Bullers™ Process Control Discs (BPCDs)

Various data are available in these production environments via the central control system. Mostly, however, these are zonal temperatures and do not tell the whole story. They are purely temperature readings, rather than an indication of total Heat Work.

Thermocouples are also regularly used in these manufacturing sectors. However, thermocouple measurements are by their very nature only local, whereas BPCDs – like the payload they sit alongside – are ceramic, of a known composition, and make the same ‘thermal journey’ as the heated product.

Only the use of a set of carefully placed BPCDs can lead to reliable thermal mapping, which ultimately provides the information needed to establish the optimum firing regime for each product type and cycle.

When we began the task of creating a next generation line, we subjected all discs to destructive testing and lengthy evaluation across all applicable temperature ranges. As an experienced manufacturer ourselves of a range of technical ceramics, we have been able to bring all our expertise to bear on this project, as well as subjecting the reformulated discs to mechanical and surface testing, and prolonged in-process thermal stressing across a very wide temperature range in our own production kilns and furnaces.

Heat Work is the action and effect of temperature over time on a product, often referred to as Heat Energy. Simply put, it is a defined measurement of the total heat energy effect on a product subjected to thermal processing. BPCDs allow you to understand the effect that variations in temperature, rate of firing, and length of soaking time have on the product and what action is required to prevent potential, costly problems.

Ideally, BPCDs are placed across a number of locations in all types of kiln, furnace or similar laboratory and full production sintering systems. Positions will vary, especially between continuous and intermittent processes, but the aim is to build up an accurate picture of overall heat distribution. It only requires a relatively short time to measure and record the BPCD data.

They can be used to increase your yields, while early notification of under-fired or over-fired products allows you to refire to the correct quality, eliminating scrap while maintaining capacity and profitability. Only Heat Work measuring and monitoring will allow you to understand what has happened to the product during thermal cycling, independently of time and temperature.

All in all, BPCDs offer a rapid and low-cost method of mapping Heat Work and Heat Energy in your process. Heat Work conditions in any firing/sintering situation must be uniform, measurable and reproducible – and BPCDs are by far and away the most cost efficient, consistent, reliable and user-friendly solution. These discs are manufactured in the UK under strictly monitored conditions, are small and lightweight, and are conveniently packaged and easily stored. Speak to our specialist team today and get peace of mind and profit protection.