Precise colour detection for 100% inline process monitoring
When processing solid to highly viscous materials such as gelatine, syrup, or plastics, the material is continuously compacted in an extruder and discharged as an extrudate under high pressure.
Precise temperature control is crucial during the extrusion process. If the material is heated too much, it can suffer thermal damage, which can lead to unwanted discoloration or burning. To detect such process deviations early on, the colour of the material is monitored directly in the extruder at specific measurement points. Depending on the material properties, the measurement is performed either using the transmission method (for transparent media such as gelatine) or the reflection method (for opaque materials such as plastics).
The CFS3 (transmission) or CFS4 (reflection) sensors are used for this inline measurement task. The sensors are integrated directly into the extruder and are available with 1/2"-20 UNF or M12 threads, as well as in various models. This makes them suitable for demanding process conditions with pressures of up to 2,400 bar and temperatures of up to 500 °C. Colour measurement is performed directly on the inner wall of the extruder. The measurement data collected is used for process control. This makes it possible to detect thermal overloads, burns, and contamination early on and take corrective action before scrap is produced.
The smart and precise colour sensors in Micro-Epsilon's colorSENSOR CFO series are characterized by high colour accuracy, excellent repeatability, and fast measurement acquisition. Even the slightest colour variations are reliably detected, allowing for immediate action during the production process. Up to 320 colors can be programmed into 254 colour groups. Configuration is easily performed via an intuitive, web-based user interface.
System design
The sensor system for colour measurement in the extruder consists of the CFO250 controller in combination with one of the following sensors:
- CFS4-T250-P200
- CFS4-BOA-T400-P2400
- CFS3-T250-P200
- CFS3-BOA-T400-P2400
- CFS4-S-E-T250 (M12)
Incl. cable set for power supply, PLC connection, or digital I/Os.
This system combination offers high measurement accuracy, a robust design for industrial use, and an excellent price-performance ratio.
Advantages:
- Sensors directly in the extruder with 1/2"-20UNF or M12 fit
- Pressure-resistant < 2,400 bar
- Temperature-resistant < 500 °C
- High repeatability ΔE < 0.3
- Multi-teach function and formation of colour groups
- Modern, user-friendly web interface
- High colour accuracy
- Quick and easy integration of the system, even into existing systems
Custom sensor solutions
In addition to the standard models, we also develop custom sensor and system combinations that are optimally tailored to your application. Contact us or use our inquiry form – we will be happy to advise you.
