPEC2.2MPL-24V
Measurement method Contactless and destruction free measurement based on NIR spectroscopy; measurement of absolute remission depending on the wave length
Wavelength range 1.36 µm – 1.94 µm 1.1 µm – 2.2 µm
Spectral resolution < 8 nm
Dispersion per pixel 4 nm
Scan rate 30 Hz – 70 Hz
Number of measurement positions Max. 64
12bit RGB sensor Integrated
Operating voltage
optical unit
24V DC, max. 3.6A (without industrial PC and control cabinet heating )
Operating voltage
industrial PC
24V DC, max. 4.8 A
Operating voltage
control cabinet heating
24V DC, 7A, 150W
Voltage 24V power supply 90…265 V AC, 50-60 Hz, fuse 20 A (T)
Input: 100 V ... 240 V AC; Output: 24V DC / 20A
Environmental operating temperature +5 °C to +45 °C
Environmental operating humidity 20 % – 95 % rel.
Weight 31 kg
Dimensions (WxHxD) 500 mm x 500 mm x 300 mm
Base device Optics module consisting of spectrograph, optical multiplexer and control electronics in cabinet, protection class IP65, external: industrial PC, 24V power supply
PC configuration Operating system Windows® 7 Embedded, 1,7 GHz, 8 GByte RAM
Solid state disk 80 GByte, Interfaces: DVI, COM, USB, Ethernet
Software Control software MPL, analysis software KustaAna
customer specific analysis evaluation and monitoring software
Optional: spectrometric development environment KustaSpec
Operation Process mode: process unit interact with the industrial PC via an Ethernet interface which evaluates the spectra. A TFT display control system, mouse and keyboard is available for service purposes but is not extent of delivery.
Probe lines PMAmpl or customised single probes upon request
Scope of delivery Multiplexed NIR spectrometer uniSPECx.xMPL-24V, industrial-PC, 24V power supply

 

Optional Equipment

Optional equipment for KUSTAx.xMPL-24V and uniSPECx.xMPL-24V

The multiplexed NIR spectrometer KUSTAx.xMPL-24V and uniSPECx.xMPL-24V can be delivered optionally with:

■ Process probes,
■ Calibration CUa and CLm,
■ Valve control for pneumatic ejection unit.

All information regarding these accessories are listed below.

Process probes

Probe line PMAmpl
Probe line PMAmpl

Compact probe lines and single probes

The process probes collect the light reflected from or transmitted through the samples. The light is transferred to the spectrometer via fibre cables. The designed probe lines are connected to the multiplexed NIR spectrometer KUSTAx.xMPL-24V or uniSPECx.xMPL-24V. Depending on the application, single probes or probe lines are offered.




Probe lines and components

The probe line PMAmpl consists of two parallel illumination units (LU) and a line with the integrated coupling optics (OL). All three items are affixed to each other by plates. The double-sided illumination unit reduces shadow formation on the input material stream, leading to an enhanced identification rate.

Mounting brackets allow installation of the probe line above the conveyor belt. Rubber buffers are added for vibration absorption. Heat-resistant glass protects the optic line (OL) in the probe lines to prevent staining and damage. Active cooling covers and automatic calibration equipment are available accessories.

The probe line PMT consists of an optic line below a shute and an illumination unit installed above the shute. The probe line PMT is designed for the evaluation of transparent material e.g. plastic foils.

Customised design of probe lines

The customisation of the probe lines is based on the following customer specific requirements:
■ Number of desired measurement tracks
■ Speed of the material stream
■ Measurement width for the material stream (conveyor belt width)
■ Height of the the material stream
■ 120 V version available

The probe lines are designed for measurement widths of 500 mm (PMAmpl500) to 2800 mm (PMAmpl2800). The measurement pitch is application specific and may be chosen between 20 mm to 50 mm. The coupling optics of the fibre cables realise a minimum track width of 25 mm. Two different probe line versions are offered for different material size: Vertical clearance ca. 300 mm (LR30) or ca. 500 mm (LR50).

 

*Customised lengths between 500 mm - 2000 mm in a 200 mm scheme on request

Calibration CUa and CLm

Calibration CUa
Calibration CUa

Valve control for pneumatic ejection unit

Valve control for pneumatic ejection unit; Software
Valve control for pneumatic ejection unit; Software

The NIR process spectrometer KUSTAx.xMPL can be optionally equipped with a valve control for pneumatic ejection unit in sorting machine systems. In addition to the standardised device control software, a complete solution for machine builders is available to realise sorting processes much easier.

The valve control unit consists of an ethernet fieldbus coupler, digital output modules of each 16 single channels are mounted side by side. Depending on the required configuration level, up to 1024 fast-switching compressed-air-valves can be controlled. Fieldbus coupler is directly connected to an control-PC of the process spectrometer via ethernet interface.

According to device control software KustaMPL, all functions to communicate with the valve control unit is already given. An individual material identification method can be loaded and sorts to be eject can be chosen in the sort table. The device control software transmits corresponding signals while sorting process to the valve control unit in real-time. The software evaluates important parameter for valve control such as e.g. time delay between identification and ejection (delay) as well as the adjustment of the close-open times of the valves.

Technical specification

Ethernet fieldbus coupler

Connection 2 x RJ-45
Transfer rate 10/100 Mbits/s
Voltage supply 24 V DC (-25 % ... +30 %)
Input current max. 280 mA at 24 V DC
Max. number bus modules 64
Protection level IP 20


16-channel digital output module

Number of outputs 16
Voltage via power jumper contacts 24 V DC
Output current per channel max. 0.5 A
Cable cross-section Unifilar:
0.08…1.5 mm²
Finely stranded:
0.25…1.5 mm²