NIRS XDS Process Analyzer – SingleFiber

Importance of the Topic

Near-infrared spectroscopy (NIRS) has become a cornerstone for real-time process analysis in chemical, pharmaceutical, and industrial settings. Inline NIR measurement enables non-destructive, reagent-free monitoring of critical quality attributes, aligning with Process Analytical Technology (PAT) initiatives and regulatory requirements. The ability to detect process deviations within seconds supports improved product consistency, reduced waste, and enhanced operational efficiency.

Aims and Overview

This document presents the NIRS XDS Process Analyzer – SingleFiber, a next-generation inline NIR system designed for direct process stream analysis. It outlines the analyzer’s design, key features, and benefits, including single-point and multipoint configurations, extended measurement distance, and robust industrial performance for quality control and process optimization across diverse industries.

Methodology and Instrumentation

• XDS Monochromator:
  • Wavelength range: 800–2200 nm with extended InGaAs detector
  • Digital encoder for precise grating positioning and seamless calibration transfer
  • Internal reference for performance diagnostics without interrupting sampling
  • Standard operating temperature: 0–30 °C
• SingleFiber Interface:
  • Low-OH optical fiber pair, 600 µm diameter, SMA fittings
  • Measurement range up to 100 m from the analyzer
• Sampling Probes:
  • Diffuse reflectance probe for solids
  • Transmission, transflectance, and immersion probes plus flow-through cells (SS316, PTFE) for liquids
• Multiplexer (optional):
  • Supports up to nine interdependent sampling points measured sequentially
  • Economical remote measurement to reduce installation complexity
• Software:
  • Vision Single-User and Multi-User for spectral acquisition, method development, and 21 CFR Part 11 compliance
  • Centralized database management for multi-user environments
• Environmental and Ex-Proof Options:
  • Cooling: heatsink & fans, air conditioning, Vortex cooling
  • ATEX certification for Zone 0, 1, 2
  • Purge and optical modem for hazardous areas
• Communication and I/O:
  • OPC, MODBUS, PROFIBUS protocols
  • VISION I/O modules with configurable analog and digital channels

Key Results and Discussion

The NIRS XDS Process Analyzer – SingleFiber delivers real-time spectral acquisition at up to two scans per second, enabling rapid detection of process variations. Modular support for single-point and multipoint measurements offers flexible monitoring. Fiber-based sampling up to 100 m away reduces installation costs while maintaining high measurement accuracy in harsh industrial environments (NEMA 4X/IP65).

Benefits and Practical Applications

• Instant data availability for process control and quality assurance
• Non-destructive analysis without chemical reagents
• Extended sampling range reduces the need for on-site analyzer placement
• Scalable multiplexing supports complex production lines
• Compliance with regulatory guidelines and PAT frameworks

Future Trends and Opportunities

Advancements in fiber-optic materials and detector technologies will expand the operational range and sensitivity of inline NIR systems. Integration with advanced data analytics, machine learning, and cloud connectivity is expected to enhance predictive maintenance and process optimization. Further miniaturization and cost reduction of probes and multiplexers will broaden adoption in decentralized and smaller-scale manufacturing environments.

Conclusion

The NIRS XDS Process Analyzer – SingleFiber represents a versatile and robust solution for inline NIR process analysis, offering high-speed, accurate, and remote measurement capabilities. Its modular architecture, combined with software compliance and environmental certifications, addresses the evolving demands of modern process industries, ensuring improved quality control and operational efficiency.

References

No specific literature references were provided in the source document.