For the manufacture of coatings, paints and varnishes as well as for many other everyday products, PUR prepolymers with specific properties are used. Through reaction tracking and end-point determination (e.g. using the Falcata XP), NIR spectroscopy ensures that the prepolymer has the desired properties. Good processability, high quality and economical production can thus be ensured.

The manufacturing process of polyurethane using isocyanates involves reactions with phosgene. Due to its toxicity, any (unreacted) phosgene is recovered and remains completely in the manufacturing process without endangering the safety of humans and the environment. By means of NIR spectroscopy, the phosgene content in relevant product streams and storage tanks can be monitored. The second barrier on Hellma HD products reliably prevents leakage. Additional monitoring options for the probes and measurement cells can be implemented on request.

Using NIR spectroscopy, efficient operation of the cracker is ensured in real time. Both the composition of the liquid naphtha (using Hellma FFV) and the gaseous products obtained (using Hellma FCP) are measured and adjusted for this purpose, thus ensuring optimum control of the process and optimal utilization of the raw materials. This not only leads to cost savings but also saves resources, thereby reducing CO2 emissions.

In many processes, solvents are used for production purposes. To save costs and avoid waste, these are recovered. Some of the solvents contain water which can damage plant components through corrosion or, at higher concentrations, even make the solvents unusable for processes. NIR spectroscopy is ideally suited for moisture monitoring. Real-time monitoring can be carried out directly in the product stream or in the respective storage tanks.

The production of personal care products, cleaning agents and detergents, as well as industrial applications, require surface-active substances. One relevant group of these are ethoxylates. The production of ethoxylates by means of ethoxylation of oils from renewable raw materials, for example, requires special care however. The ethylene oxide used in this process must be added in a controlled manner due to its reactivity and must be completely reacted due to its toxic properties. Monitoring the raw materials as well as the ethoxylation reaction in real time, e.g. in loop reactors or stirred vessels, calls for particularly safe components such as the CE-compliant Hellma HD flange.

In the production of resins it is important to produce the most consistent quality possible so as to guarantee the safety and quality of the products made from them, such as adhesives. This is achieved primarily by ensuring the quality of the raw materials and by precise process control during production. Reaction tracking and end-point determination of reactions is performed in real time using NIR spectroscopy together with Excalibur XP and HD transmission probes.

Superabsorbents, such as those used in baby diapers, contain polymers that can bind large amounts of water. Our process probes are used to monitor the production of monomers. In addition to the quality of the measurement results which ensure the highest possible yields of high-quality products, the impermeability and resistance of the materials used are also particularly important.

Additives are used in many manufacturing processes to improve product properties, save costs, or simplify processing. However, these additives can have a detrimental effect on the color of the product. Color analysis by UV/VIS spectroscopy combined with e.g. the Falcata XP can be used to assess the specific changes needed to improve, for example, polymer products. Color analysis not only provides information on color-changing additives, but can also measure molecular changes in stabilizers, fillers, processing aids and antibacterial additives to ensure the targeted product properties.