Process Instruments was founded in 1994 to develop Raman spectroscopy instrumentation specifically for industrial process monitoring. We brought together a development team focused on the design of state-of-the-art, affordable, frequency-stabilized, narrow-linewidth diode lasers and efficient, optically fast (f/2.0) spectrographs for use in industrial process control applications.

Previous Instrumentation Experience

In 1983, Lee Smith, together with other colleagues from the University of Utah, founded a medical instrumentation company (Albion Instruments) to develop laser-based Raman scattering for real-time anesthesia monitoring. The company raised $10,000,000 of venture funding over four years for product and market development. Additional funds were obtained from Phase I and II SBIR grants from NIH, EPA, and DOE. The first year of product sales with the medical Raman instrument reached 5 million dollars. In the second year (1990) the medical products company was sold to a competitor providing an exit opportunity for investors, founders, and employees. Process Instruments has its Raman systems in some of the largest refinery and petrochemical plants in the U.S. This equipment is being used to optimize the production of gasoline, chemicals, and polymers. We also work closely with pharmaceutical companies to develop Raman scattering technology for use in optimizing their manufacturing operations.

Our present focus remains on Raman instrumentation. We are privately held via employee stock ownership. Our current product development has been funded entirely from government and private contracts and from product sales. Our specialty is problem solving for industrial process control applications. We do not just sell Raman instrumentation and components, rather we use Raman instrumentation to solve critical process control problems. Our ability to design our excitation lasers for any given wavelength (630 nm to 860 nm) allows us to tune our lasers for optimum Raman signal collection while avoiding unwanted fluorescence. Our patented laser (U.S. Patent No. 6,100,975), spectrograph (U.S. Patent No. 6,028,667), and 18 channel multiplexer (U.S. Patent No. 6,859,581) designs allow for robust, compact, and stable Raman instrumentation. In addition, we offer very high power, stabilized lasers (>1,500 mW) for Raman applications that require greater power.

Frequency-Stabilized, Narrow-linewidth Diode Laser

Process Instruments is the largest producer of high-power, frequency-stabilized, narrow-linewidth NIR laser diode sources in the world and the first company to offer a 9,000 hour or one year warranty on this type of laser. Our frequency-stabilized lasers have become the "industry standard" because of their low cost, excellent frequency-stability, and long-term reliability. Since we sell our lasers directly to OEM and research customers, no sales representatives are needed which helps to keep our laser costs extremely competitive.

Optically Fast Spectrograph

We have developed and patented a compact, robust, 135 mm focal length, optically fast (f/2.0) spectrograph with NIR-AR coated optics. The optical design allows for full height imaging on the CCD chip without sacrificing spectral resolution. Operating at 785 nm excitation the spectral coverage is ~ 250 to 2400 cm^-1 with a resolution of 4 to 5 cm ^-1. We offer a wide variety of CCD chip detectors depending upon the customers' needs. The spectrograph has built-in automatic neon calibration and is temperature controlled for added stability. The effective entrance slit is ~ 40 um wide and is comprised of a linear fiber input array made up of 38 x 50 mm diameter fibers (up to 110 x 50 mm fibers for taller CCD chips). The spectrograph input can accommodate most any Raman collection probe configuration. Collecting efficiently with fibers from 100 mm to > 600 mm in diameter.

Regulatory Issues

We met all necessary CDRH regulations (FDA laser safety issues) and maintain CE certification allowing all of our instrumentation products to be sold into foreign markets.

Real-time Chemometrics

We have developed our own proprietary data acquisition software (PROspect^TM) that incorporates real-time chemometric features for on-line predictions. We build models using Thermo-Galactic PLS Plus/IQ routines, and PROspect^TM incorporates the GRAMS predictor for real-time chemometric applications.

Wavenumber Tracking

Raman data are acquired independently of laser excitation wavelength through a process of wavenumber tracking every Raman spectrum as it is acquired. If and when our laser has to be replaced, we want the customers' chemometric models to continue to work well regardless of the exact laser wavelength.

