Advanced Process Control for Moisture Monitoring and Control Applications
G. Pino Porciello MASc., P.Eng. and Dirk Doerr BASc., P.Eng.
Duntec Corporution
495 Dotzert Court
Wuterloo, ON NZL-6A7, Cunuclu
gpp@ciuntec.corn. rlrloerr@cluntec.com
Abstract
This paper descRbes fhe use of advanced process control
onrl sensing fechnologiesfor product moisture monitoring
cmrl control wifhin indusfrial process applicafions.
Moisture content is an important qual@ parameter in the
processing of many products and signflcant production
savings can be obtained through proper monitoring and
control.
Industrial dyers and ovens are used in many industries,
and are the main unit processes that affect the moisture
conlent of a producf. These unit processes typically have
large residence times and are inherently non-linenr.
Manual control and traditional closed loop control
techniques, such as PID control, fail 10 arlequafelycontrol
these processes resulting in inconsistent product quality
and product give-aways. Other control techniques fhaf
predict moisture content through advanced modeling
techniques withont on-line moisture sensing also fail lo
adequately control for moisture and require of-line
verification.
The application of fhe Generic Model-based Confrol
(GMC) control strategy, an advanced process control
technique, in conjrincfionwith on-line moisture sensors will
be shown fo provide substantial benejts and superior
confrol results. These fechnologies are reviewed and
applied, with resulfs obfained $-om a food processing
facility. The application of the presented moisture
moniforing nnd control solufion fo other indusfrial
environments is also given.
1. Introduction
Increased demand for product quality has paved the way
for advanced control solutions that can automatically and
continuously adjust process parameters on-line, In the past,
the control of these quality parameters have relied on the
expertise of operators who would periodically monitor and
adjust process parameters based on off-line samples or
visual inspection of the product. These past methods are
inadequate in today’s demand for product quality.
The requirement for automatic control of product quality
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parameters is particularly true for industries, such as food
and agriculture, where moisture and water content are key
quality parameters. The main unit process that affects this
quality parameter in these applications is the dryer. If the
drying process is not mn at an optimal setting, production
will decrease, energy will be wasted, and quality will suffer.
An automatic moisture monitoring and control solution will
reduce the amount of variation in moisture content and
control the moisture content to an optimum target.
The use of the Generic Model-based Control (GMC)
algorithm, an advanced control technique, with
corresponding on-line moisture sensors, is presented as a
complete turnkey solution for applications requiring
moisture monitoring and control. A brief background in
moisture monitoring techniques and a brief theoretical
development of the GMC algorithm is provided as a
framework before an actual industrial drying application is
presented. Extensions of this solution to other control
applications are also provided.
2. Moisture Monitoring
The moisture content of a product is an important quality
parameter for many processing applications. For food
processing, the moisture content can be related to many
important product characteristics such as shelf life, texture,
palatability, product strength, product handling ability, and
colour.
Moisture content is also a key process parameter directly
related to yield. Reduction of the standard deviation of the
moisture allows the operators to set the moisture targets
closer to the optimum setpoints, thus directly increasing
production yield. In essence, more water and less raw
materials are sold, which has a direct bottom line benefit to
production costs.
On-line sensing techniques that have been found to give
superior moisture measurement data at affordable prices are
near infra-red (NIR) sensors and sensors that measure the
dielectric properties of the product.
