Simplifying quality control using Near-Infrared Spectroscopy

Significance of the Topic

Quality control is essential for ensuring product conformity and maintaining customer trust. Traditional QC laboratories often face challenges such as high operational costs, lengthy workflows, complex multi-step analyses, chemical waste, and dependence on skilled technicians. Near-infrared spectroscopy (NIRS) offers a rapid, non-destructive approach capable of measuring multiple quality parameters simultaneously without sample preparation or reagents, thereby reducing costs and simplifying daily QC routines.

Objectives and Study Overview

This white paper evaluates how combining NIRS with dedicated smart software (Vision Air) can transform routine quality control. It presents application examples in polyols analysis, fast screening, atline and mobile testing, automated method selection, and accuracy optimization through adaptive calibration strategies.

Methodology and Instrumentation

• Implementation of Vis-NIR spectroscopy for sub-minute acquisition of complete spectral data.
• Use of Vision Air software to integrate sample identification, decision trees, method selection, quantitative analysis, and specification verification in a single workflow.
• Calibration approaches including global and split-range models, with automated selection of the optimal calibration for each sample to enhance accuracy.

Used Instrumentation

• Metrohm Vis-NIR Analyzer for rapid spectral measurements.
• Vision Air software for streamlined operation, smart method handling, and real-time decision support.

Main Results and Discussion

• All-in-one solution: Reduction of five separate wet-chemical procedures for polyols into a single NIR measurement, cutting analysis time from hours to under one minute.
• Fast screening: Immediate multi-parameter results allow on-the-spot product release or process interruption before costly off-spec batches occur.
• Atline and mobile applications: Real-time endpoint monitoring in production and in-field counterfeit detection for fuels and pharmaceuticals, increasing QC efficiency and target focus.
• Automated method selection: Vision Air’s decision tree identifies sample type (e.g., creams with or without sunscreen), selects the correct analysis method, and verifies compliance within five minutes.
• Enhanced accuracy: Adaptive calibration splits global models into low, medium, and high concentration ranges, halving standard errors in critical low-range measurements through smart software-driven model switching.

Benefits and Practical Applications

• Significant reduction in analysis time, labor requirements, and chemical consumption.
• Increased sample throughput and faster go/no-go decisions.
• Minimized human error and simplified QC workflows.
• Flexible deployment for atline, online, and mobile quality assurance tasks across industries.

Future Trends and Applications

Advances in chemometric algorithms and machine learning will further improve predictive accuracy and calibration robustness. Integration with Industry 4.0 and digitalization platforms will enable real-time process control, remote monitoring, and predictive maintenance. Expanded adoption is expected in pharmaceutical authentication, continuous manufacturing, sustainable materials analysis, and anti-counterfeiting programs.

Conclusion

The integration of NIRS with intelligent software like Vision Air revolutionizes quality control by delivering fast, accurate, and multi-parameter analysis within a single streamlined workflow. This approach cuts costs, reduces complexity, and accelerates decision-making, supporting efficient quality assurance in diverse industrial settings.

References

• World Health Organization. Substandard and Counterfeit Medicines. 2004.
• ASTM D664-17a. Standard Test Method for Acid Number of Petroleum Products by Potentiometric Titration. ASTM International; 2017.
• Metrohm White Paper WP-037. Simplifying Quality Control Using Near-Infrared Spectroscopy. August 2018.