A new dimension in process monitoring

Importance of topic

Atline process monitoring integrates the precision of laboratory analysis with the immediacy of online measurement, enabling manufacturers to maintain tight quality control, detect deviations rapidly and reduce waste. In industries with harsh environments and complex chemistries, a robust automated atline system ensures consistent product specifications and supports regulatory compliance.

Objectives and overview of study

This work presents the Metrohm 875 ProcessLab, a fully customizable atline analyzer designed to bridge laboratory and online systems. The system aims to deliver fast, reproducible results by positioning the analyzer close to the process, while offering modular flexibility for diverse analytical tasks across multiple industries.

Methodology

ProcessLab combines modular wet-chemical analysis modules with a hermetically sealed industrial PC and PLC-driven I/O controller. The software tiamo™ orchestrates sample identification, method execution, data acquisition and export to LIMS or process control systems. Communication options include analog/digital signals (4–20 mA), Ethernet for remote access and configurable I/O for feedback or alarm triggering.

Used instrumentation

• 800 Dosino automated burette
• 807 dosing units
• Reaction vessels with magnetic stirrers
• Peristaltic pumps
• Sample loops and overflow pipettes
• Multiport valves
• pH, temperature and liquid level sensors
• Industrial PC and PLC-based I/O controller

Main results and discussion

The modular design allows configuration of titration and voltammetric methods for analytes such as free and total acidity, metal ions (Cu²⁺, Zn²⁺, Cd²⁺, Tl⁺), cyanide, halides and organic additives. Typical applications span automotive and plating industries, chemical and pharmaceutical production, metallurgy, semiconductor surface treatments, food and beverage quality control, and water analysis. Close proximity to the process reduces sample transport times and improves reproducibility. Integrated data management ensures traceability and supports feedback loops in process control.

Benefits and practical applications

• Rapid on-site analysis with laboratory-grade accuracy
• Early detection of process deviations and reduced off-spec product
• Flexibility to add or reconfigure modules for future analytical needs
• Cost-effective alternative to full online systems
• Seamless integration with LIMS and process control via standard protocols

Future trends and potential applications

Advances may include integration of additional sensor technologies (e.g., spectroscopic probes), AI-driven predictive analytics, miniaturized microfluidic modules, and cloud-based data platforms. Such developments will further enhance real-time process optimization, support Industry 4.0 initiatives and expand applications in emerging bioprocessing and battery manufacturing sectors.

Conclusion

The Metrohm 875 ProcessLab represents a versatile, robust atline monitoring platform that unites laboratory accuracy with process-line convenience. Its modularity, communication capabilities and software control make it a powerful tool for ensuring product quality and process efficiency across a wide range of industrial applications.

References

1. Portala F, Steinbach A, Müller F, Feige M, Kirner G. Metals in dip coating baths. Process Worldwide. 2007;4:30–31.
2. Using ProcessLab for monitoring a phosphatizing process. Metrohm Information. 2007;36(2):17–19.
3. Determination of cyanide in process water of the steel industry. Metrohm Information. 2008;37(1):26–30.
4. Metrohm Application Bulletins AB-288, AB-289, AB-292, AB-295 and AB-300.