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Sr. Vice President

Ripik.ai has been associated with IMFA since Jan 2023 towards implementation of Industry 4.0 in our Choudwar plant located in Odisha. They are working on two machine learning / data science use related to power and metallurgical coke consumption optimization through real-time alerts. The team has good knowledge in the areas of data science & machine learning, and their problem solving skill set is high

Head Technology and Projects Electrical Maintenance

I have known Pinak, Arunabh and Navneet since 2017. They were part of Advanced analytics program in TSK between 2017 and 2020 and placed a crucial role in its delivery. The team worked end to end in conceptualization and delivery of the use cases across Blast Furnace, Sinter Plant and Steel Melt Shop.

Chief Digital Officer

Ripik.ai has been the analytics partner of Godrej & Boyce since March 2022. They have been doing projects with the Interio and Aerospace businesses already and we are exploring use cases for other businesses as well. Pinak and his team have worked with us closely on these manufacturing use cases. They have an unparalleled understanding of the process and can bring impact very quickly

Head Technology and Projects Electrical Maintenance

I am delighted to write this testimonial about Ripik.ai, one of ESL’s analytics partner since January 2023. The Ripik.ai team is working on three use cases in our Upstream section at the Bokaro plant – Digital Twin of Blast Furnace, Burden Mix optimization in Blast Furnace and Green Mix optimization in Sinter Plant Burden Mix optimization in Blast Furnace and Green Mix …

Testimonials
Real customer experiences and results showcasing the value Ripik.AI brings to industrial operations.
Blog
Explore expert-written articles, industry trends, and updates on how Vision AI is shaping manufacturing.
Partners
We strive to innovate when it comes to functionality. Our mission is to be the best, come and join the ride.

EXPLORE

Real Time Productivity Tracking
AI-Driven Real-Time Productivity Tracking for Industrial Operations
AI-Driven Productivity Tracking involves real-time monitoring...
Infrared Based Monitoring
How Infrared-Based Monitoring Enhances Predictive Maintenance in Manufacturing
IR monitoring combined with vision systems are trained to...
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Industries

Steel
Amplify Your steel plant operations with AI
Cement
Enhance Cement Plant Operations
Aluminium
Take control in your aluminum production
Chemical
Reimagining Chemical factory operations
Power
Elevate operational efficiency of boilers
Other
Elevate industrial operations

Products

Explore Vision AI Agents

Ripik’s Vision AI Agents are your automated pair of eyes — developing intelligent monitoring agents for engineered industrial performance.

Read More

Explore Ripik Vision Platform

Move beyond number crunching and reduce process variability with an automated pair of eyes—our Vision AI platform

Read More

Curious how Vision AI fits into your operations?

Let us walk you through a tailored demo experience.

Book a Demo
Contact Us

Industries

Steel
Amplify Your steel plant operations with AI
Cement
Enhance Cement Plant Operations
Aluminium
Take control in your aluminum production
Chemical
Reimagining Chemical factory operations
Power
Elevate operational efficiency of boilers
Other
Elevate industrial operations

Resources

Sr. Vice President

Ripik.ai has been associated with IMFA since Jan 2023 towards implementation of Industry 4.0 in our Choudwar plant located in Odisha. They are working on two machine learning / data science use related to power and metallurgical coke consumption optimization through real-time alerts. The team has good knowledge in the areas of data science & machine learning, and their problem solving skill set is high

Head Technology and Projects Electrical Maintenance

I have known Pinak, Arunabh and Navneet since 2017. They were part of Advanced analytics program in TSK between 2017 and 2020 and placed a crucial role in its delivery. The team worked end to end in conceptualization and delivery of the use cases across Blast Furnace, Sinter Plant and Steel Melt Shop.

