Online instruments are high-precision devices designed to be installed on production lines for real-time testing of samples flowing through pipes or tanks. These systems ensure the quality and consistency of products while maintaining smooth operations throughout the production process. By integrating online instruments with automated equipment, companies can significantly boost productivity, making it a key trend in China's industrial development.
The practical benefits of using online instruments include real-time monitoring, high automation levels, intuitive guidance for operators, reduced labor costs, and improved product quality. Many leading domestic brands have adopted these technologies to maintain control over their production processes. For example, in liquid processing lines, the CM-800a online concentration meter or PRM-100a measurement and control system allows for real-time detection and control, enhancing process reproducibility and quality stability. This reduces reliance on manual methods such as experience-based decisions, record-keeping, and manual adjustments, ensuring that every step adheres strictly to the planned procedures.
By implementing online real-time monitoring, companies can identify and address issues like CED pollution, equipment malfunctions, or errors from previous stages. Automated detection minimizes human error, improves process flexibility, and ensures that each stage operates efficiently without disrupting the entire chain.
High levels of automation also play a crucial role in improving production efficiency and product quality. In traditional settings, workers relied on experience, which often led to inconsistencies. A reliable and scientific inspection method is essential to standardize operations and increase productivity.
Labor costs are a significant factor in the profitability of manufacturing enterprises. With rising wages and social welfare expenses, many companies face pressure to reduce staffing. Countries with higher automation levels, such as those abroad, typically use fewer workers per unit of production, achieving higher efficiency and better cost control. This makes it more challenging for less automated domestic companies to compete globally.
Controlling production costs and ensuring product quality go hand in hand. Online industrial automation offers an efficient way to manage both. The more automated a system is, the higher its productivity and quality assurance. Companies that fail to adopt automation risk being left behind.
Industry applications of online concentration meters and measurement systems are widespread:
1. **Corn Starch Syrup Processing** – Online meters help monitor sugar content during mixing and fermentation.
2. **Sugar Cane Processing (ATAGO)** – The PAL handheld refractometer measures brix values to determine sugarcane maturity, while the online sugar meter tracks sugar content during evaporation and purification.
3. **Cutting Fluid Monitoring** – ATAGO’s online concentration meters detect cutting oil levels in CNC machining, ensuring optimal performance and reducing environmental impact.
4. **Beverage Filling** – Functional beverages and herbal teas require precise sugar control, and online meters ensure compliance with national standards.
5. **Soy Protein Production** – The neutralization process is critical, and online monitoring helps maintain proper alkaline and water ratios.
6. **Ketchup and Jam Production** – Online meters track Brix levels in evaporators, ensuring consistent quality and efficiency.
7. **Chemical Industry** – Online concentration meters monitor solvent absorption in exhaust gas treatment, helping optimize chemical recovery and emission control.
ATAGO has recently upgraded its CM-800a online concentration meter with IP67 waterproofing, making it suitable for outdoor environments. This improvement enhances durability and reliability, especially in high-humidity conditions. The instrument provides stable and accurate measurements, transmitting data via 4-20 mA signals for integration into control systems.
This technology not only improves operational efficiency but also supports sustainable practices by reducing waste and resource consumption. As industries continue to evolve, online instruments will remain vital tools in achieving precision, consistency, and competitiveness in global markets.
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