900 Series Chemical Process Control Case Studies

Electroplating Consultants International (ECI) demonstrates how advanced process monitoring can solve complex wastewater treatment challenges while improving manufacturing efficiency in two real-world industrial applications. In the first case, an FAA-certified aircraft maintenance, repair, and overhaul (MRO) facility faced discharge violations after hexavalent chromium concentrations in its wastewater exceeded strict regulatory limits. By replacing outdated controllers with Myron L® Company 900 Series Monitor/Controllers for precise pH and oxidation-reduction potential (ORP) control, ECI optimized chemical dosing and dramatically reduced chromium levels below compliance thresholds. Additional process improvements further decreased chemical consumption, eliminated the need for recirculation and haul-offs, enhanced worker safety, and reduced the volume and environmental impact of generated waste.

The second case highlights how the same monitoring technology improved quality and productivity for a residential HVAC manufacturer struggling with water spotting and rising chemical costs in its powder coating pretreatment process. ECI implemented a comprehensive water quality management system using Myron L 900 Series controllers to continuously monitor pH, conductivity/TDS, and temperature across all five pretreatment stages. Real-time process control stabilized chemical conditions, reduced Stage 4 chemical usage by 50%, and enabled the manufacturer to increase production throughput by more than 25% while maintaining consistent coating quality. Together, these case studies illustrate how accurate, reliable water quality monitoring can help manufacturers achieve regulatory compliance, reduce operating costs, improve process efficiency, and support safer, more sustainable operations across demanding industrial environments.