Chief Digital Officer

Ripik.ai has been the analytics partner of Godrej & Boyce since March 2022. They have been doing projects with the Interio and Aerospace businesses already and we are exploring use cases for other businesses as well. Pinak and his team have worked with us closely on these manufacturing use cases. They have an unparalleled understanding of the process and can bring impact very quickly

Head Technology and Projects Electrical Maintenance

I am delighted to write this testimonial about Ripik.ai, one of ESL’s analytics partner since January 2023. The Ripik.ai team is working on three use cases in our Upstream section at the Bokaro plant – Digital Twin of Blast Furnace, Burden Mix optimization in Blast Furnace and Green Mix optimization in Sinter Plant Burden Mix optimization in Blast Furnace and Green Mix …

Testimonials
Real customer experiences and results showcasing the value Ripik.AI brings to industrial operations.
Blog
Explore expert-written articles, industry trends, and updates on how Vision AI is shaping manufacturing.
Partners
We strive to innovate when it comes to functionality. Our mission is to be the best, come and join the ride.

EXPLORE

Real Time Productivity Tracking
AI-Driven Real-Time Productivity Tracking for Industrial Operations
AI-Driven Productivity Tracking involves real-time...
Infrared Based Monitoring
How Infrared-Based Monitoring Enhances Predictive Maintenance in Manufacturing
IR monitoring combined with vision systems are trained...
process monitoring software
The Role of AI for Process Optimization in the Manufacturing Sector
Effective manufacturing process monitoring ensures...
Read latest blog

About Us

Company
Get to know who we are and what we stand for.
Why Us
Discover what makes Ripik.AI uniquely effective.
Careers
Explore our culture, values, & work environment.
Press & news
Find out what's making headlines from Ripik.AI
Events
Ripik AI Event Appearances

Products

Explore Vision AI Agents

Ripik’s Vision AI Agents are your automated pair of eyes — developing intelligent monitoring agents for engineered industrial performance.

Read More

Explore Ripik Vision Platform

Move beyond number crunching and reduce process variability with an automated pair of eyes—our Vision AI platform

Read More

Curious how Vision AI fits into your operations?

Let us walk you through a tailored demo experience.

Book a Demo
Book a Demo

Optimize Energy Efficiency with Real-Time Material Moisture Analysis

Introducing HydroScan - For Real-time moisture measurement in Material

Enhance energy efficiency with real-time material moisture analysis using infrared-based monitoring. Reduce energy consumption, minimize waste, and ensure consistent product quality

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Setbacks from Lack of Moisture Analysis

Challenges Faced by Industries Due to Lack of Real-Time Material Moisture Analysis

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In heavy industries, improper moisture levels in coal, limestone, and sinter cause reduced combustion efficiency, material degradation, and compromised product quality. Traditional manual sampling methods offer intermittent data, leaving critical gaps and delaying adjustments. This leads to suboptimal fuel consumption, increased emissions, frequent equipment failures, and significant operational inefficiencies.

high fuel usage

High moisture content in materials leads to unnecessary fuel consumption and high operational cost

High moisture content increases fuel consumption and operational costs. Without proper moisture content measurement, energy efficiency drops, requiring more heat for processing or ignition, leading to higher fuel usage, reduced productivity, and inefficiencies.

Inefficient Combustion

High moisture levels reduce combustion efficiency by requiring extra energy to evaporate water before ignition.

High moisture levels reduce combustion efficiency by using energy to evaporate water before ignition. Without proper material moisture analysis, this results in increased fuel consumption, incomplete combustion, and higher emissions, lowering overall process efficiency.

equipment damage​

Moisture-related issues can lead to equipment blockages or failures, disrupting production schedules.

Excess moisture content in materials can cause blockages in equipment like conveyors, crushers, and kilns, leading to downtime, costly repairs, and disrupted production, ultimately increasing operational costs and reducing efficiency.

Inconsistent Quality

Lack of real-time moisture analysis leads to moisture variability, causing defects, rejections, and compliance issues that impact profitability.

Lack of real-time moisture analysis leads to moisture variability, which significantly affects product quality. Inconsistent moisture content can result in uneven material properties, leading to poor product consistency and lower overall quality.

Don’t wait for moisture-related inefficiencies — let HydroScan detect it early​

Why choose HydroScan ?