NIR sensors measure the reflection characteristics of the
product by emitting a NIR light beam onto the product. The
reflected signal can be processed to provide a surface
 moisture content which can, in some instances, be A process can be modeled by the following equations:
correlated to the bulk moisture content of the product. A
NIK sensor is ideally suited for applications where the x =f(x,u,d,1) (1)
product is i n a continuous sheet or flow and the product Y =d x ) (2)
stream does not have a large thickness. NIR sensors are
typically placed above a conveyor line at the discharge of
Where x is the state vector of dimension n, U is the
the unit process being controlled.
vector of manipulated variables of dimension m, d is the
For products that contain a large rnoishlre gradient
vector of disturbance variables dimension I, and y is the
between the surface and the center or have a non-uniform
output vector of dimension p . In general f0 and go are
distribution of water, a measuring device that can penetrate
some nonlinear functions. From equations ( I ) and (2):
the entire product stream is required to accurately measure
the moisture. Capacitance based sensors, which measure the
dielectric properties of a product, can determine the entire Y =G,rf(r,u,d,r) (3)
amount of water present. Contact capacitance sensors are where
used to measure the water content of flowing bulk
particulate solids-and are usually located at the discharge of
a dryer. A chute and bin assembly is added to the process
flow stream to ensure proper presentation of the product to The objective of the GMC control is to drive the process
the sensor. Non contact capacitance sensors can be placed output variables quickly towards steady state and ensure
above a conveyor and works well with products that flow at that there is zero offset. By using performance
a constant level or as discrete components. The dielectric specifications that use time derivatives of the output
behavior of the material is measured as the product moves variables, good performance that meets the control
under this sensor. objective can be given by:
The accuracy of the these sensors is affected by the
product temperature, product density, and the variability of
the dry product dielectric (in particular, to changes in the
amount of fat). Compensation of these product parameters
is usually completed by calibration software embedded in where y* represents the nominal trajectory that y is
the sensor itself or as part of the system in which the sensor measured against. Suitable choices for K, and K2can be
is attached. made to achieve a variety of responses in y(t). This is
Sensor operation knowledge, applications experience on analogous to choosing the appropriate P and I components
how different sensing techniques are affected by the in a traditional PI controller.
different types of products, and knowledge of the product By choosing u ( t ) such that the system follows y * (1) as
characteristics are required to successfully apply an
appropriate moisture monitoring solution. Selection of the closely as possible, this control problem transforms to an
appropriate sensor is the first step in a complete moisture optimal control problem as follows:
monitoring and control solution. Without an on-line sensor,
the actual moisture can only be inferred. Given: x =/(X,U,d,I)
Y = g(x)
3. Generic Model-based Control choose u(t)
such that IuI 5 a
The basic objective of the Generic Model-based Control
(GMC) strategy is to provide a framework for process to minimize
I,
controllers that rely upon a model to approximate plant
behavior. The GMC stmcture allows non-linear process M
j x 9 UI d9 r)TWh(x,u,d,t)]dt (5)
models to be embedded directly into the controller without 0
resorting to linearization. Furthermore, it can be shown that
by proper selection of a performance index and an where:
approximate plant model, single loop PI control,
feedfonvard and decoupling control, multi-variable
regulators, and process model based control can all be
derived from this generic framework. The following
provides a brief overview of the GMC theoretical
development as developed by Sullivan and Lee[ I].

