Wet Paper-Plastic Ratio Control Using NIR Dry Flow Measurement

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional systems struggle to accurately adjust the paper/plastic ratio in recycled material streams without drying the combined stream first, leading to inefficiencies in time, space, and cost.

Innovation Solution

Utilizing near-infrared (NIR) devices to determine the dry flow rates of paper and plastic material streams from solid waste, allowing a controller to adjust the flow rates of these streams to achieve a precise paper/plastic ratio in a wet combined stream, eliminating the need for extraneous dryers and storage bins.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If the combined stream is dried before adjusting the paper/plastic ratio, then the measurement precision of dry flow rates is improved, but the production time and cost increase

Engineering Contradiction:

Improvedry flow rate measurementVSAvoidproduction time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The system performs preliminary measurements of moisture content and contaminant levels in the wet stream using NIR devices before the drying process. This allows the controller to calculate dry flow rates in advance and adjust the paper/plastic ratio accordingly, eliminating the need to wait for drying to complete before making adjustments.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces the mechanical drying process with optical measurement technology. Instead of physically drying the stream to measure dry flow rates, the system uses near-infrared spectroscopy to non-contact measure moisture content and contaminant levels, then calculates dry flow rates mathematically. This substitution eliminates the time-consuming drying step while maintaining measurement accuracy.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If extraneous dryers and storage bins are used to adjust paper/plastic ratio, then the manufacturing precision is improved, but the device complexity and cost increase

Engineering Contradiction:

Improvepaper/plastic ratio controlVSAvoidsystem complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The controller performs multiple functions: it receives moisture content data from NIR devices, calculates dry flow rates, determines paper/plastic ratios, and adjusts flow rates of both paper and plastic streams. This multi-functional approach replaces what would traditionally require separate drying equipment, measurement devices, and control systems, thereby reducing overall device complexity while maintaining precision.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The controller acts as an intermediary that processes optical measurement data and translates it into flow rate adjustments. Instead of directly manipulating physical materials through complex mechanical systems, the controller uses computational algorithms to determine the necessary adjustments based on NIR measurements, simplifying the overall system architecture.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Productivity

If the wet stream flow rates are adjusted directly, then the productivity is improved, but the measurement precision of dry flow rates deteriorates

Engineering Contradiction:

Improveproduction efficiencyVSAvoiddry flow rate calculation accuracy

Core Design Contradiction:

ProductivityVSMeasurement precision

Solution Approach 1:

The system continuously measures moisture content and contaminant levels in the wet stream using NIR devices, calculates dry flow rates based on these measurements, and adjusts paper and plastic flow rates accordingly. This closed-loop feedback mechanism ensures that dry flow rate calculations remain accurate even as wet stream conditions vary, allowing direct adjustment of wet flows while maintaining precision.

Inventive Principle:

Principle #23Feedback

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Enables precise adjustment of the paper/plastic ratio and moisture content in the combined stream, reducing production time and costs by accurately calculating dry flow rates without prior drying, thus enhancing the efficiency of producing finished products.

Implementation Method 1

determining the dry flow rate of a paper material stream from solid waste using a near-infrared (NIR) device

Methodology Applied

Scientific EffectNear-infrared spectroscopy: Absorption Spectroscopy

Data Source

PatentUS12539532B2Combining wet paper and plastic to a controlled dry weight ratio

Publication Date: 2026.02.03 CONTINUUS MATERIALS INTPROP LLC

AI summary

A method may include determining a first dry mass flow rate of a wet paper material stream based on a first amount of contaminants, a first moisture content, and a first wet mass flow rate of the wet paper material stream, determining a second dry mass flow rate of a wet plastic material stream based on a second amount of contaminants, a second moisture content, and a second wet mass flow rate of the wet plastic material stream, calculating, using the first dry mass flow rate and the second dry mass flow rate, a paper/plastic ratio of a combined stream of the paper material stream and the plastic material stream, and adjusting, a flow rate of paper into the paper material stream and a flow rate of plastic into the plastic material stream such that the calculated paper/plastic ratio of the combined stream equals a target paper/plastic ratio.