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The Finna Sensors OMNIR V3 is a non-contact near-infrared (NIR) sensor that measures moisture continuously and in real time. It gives operators immediate visibility into moisture changes in asphalt, cat litter, biomass, aggregates, pulp and paper, building materials, and other industrial processes. The result is tighter process control, more consistent product and less reliance on manual sampling.
The OMNIR measures moisture, coat weight and optionally temperature on a variety of materials. It can be mounted on screw conveyors, belts, chutes, silos and lab environments, offering versatile placement options that can be tailored to the needs of your operation. It has a mounting distance of 8-16 inches (20.3-40.6 cm) from products, allowing for non-contact, non-destructive moisture measurement results.
The OMNIR shines near-infrared (NIR) light on a material to measure its moisture content. Some of this NIR light is absorbed, some of it is scattered and some of it is reflected back at the sensor. The sensor measures the reflected light intensity at wavelengths specific to water absorption. The higher the moisture content in the material being measured, the more NIR light will be absorbed. Therefore, lower levels of NIR light reflection typically indicate higher moisture levels in the measured material.
The OMNIR uses a patented method that filters light after it reflects off the product, rather than before. Filtering light after reflection reduces noise in the sensing field and allows deeper product penetration of the non-filtered, full-spectrum white light. This significantly decreases interference from:
Sensors that filter light before it hits the product must be calibrated to cancel out these sources of interference. That process can create challenges in sensor setup and stability. Filtering after reflection avoids these issues, allowing the OMNIR to measure moisture from 0.1% to 95% with greatly improved accuracy.
Pulling samples for lab analysis is a labor-intensive and inefficient way to measure moisture in manufacturing plants. Oven drying is accurate but slow. By the time results come back, the sampled material has usually moved on to the next production step, along with all material produced after the sample was taken. Each sample also shows moisture at a single point in time, so fluctuations that happen between tests can go unnoticed. When a change in moisture levels does show up, it’s hard to tell when it started or how much material it affected.
The OMNIR measures moisture on the production line at 60 calculations per second without contacting the product. Your operators see changes as they happen, including short-term fluctuations that lab samples miss. Every reading is recorded, so it’s easy to see when a change started and how long it lasted. That makes it possible to correct problems before they affect large amounts of material.
Learn More About the Benefits of On-Line Moisture Measurement
The OMNIR measures moisture in powders, granular materials, sheets and webs. It can be used in a wide range of industries and applications.
Asphalt plants use the OMNIR to measure moisture in virgin aggregates and reclaimed asphalt pavement (RAP). The sensor mounts at cold feed bins and RAP processing points. There, it measures material without contact before it goes into the mix. Real-time readings help operators confirm the right materials go into each batch.
Learn More About Moisture Measurement in Asphalt ProductionFinna Sensors has measured moisture in cat litter and pet food production for many years. In many plants, moisture checks rely on manual sampling. The line stops while a worker pulls a sample, dries it and measures it. That takes about 30 minutes. By the time results come back, a large amount of off-spec material may already have been produced. Semi-automated systems that divert samples to an off-ramp for drying have the same delay.
The OMNIR measures moisture continuously as product moves along the conveyor, making 60 calculations per second. Operators see moisture trends as they happen and can adjust drying right away. Leading pet food and cat litter manufacturers use the OMNIR as part of their moisture control processes.
Learn More About Moisture Measurement in Pet Food and Animal Feed| Industry | Typical materials | Typical measurement points |
|---|---|---|
| Biomass | Agricultural and forestry waste, finished biomass products | Conveyors before and after drying |
| Building materials | Gypsum board, asphalt shingles and roofing granules, painted or coated wallboard, wood and concrete | Gypsum board manufacturing; before and after coating (moisture and coat weight); after shingle washing; finished shingles |
| Chemical and pharmaceutical | Pharmaceutical powders, ingredients, gelatin capsules | Belt and screw conveyors, small sample flows, inside spray dryers |
| Food and agriculture | Dried and dehydrated foods, wet and canned foods, raw products, packaging materials | Incoming raw material; before and after centrifuges; belt, screw, pneumatic and vibratory conveyors |
| Minerals and mining | Cement, frac sand, gypsum rock, kaolin clay, bulk powders | Before the rotary dryer, at the dryer exit, before shipping |
| Pulp and paper | Bark, market pulp, pulp rolls, finished paper, water-based coatings | Both ends of the paper machine; coatings (moisture and coat weight) |
| Textiles | Cotton batting, coated or fire-retardant-treated fabrics, carpet and rugs | Over the lint slide in cotton gins; drying after coating or fire-retardant treatment |
The OMNIR offers a variety of features and benefits that allow you to optimize your moisture control efforts.
