Particle size variation negatively impacts combustion efficiency, product quality, yield, and equipment health. Manual sampling is delayed and intermittent, making it impossible to support real-time process control or react to rapid material changes. Faclon Labs uses vision-based analytics to measure particle size distribution continuously and non-intrusively directly from the conveyor-based material flow
Continuous measurement of particle size directly from conveyor-based material flow
Early detection of size deviations enabling proactive upstream process adjustments
Digital visibility into material consistency supporting quality and efficiency goals
Continuous measurement of particle size directly from conveyor video feeds
Automated Size Classification
Instant bucket-wise classification and distribution trend analysis
Oversize/Undersize Detection
Immediate identification of material that falls outside of operational tolerances
Pixel-to-Millimeter Calibration
High-precision calibration methodologies to ensure accurate physical measurements
Process Trend Correlation
Correlating size distribution with upstream process parameters for root-cause analysis
Intelligent Deviation Alerts
Automated notifications when material size drifts from the set-point
Conveyor-Based Monitoring
Non-intrusive monitoring designed for high-speed industrial conveyor environments
Quality Dashboards
Real-time visibility into historical trends and current distribution metrics
Why Faclon Labs
Key strengths behind accurate and scalable particle size analytics deployments
Proven Industry Success
Successful particle size deployments in demanding thermal power and metal plants
Global System Integration Capability
Seamlessly connects with existing plant control systems and conveyor infrastructure
Advanced AI and LLM Driven Features
AI models specifically tuned for varying material textures and lighting conditions
Rapid Non-Intrusive Deployment
System rollout requires no mechanical changes or process downtime
Accurate Vision Calibration
Proprietary methodologies for converting visual data into precise physical metrics
Scalable Infrastructure
Architecture built to scale across dozens of conveyors and multiple sites
Cybersecurity Compliant
Meets rigorous OT/IT standards for secure industrial data handling
Edge + Cloud Architecture
Optimal balance of local processing for speed and cloud for deep analytics
Dedicated Customer Success
Expert support to ensure model accuracy and continuous system upkeep
CASE STUDY - PARTICLE SIZE ANALYSIS
Optimizing Fuel Quality: Continuous Coal Monitoring for a Thermal Power Plant
Faclon deployed a vision-based particle size analysis system at a large thermal power plant to monitor coal quality in real-time before it enters the boiler. This digital transition replaced intermittent manual sieve analysis with a continuous diagnostic hub, providing the operations team with a real-time "size map" of the incoming fuel. The system allows for immediate adjustments to the milling process, ensuring optimal combustion and reducing the losses associated with unburned carbon
2.5% Improvement in Combustion Efficiency by ensuring consistent coal fineness for the boiler feed
15% Reduction in Unburned Fuel through precise real-time control of the pulverizer output size
Real-Time Process Corrections enabled by instant alerts on coal size deviations
Data-Driven Operational Optimization across the entire fuel handling and milling circuit
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