Boost efficiency in the QC laboratory: How NIRS helps reduce costs up to 90%

Importance of the Topic

Ensuring robust quality control (QC) and quality assurance (QA) prevents costly internal rework and external failures that can erode up to 30 percent of turnover. Near-infrared spectroscopy (NIRS) offers rapid, non destructive analysis that significantly reduces chemical and labor costs.

Objectives and Study Overview

This paper evaluates the potential of NIRS to boost QC laboratory efficiency and lower running costs by up to 90 percent. It outlines common failure cost sources and compares conventional titration and viscometry methods to NIRS across multiple industry examples.

Methodology and Instrumentation

NIRS measures sample absorbance in the 800 to 2500 nm range to quantify functional groups and material properties in under one minute without sample preparation. Spectral data is processed with chemometric software for multi parameter evaluation.

Instrumentation Used

• DS2500 NIR Analyzer covering 12500 to 4000 cm-1 spectral range

Main Results and Discussion

Cost comparison shows elimination of consumable expenses and a reduction in annual labor costs from around 58500 to 469 USD, achieving full return on investment within 11 months. Application data include polyol analysis (hydroxyl value precision 0.68 mg KOH/g; moisture 52 mg/L), PET granulate (DEG 0.066 percent; IPA 0.143 percent; acid number 0.143 mg KOH/g), and gasoline parameters (RON precision 0.68; MON 0.53; aromatics 1.1 percent).

Benefits and Practical Applications

• Up to 90 percent cost reduction in routine QC
• Fast, non destructive, multi parameter analysis in under one minute
• Standardized operation and minimal operator training

Future Trends and Opportunities

Next generation QC will integrate NIRS with digital data platforms and machine learning for predictive quality control. Expanded calibrations will enable new applications and tighter specification monitoring.

Conclusion

NIRS delivers a sustainable efficiency boost in QC laboratories by cutting consumables and labor costs while maintaining accuracy and precision for diverse analytes.

References

1. Why Improving Quality Leads to Lower Manufacturing Costs, QualityInspection.org, accessed October 30, 2019
2. Metrohm Application Note NIR-035 Hydroxyl number in liquid polyols using Vis-NIR spectroscopy
3. Metrohm Application Note NIR-023 Diethylene glycol, isophthalic acid, intrinsic viscosity, and acid number in PET granulate by NIRS