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 Providing certain conditions are meet, the solution to the
optimal control problem can be given by the solution of 111
equations and III unknowns:
G . / ( x , ~ , d , f )- K , (Y * - y ) - K z J(y*-y)dl = 0 (7)
ad4ition of on-line model parameter updating for more
accurate process model approximation.
I

In general, since the exact process model is rarely

known, an approximate model is introduced such that
equation (7) becomes:

&i(x,u,d,O- K , (Y *-Y) - K zJ(Y * - y W = 0 (8)

where G,rand ,?() represent approximations to the true

model.
The control manipulation that satisfy equation (8) will
result in good control if the process m a d e l i ( ) and G,r are
reasonable and y * ( I ) is reasonable such that the control
operates within the control action constraints.
This GMC control strategy has several desirable
4. Moisture Control for Industrial Dryers
characteristics:
The drying process provides an ideal application for the
1) The control law as represented by equation (8) has implementation of a control algorithm based on GMC. The
within its structure an approximate process model. drying process is inherently non-linear where changes in
2) Any inaccuracies introduced by the approximate moisture content of the product at the exit of the dryer are
process model will result in y ( t ) not tracking nonlinear with respect to the dryer zone temperatures. The
y * (1) , however, this will be compensated by the drying process is fkrther complicated by the introduction of
integral term in the control algorithm. The integral long dead-times, relative to the process time constant, that
term in the control ensures that the controller is are due to the transport lag and thermal inertia of the dryer.
robust despite modeling errors. Conventional control schemes, such as PID control, can not
3) There is no need to perform an on-line integration of adequately control this process. An advanced control
the process model providing that all the states are technique, such as one based on GMC, is required.
observable. A general form of a dynamic drying model can be given
as follows [6]:
Specifying the controller performance can be obtained
by the proper selection of matrices KI and Kl. It can be Mitt = F(MjnJ,,T,H , V,) (10)
shown that in the single input, single output case, kl and kx
are defined as:
where: M,4,,, is the predicted rate of change in outlet
moisture
Mi,, is the measured inlet moisture content
7, is the process residence time
This system yields similar responses to a classic second- T is a vector of zone temperatures
order system. By plotting the normalized response of y / y * H is the air humidity
V, is the air velocity
vs. normalized time t/? , 5 can be specified to define the
shape of the desired controller response. This is illustrated
in Figure 1.
Further research work related to GMC has extended the
original development to include the incorporation of steady
state models[2], constraint handling[3], robust stability[rl],
control of systems with large dead times[S], the ability to
handle inlet disturbances via a feedforward element, and the

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 I n order to allow the cotitroller to compensate for the based on the behavior of the process. This on-line updating
dead-tinic associated with changes in dryer temperatures, a has the effect of improving the response of the control since
dead-time compensator is developed as follows: the error between the estimated plant model and the actual
plant model is reduced. Factors such as deterioration of the
process equipment, equipment fouling and seasonal changes
M Y =
(-'\lir )
can be taken into account. Without the on-line parameter
e D Mfy model update, periodic model updating would need to be
made manually.
where: Me"" is the corrected predicted outlet
moisture content Finished Producl

TP
is the process residence time

A dead-time corrected trajectory of the actual moisture is

then given by: ..

Meonrrol =MO,,,+MCO" (12)

I ModelBased
Controller
Dead Time
cornpenra1sr
where: M,,, is the actual measured outlet moisture.
Md~lure
Selpolnt
Updales
An error term can then be defined as follows:
Figure 2
e =M * -Mco",roi (13) Example GMC Control Structure Block Diagram

which basically takes the difference between the desired

exit moisture, M*, and the dead-time corrected outlet
moisture.
To simplify the control calculations, and to provide
bumpless transfer from manual to automatic moisture
control, the GMC controller can be converted to velocity
form as follows:
Ae =e,-@,_,
The change required in the temperature of the dryer
zones may then be calculated by substituting the process
model equation (10) into the control law equation (8) as
below:
AF( .....)-( K,Ae+K2eAt)=0
The dryer model can be developed to incorporate as
many on-line variables as can be economically measured.
This may include supply and exhaust air temperature, air
humidity, air velocity, belt speed, and product loading. A
block diagram of the overall control structure is provided in
Figure 2.
An on-line parameter model update function can be
incorporated to automatically adjust the process model
5. Example Application
To illustrate the implementation of the presented
automatic moisture monitoring and control solution, an
actual exaniple from a petfood processing facility is
presented. This plant produces 12 different products that
vary in size from 5 to 25mm. with production rates ranging
(14) from 6 to 16 tonnes per hour. Figure 3 illustrates the
process layout. Multiple extruders feed a direct fired
multiple pass dryer which leads to a small surge hopper
before product coating and packaging. Base level
automation (PLCs and inshumentation) and a SCADA
system (for user interface and data acquisition functions)
were in place at this facility. Manual operation of the dryer
(15) consists of operators adjusting the zone temperatures based
on moisture content data obtained from off-line lab analysis
of product samples taken at packaging every hour. This
manual control scheme resulted in moisture variations that
made product coating and packaging difficult. This also
caused a decrease in production yield, a reduction in
product quality, and an increase in product waste.
The objective was to add an automatic moisture
monitoring and control system capable of maintaining the

