Metrohm ProcessLab: Bringing the Laboratory At-line

Significance of the Topic

At-line analytical systems provide a critical link between laboratory and fully online process control. By positioning robust analyzers adjacent to production lines, manufacturers can obtain rapid, reproducible results without the cost and complexity of fully integrated online instruments. This capability supports tighter quality specifications, early problem detection and reduced material waste across diverse industries.

Goals and Scope of the Study

This study presents Metrohm’s 875 ProcessLab, an automated at-line platform designed to combine laboratory flexibility with industrial robustness. The aim is to demonstrate how a modular, customizable system can meet evolving analytical requirements in harsh production environments while maintaining ease of installation and operation at any skill level.

Methodology

ProcessLab operates by automatically drawing samples from the process, identifying them at the unit and running preconfigured analyses on site. The system uses a compact, powder-coated steel housing with hermetically sealed wet-part modules, protecting electronics from dust and splashes. Real-time results can be output via analog/digital signals or network protocols for integration with process control and LIMS.

Instrumentation Used

• 875 ProcessLab at-line analyzer platform
• Industrial PC and PLC-driven I/O Controller (MDM Controller)
• Up to 16 interchangeable wet-part modules including Dosinos, dosing units, peristaltic pumps, stirrers, valves and sensors
• Analytical modules for pH, ion-selective electrodes, oxidation-reduction potential, cyclic voltammetric stripping, conductivity, acid/base titration, Karl Fischer moisture determination, free and total sulfur dioxide, nitrite/phosphate, hydrogen sulfide, mercaptans, vitamin C, free fatty acids and more
• Software control via tiamo™ with client/server architecture and data export (CSV, LIMS, XML)

Key Results and Discussion

The ProcessLab demonstrates fast, reproducible analytical performance when situated directly at the process line or in a plant laboratory. Its modular design allows users to tailor and expand configurations for multiple applications. Integration of real-time data into control systems enables early detection of deviations, while networked operation and remote control capabilities support decentralized monitoring.

Benefits and Practical Applications

• Covers a wide range of application areas: chemical, petrochemical, pharmaceutical, food and beverage, environmental, textile, mining, metal finishing, pulp and paper and more
• Reduces capital and maintenance costs compared to full online analyzers
• Ensures reproducibility by minimizing sample transport delays
• Facilitates compliance with quality and regulatory standards through automated control charts and alarms
• Allows easy reconfiguration or expansion to address future analytical needs

Future Trends and Potential Applications

Advances in sensor technology, miniaturized spectroscopic and biosensor modules, and integration of artificial intelligence for predictive analytics will further enhance at-line systems. Industry 4.0 networking and cloud connectivity will enable centralized data management and advanced process optimization across multi-site operations.

Conclusion

Metrohm’s 875 ProcessLab successfully merges laboratory-style analytics with industrial robustness in an at-line format. Its modular architecture, comprehensive method support and seamless process integration deliver a cost-effective solution for maintaining product quality and operational efficiency in demanding production environments.

References

• J. Camarda and F. Portala, Metrohm ProcessLab: Bringing the Laboratory At-line, Brinkmann Instruments, Inc. and Metrohm AG, 2006.