Simply put, process control deals with the science of maintaining the output of a

specific process within a desired range. The proportion of one ingredient to

another, the temperature of materials, how well ingredients are mixed and the
pressure under which materials are held can significantly impact the quality of an
end product. That’s why process control solutions are so important.

Process control technology allows manufacturers to keep their operations running

within specified limits and to set more precise limits to maximize profitability,
ensure quality and prioritize safety.

To help manufacturers better understand the industry, we broke down five important
things you need to know about process control.

1. Process control enables automation.

Process control is commonly used for mass production. Due to its precise nature, it
enables the automation of industrial processes. With the proper information and
equipment, a small staff of operation personnel can operate even the most complex
processes from a central control room.

It’s important to note, however, that process control is not automation. Instead,
the two work together to perform efficiently. Without automation, plant operators
have to physically monitor outputs to determine the best settings to use with
production equipment. By using automated sensors, data can be collected and stores
to make more effective decisions.

2. It’s a common process.

Since so many tools fall under the umbrella of process control, it’s a very common
system practiced across a variety of disciples. Process control applications can
cover anything that measures or controls the following variables

Analytical
Connectors
Flow
Level
Pressure
Temperature
Vibration
3. When used properly, process control ensures safety.
Manipulating substances to produce a product is a very demanding (and potentially
hazardous) process. Even the smallest of changes can yield drastic differences in
the end results. Improper boiler pressure, for example, could affect the inflow of
air and the outflow of exhaust gases — threatening the safety of workers.

Proportions, temperature, flow, turbulence and many other factors must be carefully
and consistently controlled to produce the desired end product with a minimum of raw
materials and energy.

4. Process control is energy efficient.

Energy consumption in the industrial sector grows faster than in other sectors in
the U.S. When it comes to manufacturing, factory managers want their equipment to
deliver the highest output with as little production cost as possible.

With process control, factory leaders can oversee production, measure how a plant is
working and make educated decisions based on that data. By adapting in response to
this information, a strategy can be put into place so equipment can be used at
optimum levels. This ensures consistency of quality — meaning less energy is wasted
producing defective products.
5. It’s used across a variety of industries.
No matter its use, process control ensures effective systems. For that reason, it’s
used across a variety of different industrial processes. Some of the most popular
industries that use process control include:

BioPharm
Food and diary
Heat treaters
OEM
Oil and gas
Petro chem
Power generation
Pulp and paper
Semiconductor
Water
The right process control solution.
Want to learn more about process control? Here at ACI, we offer a full range of
consulting services for process control equipment, instrumentation, sub-assembly,
design and fabrication, engineering, calibration and certification.