Online instruments are high-precision devices installed on production lines to monitor samples flowing through pipes or tanks, ensuring the pass rate of products and maintaining smooth operation throughout the manufacturing process. Integrating online instruments with automated equipment is a growing trend in China's industrial development, offering significant practical benefits. These systems enable real-time monitoring, increase automation levels, provide clearer guidance for operators, reduce labor costs, lower production expenses, and ensure more efficient quality control.
Many domestic companies are now implementing online product control systems. For example, in liquid production lines, the CM-800a online concentration meter or PRM-100a online measurement and control system can be used to monitor and manage the entire process in real time. This enhances process reproducibility and ensures consistent product quality, replacing traditional manual methods like experience-based operations, manual record-keeping, and manual adjustments. By following strict process plans, these systems guarantee that products meet international standards while also reducing waste of water, raw materials, and energy, promoting energy efficiency and environmental protection.
The importance of real-time online monitoring lies in its ability to detect defects early in the production process. Common causes of defects include contamination, equipment failure, detection errors, and issues from previous stages. Online monitoring helps identify changes in concentration, reduces human error through full automation, and allows each process to be controlled independently, increasing overall flexibility and preventing single-stage failures from affecting the entire chain.
High levels of automation improve production efficiency, which is critical for manufacturing enterprises. Employees who are well-trained in automated technologies play a key role in enhancing productivity and maintaining product quality. Traditional methods often rely on workers' experience, leading to inconsistencies and potential errors. A scientific and reliable inspection method is essential to standardize operations and ensure efficient production.
Labor costs are a major concern for manufacturers, especially as wages rise and social welfare requirements become stricter. Companies face pressure from both internal costs and external competition. Reducing labor costs is vital for long-term sustainability. In many foreign countries, highly automated companies operate with significantly fewer staff compared to Chinese enterprises, yet they achieve much higher production efficiency.
Controlling production costs and ensuring product quality go hand in hand. Online industrial automation is the most effective way to achieve this. The higher the level of automation, the better the production efficiency and quality control. Conversely, low automation can lead to a company being outcompeted.
In terms of industry applications:
1. **Corn Starch Syrup Processing** – Online concentration meters help monitor sugar content at various stages of production.
2. **Sugar Cane Sugar Production** – ATAGO’s online sugar meter is used to measure brix values, ensuring optimal harvesting and processing.
3. **Cutting Fluid Monitoring** – ATAGO’s online concentration meter detects cutting fluid concentration, improving machining precision and surface quality.
4. **Beverage Filling** – In functional beverages and herbal teas, precise sugar value control is essential to meet national standards.
5. **Soy Protein Production** – Online concentration meters monitor the neutralization process, ensuring accurate control of lye and water.
6. **Ketchup and Jam Production** – Online concentration meters are used to monitor Brix levels during evaporation, improving efficiency and reducing costs.
7. **Chemical Industry** – Online concentration meters help monitor solvent absorption in exhaust gas treatment, ensuring efficient recovery and purification.
ATAGO’s CM-800a has been upgraded to IP67 waterproofing, making it suitable for outdoor environments. This improvement ensures durability in high-humidity conditions and provides better dust resistance than previous models. All images and content are protected by copyright, and unauthorized use may result in legal action.
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