Problems solved by Spectrally™ analyzers
Gekko Photonics for:
KremsChem Austria GmbH
We have developed a solution that helped European resin manufacturers save over $2.7 million annually. Now with potential implementation at KremsChem Austria GmbH Krems an der Donau
Challenges in resin production
Low inspection accuracy
Traditional resin quality testing methods lack sufficient precision, leading to the rejection of product batches that actually meet acceptable quality standards.
Production delays
Long waiting times for laboratory results slow down production processes and increase the storage costs of semi-finished products.
Raw material losses
The inability to detect anomalies in real time results in unnecessary consumption of valuable raw materials and an increase in production waste.
Case study
For a resin manufacturer whose client had highly stringent product requirements, enabling our client to achieve stable product quality.
We implemented our inline Spectrally™ analyzer to monitor phenol and formaldehyde composition in real time. This provided the manufacturer with significantly tighter process control, resulting in optimized production parameters and reduced customer complaints by approximately 90%.
-
80% - Shorter production time per batch
Directly lower energy use per tonne of resin.
-
94% - Batches within internal specification
Higher and more stable first-pass yield (FPY).
-
90% - Fewer customer complaints
Significant reduction of claims and rework costs.
-
10% - Lower raw-material losses
Better utilization of phenol and formaldehyde through precise endpoint control
-
100% - Digital batch documentation
Complete, time-stamped analytical history for each batch.
Implementation pathway
Possible cooperation plan for KremsChem Austria GmbH
1. Feasibility workshop (3 hours)
Joint session with your technology, production and QA teams to identify measurement points and key KPIs at Krems an der Donau.
2. Feasibility study
(4 weeks)
We analyze 3–5 representative batches or samples from your phenol-formaldehyde lines and:
- build preliminary calibration models,
- quantify potential savings (raw materials, energy, quality),
- prepare an ROI scenario specific to
KremsChem Austria GmbH.
3. Installation & scale-up (6-12 weeks)
- Installation of Spectrally™ inline on selected reactors,
- validation against your lab methods,
- operator training and integration with your control systems,
- option to replicate to other plants (same model, different location).
Spectrally™ analyzer family
Designed for 24/7, on-demand operation, both in-plant and in the field. Powered by advanced signal analysis and AI algorithms.
PAT
- on-line
- at-line
Benchtop
- LAB
- at-line
Portable
- at-line
- Portable
Spectrally OS
Contact Us
Find out how much you can save with Spectrally™
Contact
Aleksandra Łukasiewicz
Let's discuss the optimization of your resin production lines.
- a.lukasiewicz@gekkophotonics.com
- +48 512 554 952