Mosaic develops technology that reduces response time in NPK fertilizer analyses by up to 99%

Mosaic pioneered the application of Near-Infrared (NIR) Spectroscopy technology for chemical analysis of inorganic compounds (fertilizers and raw materials). Advances in this analysis method have simplified and optimized product quality control, and its use has already been adopted by some food and pharmaceutical industries for the analysis of organic products.

Mosaic's initiative helps ensure the quality and efficiency of the company's products. This work and its benefits were only possible due to partnerships between the company's Quality, Process Engineering, Operations, Projects and Maintenance teams.

According to the statement, two years of investment in research were made in the search for new technologies. The method allows the diagnosis of solid and liquid samples, in the laboratory, in portable devices and directly in the process. NIR can measure the concentrations of phosphates, nitrogen and potassium in products immediately. Speed ​​is one of its main advantages. The entire process takes about 90 seconds. There was a 99% reduction in chemical analysis time, with a 20% increase in laboratory productivity, without increasing staff.

“Process NIR allows operational decision-making to be much faster, since the operator has the chemical analysis of the fertilizer performed every five minutes. This ensures better quality results, optimization of raw material consumption, risk reduction, increased productivity and increases customer satisfaction,” he says. Elias Lima (pictured above), Vice President of Operations at Mosaic.

Benefits of NIR 

Since the project was implemented in 2021, water and effluent consumption has been reduced by approximately 3 million liters, equivalent to an Olympic-sized swimming pool. Another benefit is related to the safety of professionals. The method eliminates 100% of contact with chemical reagents, preventing accidents during analyses. The use of AI - Artificial Intelligence - also helps with data accuracy, creating references and helping to identify problems or variations in product samples.

The use of NIR technology has become an important tool for intermediate control, bringing representation to processes and agility in decision-making. This technology works in parallel with official analytical methods through comparative analyses to ensure compliance with standards and regulations. Thus, the company achieves a balance in its analyses with speed, precision and reliable data.

Mosaic's goal is to implement the project in all units by 2028, confirming its commitment to quality 4.0. Aiming to apply advanced and sustainable technologies that increase efficiency, reduce waste and offer safety to employees and customers.