The OMNIR V3 is the latest version of our NIR moisture sensor. It adds a touchscreen HMI, more analog outputs and expanded PLC data. It also supports longer cable runs and a simpler software install.
| Feature | OMNIR V1 | OMNIR V3 |
|---|---|---|
| HMI display | 4-line LCD with buttons | 7″ color touchscreen |
| Analog outputs (4–20 mA) | 2 channels | 4 user-configurable channels. Assign moisture, temperature or another measurement to each. |
| PLC data | Moisture and temperature, through optional EtherNet/IP, PROFINET, Modbus TCP or Modbus | All V1 data plus active product code, product runtime, sensor status, process alarms, measurement status and scaled sensor values |
| Product code switching from PLC | Not available | Available (requires PLC integration purchase) |
| HMI hardware | — | New motherboard with more I/O for future expansion |
| Maximum cable length | 66 ft (20 m) | 328 ft (100 m), with no signal loss over longer runs |
| Controller communication | — | Faster response and fewer dropped packets, especially over Wi-Fi |
| Multiple sensor units | Not available | Saved connections for quick switching between units |
| Software installation | Windows application with SQL Server database | Simplified install with a lightweight SQLite database. SQL Server stays optional for centralized reporting. |
| Calibration model | Look-up table | Look-up table or a linear model that works like other common NIR meters |
| SPC charts | Included in reports | Choose what to plot: M1 and M2 (raw or scaled), LOP and temperature |
| Licensing options | None | PLC protocol licensing |
The OMNIR integrates with most PLC brands and supports cable runs up to 328 ft (100 m). It also supports two calibration models, including a linear model that works like other common NIR meters.
The OMNIR works with most PLC brands, including Allen-Bradley, Siemens and Omron. PLC integration is an optional purchase. Supported interfaces include EtherNet/IP, PROFINET and Modbus TCP, with the full list in the specifications below.
With PLC integration, the OMNIR sends:
The PLC can also switch the OMNIR between saved product calibrations. A photo-eye or PLC output can control when the sensor measures through the external trigger.
The OMNIR V3 also has four user-configurable 4–20 mA analog outputs. Each can carry moisture, temperature or another measurement.
Finna Sensors offers installation services when you purchase our OMNIR sensors. Most OMNIR installations take about a day. The OMNIR mounts 8–16 in. (20.3–40.6 cm) from the product and measures an area of about 1 in. (25 mm). It can be installed on belts, screw conveyors, chutes and silos, or used in a lab. For screw conveyors and free-fall conveyors, the stainless-steel opto-port attachment adapts the sensor to the process. It can be ordered with an air blast system for free-falling samples.
The modular design keeps the most sensitive electronics away from the production line. Cable runs between the sensor and the HMI controller can reach 328 ft (100 m) with no signal loss.
The OMNIR software is a Windows application that installs with a lightweight SQLite database. SQL Server stays available as an option for centralized reporting. Saved connections let operators switch quickly between multiple OMNIR units.
The OMNIR V3 supports two calibration models: a look-up table and a linear model. The linear model works like other common NIR meters, which makes the OMNIR familiar to plants that use another brand. The OMNIR stores up to 80 product calibrations and integrates with your PLC, allowing your PLC to switch between saved calibrations as you change products.
