Many process plants are still just one missed endpoint away from irreversible batch failure.
In a high-stakes polymerisation reaction, a missed endpoint isn’t a quality deviation you can rework downstream. It’s an irreversible failure. A solidified tank. Production offline. Remediation measured in days, not hours.
That can be the harsh reality of making termination decisions based on manual sampling and a lab result that arrived 30 minutes too late.
We give you real-time viscosity measurements to determine reaction endpoint.
As polymer chains grow, viscosity rises – a direct indicator of reaction progress. Hydramotion’s inline viscometers give you instant insight into reaction progress, so you can hit the endpoint exactly when it matters – avoiding costly and irreversible process failures.
A solidified reactor doesn’t just cost you a batch. It costs you days of production, significant remediation, and in some cases, the reactor itself.
.png?) Reduce WasteEliminate manual sampling errors, and avoid missed endpoints that lead to costly over-or-under processing failures. |
 Increase QualityEnable reactions to be terminated at the optimal point, optimising product quality and reducing batch inconsistencies. |
 Improve ProductivityReduce lag from lab results, shorten batch times, and enhance throughput. Run more batches per day with reduced energy consumption. |
Trusted By
“The Hydramotion viscometer is the largest single improvement we have made in the manufacturing process and it continues to help us keep our products within specification and reduce waste.”
“a truly ‘fit-and-forget’ instrument that enabled us to remove some of the ‘art’ from polymerisation and replace it with science.”
Zetachem (Division of Omnia Group)
Case Study
Proven to Reduce Waste, Rework and Off-Spec Production
A leading polyamine manufacturer installed a Hydramotion viscometer to gain continuous visibility of polymerisation progress and eliminate the delays associated with manual sampling.
The Results
| Outcome | Result |
|---|---|
| Off-spec production | Reduced to less than 1% |
| Sampling delays | Up to 30 minutes eliminated |
| Production scale | Increased from 5,000 kg to 20,000 kg batches |
| Maintenance | Virtually none over years of continuous operation |
These improvements helped reduce the costs commonly associated with poor endpoint control, including off-spec product, wasted raw materials, excess energy consumption, lost reactor utilisation, operator sampling time, waste disposal costs and lost production capacity.
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OPTIMISE EVERY REACTION
MAXIMISE EVERY BATCH
Hydramotion XL7 viscometers provide precise, real-time monitoring of viscosity changes throughout polymerisation or depolymerisation, enabling complete reaction tracking.
The robust stainless-steel sensor sits in the heart of the reaction and captures changes every second, ensuring you know exactly the progress of the reaction and when the endpoint is reached.
That real-time visibility routinely results in huge cost savings and batch failure reductions, in some cases down to zero.
We’ve got you covered
The XL Series has become the global standard for reaction processes. These are true in-line workhorses designed for continuous use without intervention in extremes of temperature, pressure, flow and viscosity range. High accuracy and repeatability is rigorously maintained regardless of process conditions or plant noise.XL7’s are configurable for almost every possible installation with virtually any process fitting. All viscometers carry IS Safety Certifications and are provided in a range of optional materials including; Alloy C22, C276, 2507 and more.
Reactor Installations
Engineered Solutions
BUILT FOR ANY TANK
Install in any orientation. In a tank or reactor of any size. All that is required is a suitable mating process fitting. And where there’s limited availability, we will design something custom to fit.
Our special ops division routinely deals with many complex design objectives. Working with your existing plant layout, our engineers use their knowledge and expertise to create a perfect fit – anything from a slight alteration to an extension of several metres. We have a huge legacy of experience to draw on and can cope with just about anything.
Application Note
XL7 Eliminates Batch Failures Through Endpoint Detection
Hydramotion’s custom XL7 viscometer, built to handle demanding formaldehyde resin processes, provides a precise solution for identifying reaction endpoints.
By allowing operators to monitor viscosity in real-time, the XL7 ensures accurate quenching at just the right moment, eliminating batch failures and driving down production costs.
Application Note
Streamlining PET Flake Recycling with In-Tank Viscosity Monitoring
A PET recycling facility struggled with energy efficiency and consistency in their glycolysis depolymerisation process because of variability in post-consumer recyclable materials.
After installing the XL7-HT they were able to observe the variability in real time and adjust the process conditions accordingly. Batch processing time was also reduced by up to 2 hours, resulting in significantly lower energy consumption. The time saved meant the facility could run more batches per day whilst also achieving a greater batch-to-batch consistency.
Read the application note>
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XL7 KEY FEATURES
Ready to learn more?
If you’re facing inconsistent product quality, high batch failure rates, excessive energy consumption, or concerns about manual sampling, Hydramotion’s inline viscometers may be the ideal solution:- Real-time tracking of reaction progress for precise endpoint detection
- Measure viscosity with high accuracy and repeatability, regardless of process conditions
- Eliminate time delays and human error associated with manual sampling
- Cut production costs by preventing over-runs, improving consistency and reducing failure rates