Problems solved by Spectrally™ analyzers
Gekko Photonics for:
Bakelite LLC – Louisville
We've developed solution that helped European resin manufacturers save over 2,7 million dollars annually. Now with possible implementation at Bakelite LLC Louisville
Challenges in resin production
Low inspection accuracy
Traditional resin quality testing methods do not provide sufficient precision, which leads to rejecting batches of product that are actually of acceptable quality.
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 resin manufacturer, whose client had very exaggerated product requirements and our client could make stable product quality.
We implemented our inline Spectrally™ analyzer to monitor phenol and formaldehyde composition in real time. This gave the manufacturer significantly tighter process control, resulting in optimised production parameters and reduced customer complaints by approximately 90%.
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80% - Shorter production time per batch
Directly lower energy use per tonne of resin.
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94% - Batches within internal specification
Higher and more stable first-pass yield (FPY).
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90% - Fewer customer complaints
Significant reduction of claims and rework costs.
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10% - Lower raw-material losses
Better utilisation of phenol and formaldehyde through precise endpoint control
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100% - Digital batch documentation
Complete, time-stamped analytical history for each batch.
Implementation pathway
Possible cooperation plan for Bakelite LLC
1. Feasibility workshop (3 hours)
Joint session with your technology, production and QA teams to identify measurement points and key KPIs at Louisville.
2. Feasibility study
(4 weeks)
We analyse 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
Bakelite LLC.
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, your 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 talk about optimization of Your resin lines
- a.lukasiewicz@gekkophotonics.com
- +48 512 554 952