Granulation — AI for particle size, moisture and yield
AI Autopilot controls moisture, binder addition, spray pattern and drum rotation across pharmaceutical, fertilizer and food granulation lines — maximizing in-spec granules on the first pass and cutting recycle.
Überblick
Granulation sits between formulation and packaging. Out-of-spec granules recycle — and recycle is a direct hit on yield, throughput, and quality consistency. Every percentage point of first-pass yield is meaningful in high-volume lines.
Moisture is the single most important variable. Operators manage it visually and by feel. That works at one temperature and one feedstock; it breaks down under seasonal shifts.
BrainiAll AI Autopilot fuses NIR moisture readings, drum camera imagery, exhaust humidity, and load-cell data to predict granule size distribution in near real time. It adjusts spray, binder, and drum rotation before out-of-spec product is formed.
Was Autopilot tut
Kontinuierliche, multivariable Regelung – kein Single-Loop-PID. Die Advisory-Layer-Architektur lässt die Sicherheitsebene unberührt.
Real-time PSD prediction
Camera + NIR fusion estimates granule size distribution continuously.
Moisture control
Spray / binder dosing adjusts automatically to hold target moisture envelope.
First-pass yield maximization
Cuts fines and oversize that would otherwise go to recycle.
GMP / FDA traceability
All parameter adjustments logged with batch record — audit-ready for pharma.
Recipe self-learning
Each batch refines the next without rewriting the master recipe.
Kontinuierlich angepasste Variablen
Die KI liest jeden Sensor im Stromkreis und berechnet die optimale Sollwertkombination in Echtzeit.
- Binder / water additionPrimary driver of agglomeration.
- Drum rotation speed (RPM)Residence time and bed dynamics.
- Feed rate (t/h)Sets load.
- Exhaust temperature / humidityDrying rate signal.
- Bed moisture (NIR)Online quality proxy.
A fertilizer granulation line producing 500 kt/y with an 8% recycle rate wastes the energy and labor of moving 40 kt of finished product through the loop again. A 3% first-pass yield uplift equates to approximately 12 kt/y of "free" production.