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 then analyzed by the plant’s standard laboratory procedures
I ‘- I and the result is entered into the sensor calibration sohvare.
A database of readings is maintained for each product with
the software performing a regression analysis to update the
sensor calibration for the product.
The GMC control algorithm, and supporting software,
was added to the SCADA system and obtains the process
data via the IIO drivers currently used on the system. The
GMC control algorithm was quickly tuned by incorporating
an approximate model of the process for each product. This
model utilizes feedforward information from the extruder
and various dryer parameters, as illustrated in Figure 3. The
model updating fbnction ensures that the parameters in the
approximate model are updated on-line.
Before attempting automatic control, the sensor accuracy
.I*
was verified. Figure 4 illustrates the performance of the
*...,--
sensor over a wide range of product moistures as compared
to the reference methods used at the plant. Sensor accuracy
Figure 3 Example Application Process Layout of 0.1-0.25% was obtained and is typical in most
applications.
product moisture at the dryer exit within tight specification
tolerances to allow for optimal product coating, Also, any
implemented solution was to integrate seamlessly into the
existing automation equipment and SCADA system.
Utilizing the theory and techniques presented earlier in
this paper, an automatic moisture monitoring and control
solution was implemented that included the following main
features:
Installation of a capacitance based moisture sensor
at the dryer discharge
Utilization of the existing PLC as the IIO system for
the controller, including connection of the installed
moisture sensor
-7- I x
I

Addition of the control and sensor calibration

software to the computer workstation and
. . -0.-

LI.., *I

embedding this software within the SCADA system.
New user interface screens were also added to the
existine svstem.
I .
A capacitance sensor was selected for this application
because of its ability to measure the bulk moisture of the
product. Other sensing technologies would not have
provided suitable readings because of the large moisture
gradient present in the product directly after drying. To
minimize the effects of flow and production rate changes, a
special sensor chute was constructed to sample a portion of
the product at a constant rate. This assembly keeps the
packing density constant during changes in production rate.
The sensor calibration software utilizes data related to
the characteristics of the different products, thus taking into
account specific material properties and individual flow
characteristics. Calibration of the sensor with off-line QA
lab samples ensures accurate readings for each product. A
calibration push button is used to indicate to the control
system a lab sample is being taken, The collected sample is
Figure 4 On-line Sensor vs. Lab Reference
Figure 5 illustrates the dryer performance for a typical
manual startup operation. During this startup, the extruders
are started at a fixed rate and the dryer temperatures are set
high to prevent high moisture product. This results in off
spec product with low initial product moistures. The
operator then begins to reduce the temperature to increase
the product moisture. This procedure generally takes several
hours, as the operator must wait for the dryer residence time
before the effect of their changes can be seen. In this
example, the operator starts up the extruders at a fixed rate
of 8.75 tonnes per hour with a drying temperature of 130°C.
An hour later

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 The use of the iliitoinatic moisture monitoring and
control solution in this facility has resulted in a 50%
reduction i n standard deviation of the moishlre content of
the product and has improved the coater processing
performance. This has increased production yield, reduced
waste, and decreased production costs. The system payback
at this facility was obtained in a short time frame.

Figure 5 Typical Manual Startup Example

when product is finally coming out of the dryer, the
operator begins to reduce the temperature in order to bring
the product moisture up to the target of 6%. Five hours
after the initial product exits the dryer, the operator makes
another temperature adjustment that causes the product
moisture to increase to within 0.25% of the target. The
result of this typical startup is almost 50 tonnes of product
being over dried by an average 1.4%. During a typical
automatic startup, the control system reacts to the error
immediately and, because of this, the model is able to make
one large change to correct the moisture. As a result, the
startup time is reduced to 1.5 hours (U4 the time). This
results in significant savings to the plant in energy usage
I
and yield. The yield savings for these conditions can be
calculated to be approximately $75,00OUSper year.
Figure 6 illustrates the dryer performance for manual
control during a typical rate change. The operator decreases
the production rate from IO tonnes per hour to 8 tonnes per
hour shortly before 4:OOam. A small temperature change is
made to account for the decrease in production rate. No
further changes are made until the subsequent rate increase
10 hours later. The reduced production rate caused the
product to be over-dried by one percent for the duration of
w>mam IYI*.oD t>,",,*m IYIUII* 11111,01 *Z,U,.* 12111*1.m
the low production. The net result is 80 tonnes of product I-- -wu.--W.
1>1*11*