You can calibrate the OMNIR for your materials yourself, or Finna Sensors can do it for you. Many customers send material samples to our lab, where our team builds a calibration model for their product.
| Specification | Value |
|---|---|
| Moisture range | 0.1–95% |
| Moisture accuracy | Up to ±0.1% depending on application |
| Coat weight range | 0.1–200 gr./m2 |
| Coat weight accuracy | ±0.1% gr./m2 |
| Sample rate | 60 calculations per second |
| Measurement area | Approximately 25 mm (1 in.) |
| Product distance | 8–16 in. (20.3–40.6 cm) |
| Specification | Value |
|---|---|
| Display | 7″ color touchscreen |
| Optional bus interfaces | Ethernet, EtherNet/IP, PROFINET, PROFIBUS DP, Modbus TCP/IP, Modbus RTU, RS-485, DeviceNet |
| Software | Windows-based application with SQLite database (SQL Server optional), requires Windows 7 or newer |
| Power | 90–260 VAC, 47–63 Hz |
| Operating temperature | -20 to 70°C (-4 to 158°F) |
| Enclosure | Fiberglass |
| Weight | 9 lb (4.1 kg) |
The following optional accessories are available to enhance the performance of the OMNIR V3:
Finna Sensors also offers a stainless-steel version of the OMNIR, called OMNIR-SS. It is most often used by manufacturers in the food or chemicals and pharmaceuticals industries. It’s also an ideal solution for industries who require protection against corrosion caused by caustic elements, wet and humid environments, and high-pressure wash-down procedures.
Explore the OMNIR-SS SensorScanframe allows the OMNIR sensor and its advanced software to take multiple-point readings of moisture and coat weight to drive new efficiencies across the production line. This non-contact aluminum beam is powered by a motor and gear system, allowing operators to position the OMNIR sensor to take both manual and pre-programmed readings from multiple points across the web.
Explore Scanframe’s CapabilitiesThe OMNIR measures moisture from 0.1% to 95% with up to ±0.1% accuracy depending on the application. It makes 60 calculations per second, so it captures short-term moisture changes that periodic lab samples can miss.
The OMNIR measures moisture in materials such as asphalt aggregates and RAP, cat litter, pet food, gypsum, pharmaceutical powders, food products, cement, frac sand, pulp, paper and cotton. It also measures coat weight on coated products.
No. The OMNIR is a non-contact sensor that mounts 8–16 in. (20.3–40.6 cm) from the product. Measurement is non-destructive, so the product continues down the line unchanged.
The OMNIR can be installed on belts, screw conveyors, chutes and silos, or used in a lab. An optional stainless-steel opto-port adapts the sensor to screw conveyors and product free-fall situations. The sensor carries an IP69K rating and is built to withstand harsh conditions.
The OMNIR integrates with most PLC brands, including Allen-Bradley, Siemens and Omron. Supported interfaces include EtherNet/IP, PROFINET and Modbus TCP. PLC integration is an optional purchase.
The OMNIR V3 supports two calibration models: a look-up table and a linear model. The linear model works like other common NIR meters, which makes switching from another brand easier. The look-up table model allows fast calibration with minimal lab sample comparisons. The OMNIR stores up to 80 product calibrations, and your PLC can switch between them with PLC integration. Finna Sensors can also calibrate the OMNIR for you using samples of your material.
Yes. Send samples of your material to Finna Sensors, and our team will build a calibration model for your product in our lab. You can also calibrate the OMNIR yourself.
The OMNIR continuously reports on 19 internal points to monitor sensor health. This helps your operators find problems early, which increases uptime.
The OMNIR V3 replaces the V1’s 4-line LCD with a 7″ color touchscreen. It sends more data to the PLC and lets the PLC switch product calibrations. Cable runs extend from 66 ft (20 m) to 328 ft (100 m). The V3 also adds a simpler software install and a linear calibration model.
Yes. The OMNIR measures coat weight from 0.1 to 200 gr./m2 with ±0.1% accuracy depending on the application. Applications include paint and coatings on building materials, and water-based coatings and adhesives in paper production.
At Finna Sensors, we’re committed to providing you with the detailed information you need to make the proper decisions regarding moisture control. We’ve put together a variety of resources on our website to help you understand how NIR moisture measurement works and the OMNIR’s capabilities. Download the brochure or explore the articles in this section to learn more.
Request a quote for OMNIR V3 NIR sensors at your manufacturing facility. Our team can supply and install the OMNIR sensors you need to maintain proper moisture control throughout your processes.
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