DigiFer® Size Green Pelletizing Automation and Control System

DigiFer® Size is a digital solution designed  to stabilize and optimize the green pelletizing process through real-time measurement and advanced control of pellet size distribution. By combining industrial image analysis with advanced process control strategies, DigiFer® Size transforms visual process information into consistent and actionable data, enabling stable pellet production, improved process predictability, and reduced operational variability under continuously changing raw material and operating conditions.

Image Analysis System

The DigiFer® Size image analysis system continuously measures the green pellet size distribution directly on the process, either on conveyor belts or at pelletizing disc discharge points.

Our machine learning image analysis system provides increased robustness against changes in scene conditions such as lighting variations, dust, surface moisture, pellet color, and background disturbances. This ensures stable and reliable measurements under real industrial operating conditions.

Advanced Process Control System (APCS)

The APCS of DigiFer® Size operates as a Level 2 automation system, acting above the basic regulatory control layer of the plant.

Based on real-time image-derived measurements, the system applies advanced control strategies to stabilize pelletizing disc operation by coordinating disc speed and feed rate adjustments.

The control logic is designed to reduce process variability, maintain the target pellet size distribution, and mitigate disturbances caused by changes in raw material properties or operating conditions. DigiFer® Size can operate in advisory mode, supporting operators with clear recommendations, or in closed-loop mode, executing control actions automatically while respecting existing PLC and DCS hierarchies.

Flexibility for New Installations and Retrofit

DigiFer® Size is designed for maximum flexibility and can be applied both in greenfield projects and in retrofit installations. The modular system architecture allows seamless integration into existing automation environments without interfering with basic regulatory control loops.

Expandability and Feature Development

A key strength of DigiFer® Size lies in the flexibility of its Level 2 APCS architecture. Building on our deep know-how in pelletizing process technology, the system allows the continuous introduction of new control and optimization features as plant requirements evolve.

Beyond disc speed and feed rate coordination, the APCS can be progressively extended to incorporate additional process actions, such as water addition and bentonite dosing.