Automated sensor management for pH and conductivity sensors is a convenient way to reduce risk factors. However, outside of convenience, managers and operators have a myriad of factors to consider before introducing a new system into their process. The real question at hand is, where is the impact from systems like the Unical 9000 or CL-90 really noticeable?

Where do the true intentions of automated sensor management, enhancements in accuracy, safety, reliability, and cost really emerge? Based on what we observe in the field and what we hear from our colleagues on the production line, we’ve identified five critical areas where automation delivers measurable value.

1. Higher Product Quality

No matter the process, the product is the point, right? Inconsistent product quality can often be directly tied to irregular sensor maintenance. This is where measurement drift, inaccurate readings, and delayed adjustments become an issue. After automation, operators and engineers experience consistent, real-time pH control that enforces stability, ensuring fewer deviations. Reliable automated maintenance, cleaning, and calibration schedules of sensors enhance end-product quality that must meet strict regulatory and/or customer standards.

• Consistent and accurate pH control
• Fewer deviations and less rework

2. Reduced Compliance Risk

Speaking of standards, anyone working in the process industry is aware of compliance risks in various areas. From incomplete records, inconsistent calibration practices, or potential data integrity gaps, the use of manual records and inaccurate calibrations can draw concerns during audits from compliance agencies. The cCare system adds automated, traceable documentation for record keeping. A customizable measurement and cleaning cycle for pH sensors also reduces the chance of non-compliance. In short, automation helps meet regulatory requirements with greater confidence and less manual oversight.

• Automatic audit trails and secure data logging for pharmaceutical companies or for environmental requirement
• Easier FDA/GMP alignment

3. Lower Operating Costs

The downtime caused by frequent manual operations like calibration or unplanned sensor replacement can negatively impact operating costs. Troubleshooting inaccurate measurements with manual intervention can cause further downtime, exacerbating this issue. Automated sensor management introduces an expectation of reduced labor needs, longer sensor life, and fewer process interruptions—ultimately lowering total maintenance expenses and improving overall cost efficiency.

• Less manual sampling and re-calibration
• Extended sensor life, fewer consumables

4. Increased Productivity

The frequency of downtime and the manual interventions we’ve listed don’t just harpen the process itself, they negatively impact the overall productivity of the plant. Productivity losses due to frequent manual interventions, process slowdowns during sensor maintenance, and unreliable measurements are avoidable. After installation of a cCare system, they can expect smoother operations with less manual handling, faster turnaround, and sustained process uptime—allowing staff to focus on higher-value tasks and overall productivity to increase.

• Operators freed from routine pH tasks
• Focus on higher-value process work

5. Enhanced Safety

Employee safety is paramount to any industry, but some struggle with safety risks from frequent manual handling of probes, exposure to chemicals during cleaning and calibration, and the potential for hazardous process upsets from inaccurate measurements. An automated care system provides improved safety through reduced operator exposure, fewer manual interventions, and more reliable pH control that helps prevent unsafe process conditions.

• Reduced risk to maintenance personnel
• Healthier work environment

Bring Automation to Your Process

Automation isn’t just about convenience. Several positive impacts are made all across the process line, from accuracy and reliability to safety and productivity. Interested in optimizing your measurements? Consider scheduling a training with us for a comprehensive look at where our automated solutions really make their impact felt.