Model Transfer Capability

We developed the routines necessary to normalize the Raman spectrum with respect to the individual Raman instrument's throughput, including the Raman collection probe and any optical filters. This normalization process allows for simplified model transfer from one Raman instrument to another. Even in the event that a Raman probe requires replacement, the chemometric models built with one particular probe will continue to work well with a replacement probe.

Multiplexing Capability

One of the real advantages of Raman Spectroscopy is its compatibility with optical fibers and its ease of multiplexing. We have developed the necessary software and mechanical features to allow up to 18 channels to be multiplexed to one instrument. Each channel (chemical stream) can operate with its own unique Raman probe, wavenumber tracking parameters, throughput normalization, and chemometric model routine. We prefer sequential multiplexing over on-chip multiplexing for several reasons including cost, the ability to tailor each individual channel's integration period, and the need for only one laser to serve many channels.

Data Output

We can provide data output from our instrument pc to the customers' DCS via a number of methods including analog (4 to 20 mA) or digital (MODBUS, OPC, etc). Each channel can accommodate up to >32 individual prediction parameters.

Simplified Calibration

We developed simplified calibration procedures. We provide a built-in neon calibration source for spectrograph wavelength calibration that together with the wavenumber tracking algorithms maintain excellent system calibration.

Installation

Our Raman instrumentation is especially easy to install. For most applications, the instruments are packaged in a 19" Rack mount configuration. The equipment is installed in the control room with optical fiber cable running to the individual process streams. Typical fiber runs are 200 to 500 feet. Once the fiber cables have been laid, the fibers are simply connected to the Raman instrument and to their respective Raman probes. Routine calibrations are performed and the customer is up and operating.

Training

We provide our customers with instrument training including instruction on the operation, maintenance, and upkeep of the Raman equipment. In addition, we train them in the preparation and maintenance of chemometric models. We can provide model building services if required, but we prefer that the customer learns this technique.

Repair Service

Until we developed our own laser product, lasers sources commonly used for industrial Raman applications were very expensive, prone to failure, and required ~ 3 to 4 months for repair. All of these issues became major stumbling blocks for implementing Raman spectroscopy into industrial applications. In addition to developing a far superior, stable, long-life laser product, we make a concerted effort to perform most laser repairs within two weeks after the laser is in our shop and many are repaired much faster. We stock all of the common excitation wavelength diodes including 785, 808, 830 nm.

For industrial instrumentation users that have a second laser as a backup, we offer a two year warranty on laser life. The backup laser warranty does not start until the first laser is taken out of service and/or at the end of the first year, which ever comes first. After our lasers are rebuilt, they carry a new 9,000 hour or one year warranty. Our standard NIR (300 mW) laser rebuild cost is less than half of the original laser cost helping to lower the cost of long-term laser ownership. A current laser life test demonstrates only a ~ 15% power loss after ~ 6 years of continuous operation.

We offer Raman analysis and chemometric model development for customers' samples. We have complete laboratory facilities to perform Raman analysis at many different excitation wavelengths and under many different environmental conditions. If possible, we have our customers send us a broad selection of their process samples. Using our laboratory Raman instrumentation, we quickly develop chemometric models that can be easily transferred to one of our industrial Raman instruments allowing the customer to be rapidly on-line.

Process Instruments, Inc. has ~5,000 square feet of development and manufacturing space. We subcontract functions such as accounting, machining, optical processing, and circuit board fabrication. This allows us to focus our attention on product design, assembly, quality control, testing, and application engineering. We use 9 independent Reps to market throughout the U.S. to industrial customers. We are currently developing foreign markets as well. Individuals interested in discussing product representation in other domestic and foreign markets, please contact our Sales Manager, Mr. Don Crider or contact him at (949)636-1080.

We have developed some very high throughput instrumentation that has proven to work well in some specialized medical market opportunities such as non-invasive glucose determination. In this application, a high-tech medical company is using our high-performance laser and spectrograph instrumentation to measure glucose concentrations non-invasively through the patients' skin. A very difficult task, but the market opportunity is huge if this can be cost reduced and properly developed. We have done similar development for law enforcement applications where Raman is being used for detecting drugs, hazardous chemicals, etc. We continue to look at new opportunities that match the capabilities of our technology.