“Quality means doing it right when no one is looking”
– Henry Ford
Did you ever come across the term “process control” while researching industrial equipment and thought, ‘Wait…what is that exactly?’ You’re not alone. Whether you’re tackling college projects or working in R&D, you may have come across this term used by manufacturing companies. Now let’s be honest it can sound intimidating at first.
So, what exactly does it mean? To help clear things up, this blog will provide information on what process control is, its purpose, various types, and the benefits it offers across the industry.
What Is Process Control?
Process control plays a vital role in the generation we live in. The whole process is based on principles from control theory and relies on physical systems to monitor and regulate industrial operations. Control theory blends engineering and mathematics to help machines and systems stay on track even when conditions change. So together we can say that they help to monitor, control, and optimize continuous production processes through a control system.
This ensures your machines stay in good working order, remain safe within factories, and use just the right amount of energy for the work they’re designed to do. Now, let’s move forward to understanding where we use process control.
Where Is Process Control Being Used?
Simple formula: whenever someone says process control, it means it is used in continuous production. We know it is used in manufacturing, but it depends on and can be used in different fields and in batch processing as well. In manufacturing, batch processing refers to producing a set quantity of goods by following a defined sequence of steps.
For instance, in wastewater treatment, it involves continuous treatment of wastewater like sewage or debris without any disturbances. In this field, process control is used. In another example of oil and gas refining, there also, in the flow of material through the pipelines, process control is used. It combines control and chemical engineering together with the help of systems like combustion control systems or control systems.
The Different Types of Process Control
Let’s look at the different types of process control and understand how they work and how they are different from each other.
Open-Loop Control:
This is the control type where you already have predefined parameters in the process. In this process, there is zero continuous feedback received via sensors, let’s say, to adjust the changes in workflow. Hence, it is a good option for workstations with stable conditions, where the results can be achieved with the help of a predetermined sequence of actions.
Closed-Loop Control:
This one is the most common type, and it is where real-time sensor data is used. It makes use of that to continuously monitor the process conditions and compare them with the desired parameters. The feedback received helps to adjust to maintain the process within required limits. This is important for functions which are sensitive to different variations and need monitoring and adjustments.
What Is the Importance of Process Control Systems?
- It helps to make sure that the product has little quality difference, minimizing variations and any sort of defect enhancing product quality and customer satisfaction.
- It helps reduce waste and improve production efficiency. This leads to better output and lower production costs.
- This system helps in controlling critical features and detecting safety problems, which helps prevent dangerous hazards.
- When industries adhere to standards, it maintains operations and helps avoid legal and financial penalties.
What are the Benefits of Process Control?
- Predictable outcomes make production planning, inventory tracking, and scheduling more precise and reliable.
- Early detection allows everyone to act in a prompt manner and avoid costly disruptions.
- Optimized resource usage supports eco-conscious operations and helps companies meet sustainability and CSR goals.
- Flexible control mechanisms make it easier to respond to shifting market demands and external pressures.
- Data-driven insights from control systems reveal patterns, highlight inefficiencies, and unlock opportunities for improvement.
- Consistent product quality builds trust and gives businesses a competitive edge in demanding markets.
- Automation reduces human error, boosting accuracy and ensuring dependable performance across operations.
- Continuous improvement becomes second nature, as real-time analytics guide smarter decisions and long-term improvements.
Final Note:
Now you might have gotten to know the real reason behind using process control systems in industrial manufacturing since they play such an important role in managing and regulating industrial processes with precision. So, if you have any doubts regarding process control, do let us know in the comments below.
Plus, if you want to learn more about industrial equipment like what to look for in butterfly valves or understand how safeguard controls work, we have an entire blog list curated just for you. Feel free to check those blogs out and get to know the basics of industrial manufacturing. If you’d like support with process control, contact our team of experts today to get started.