Real-Time Thermal Monitoring​
Real-time alerts enable proactive intervention before wet material causes chute clogging, belt slippage, or buildup—minimizing breakdowns and unplanned stoppages.​
Ensures Consistent Product Quality​
By stabilizing raw material input conditions, HydroScan helps maintain uniform process parameters— resulting in more consistent output and fewer quality deviations.​
Enables Intelligent Process Control​
Moisture data is integrated with control systems (e.g., DCS/SCADA), allowing automatic adjustments to feed rates, drying temperatures, or material routing—enhancing overall plant efficiency.​

Vision AI with Infrared based monitoring

Vision AI Solutions for Material Moisture Monitoring

  • Real-time Infrared Monitoring: Advanced infrared cameras are strategically placed at key points such as the Tippler point, crushers, conveyor belts, and kiln feed areas to capture real-time data on temperature and moisture levels.

 

  • Non-Contact Monitoring: Infrared monitoring allows for the detection of temperature and moisture levels without physical contact, ensuring safe and efficient data capture in critical and hazardous areas.
  • Real-time Moisture Measurement: Infrared-based monitoring ensures continuous oversight of moisture levels throughout key processing points, enabling accurate, real-time measurements.

  • Instant Alerts for Exceeding Limits:  Instant alerts whenever moisture levels exceed acceptable limits, for quick corrective actions.

  • Precise Real-time Insights: Real-time insights of moisture levels enable operators can make informed, data-driven decisions.
  • Infrared Temperature Gradient and Corresponding IR Images: Infrared-based monitoring captures temperature variations linked to moisture content, visualized through corresponding IR images.

  • Moisture Levels: Infrared monitoring links temperature to moisture: high moisture shows bluish/purplish IR images, moderate moisture appears pinkish/reddish, and low moisture shows orange/yellowish IR images.
  • Real-Time Anomaly Detection: AI detects anomalies in real time caused by high moisture content, such as flow irregularities, blockages, and material clumping.

  • Instant Alerts and Recommendations: Operators receive immediate alerts and actionable recommendations to address high moisture-related issues and prevent operational disruptions.
  • Access to Past Video Feeds: Allows users to review historical video footage to analyze material conditions and moisture levels at key processing points.
    •  
  • Comprehensive Moisture Reporting: Generates detailed reports on moisture levels, including variations and trends, to improve material handling and optimize processing efficiency.

    • Real-time moisture analysis of raw materials

    Benefits of Material Moisture Analysis in Heavy Industries

    Implementing Vision AI with Infrared-based Monitoring for material moisture analysis helps industries relying on coal, limestone, and sinter by reducing production costs, improving fuel efficiency, preventing blockages, and enhancing sustainability through better resource utilization and lower energy consumption.

    consistent fuel performance

    Material moisture analysis ensures stable fuel consumption, improving combustion efficiency, reducing fuel wastage, and enhancing overall process stability in heavy industries.

    optimize combustion

    Moisture content monitoring helps maintain consistent material moisture levels, optimizing combustion efficiency, reducing fuel consumption, and minimizing emissions in heavy industries.

    Cost Reduction

    Accurate moisture analysis optimizes material handling, reducing waste and improving fuel efficiency, leading to significant cost savings.

    Enhanced energy efficiency

    Moisture content monitoring improves energy efficiency by optimizing fuel usage, reducing excess energy consumption, and ensuring more effective heat generation, reducing carbon footprint.

    AI Agents in Action

    Meet the rest of our AI Agents

    A powerful suite of intelligent agents working in sync to transform manufacturing with speed, precision, and autonomy.

    Blast Furnace Operations
    Enhance blast furnace stability, efficiency, and productivity with AI agents driven insights.
    Read More
    Alternative Fuels
    Reduce carbon footprint in cement industry​ Optimize Alternative Fuels in cement industry with MatScan...
    Read More
    Moisture Detection
    Enhance energy efficiency with real-time AI agents to manage material moisture analysis with IR Came...
    Read More

    Discover deeper insights, drive smarter decisions with Ripik Vision

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    • +91-9266901573
    • +1 (641) 346-4402

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    Get in touch

    • hello@ripik.ai
    • +91-9266901573
    • +1 (641) 346-4402

    Subscribe to get latest insights

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