over-dried by an average 1%. These incidents, which occur
many times during the day, are not limited to operator
introduced changes, but are also caused by changes in raw
ingredients, weather conditions, and extrusion
characteristics. As illustrated in figure 7, production rate
changes with an automatic control system are handled
differently. Each time the rate is changed (9:00, 11:OO and
12:00), the control system adjusts the temperature
compensate. These temperature changes are phased in as
the product moves through the dryer, which enables the
moisture control system to maintain tight control even
during the transition periods. At this facility, savings
related to these conditions can be shown to approximately
$8O,OOOUS per year.
-,-.".I
Figure 7 Typical Rate Changes Under Automatic
Operation Example
6 . Other Applications
to Other drying applications where the presented moisture
monitoring and control solution have been applied include
soymeal, spent grain, fishfood, instant rice, coffee, breakfast
cereals, sand and gravel, and wood strands.
The control algorithm has also been modified to control
the residence time (i.e. belt speed) of a dryer. This is
particularly useful in corn and grain drying applications,
where in the tower grain dryers, the temperature is normally

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 hcld constant with an operator leR to modify the discharge
rate.
Similar to drying applications, toaster and oven control
is another area where the GMC control algorithm has been
applied. These applications include cookies, crackers,
cakes, and bread. Also, in these applications the control
algorithm has further been extended to incorporate the
control of product colour in conjunction with the moisture.
Numerous applications outside the food processing
industry have also been adapted for use with the GMC
controller for other process variables besides moisture.
Examples include continuous and batch reactors,
evaporators, and distillation columns
7. Conclusions
An automatic moisture monitoring and control solution,
using on-line sensors and advanced control algorithms, has
been shown to improve product quality, increase production
yield, and reduce production costs.
A himkey process control solution has been developed
which incorporates sophisticated technologies, integrates
easily into an existing automation framework, has a
relatively little cost as compared to the payback, and is
simple to use. The solution has been proven to give superior
results to systems that use conventional control strategies,
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such as PID control, and systems that try to infer product
moiktiire without on-line sensors.
This solution can be used as part of an overall process
optimization strategy for a production facility and has been
implemented in over IO00 installations worldwide.
At present time work is being undertaken to apply the
presented technology to the control of other unit processes
such as extruders and coolers.
8. References
[ I ] Lee, P.L., Sullivan, G.R., “Generic Model Control”, Conrpirl.
d C/reni.Eng.,12:573-580, 1988.
Cott, B.J., Durham, R.G.. Lee, P.L., and Sullivan, G.R.,
“Process Model Based Engineering”, . Cornput. & Chem.
Eng.,13:973-984, 1989.
.
Brown. M.W.., Lee., P.L.., Sullivan. G.R.. and Zhou.. W... “A
Constrained Nonlinear Multivariable Control Algorithm”,
Proc. AlChE Ann. Meeting, San Francisco, 1989.
Zhou, W., Lee, P.L., and Sullivan, G.R., “Robust Stability
Analysis of Generic Model Control”, Chem. Eng. Commun.
17:41-72, 1992.
Lee, P.L., Sullivan, G.R., and Zhou, W., “A New
Multivariable Deadtirne Control Algorithm”, Chern. Eng.
Commun. 91:49-63, 1990.
Mujumdar, AS., ed., Handbook of Industrial Drying, Marcel
Dekker Inc., New York, USA, 1987.