Multi
analysis
titration
system

Background

Our client is a global leader in alumina production, supplying approximately 8% of the world market.  The efficiency of the refining process is critically dependent upon analysis of the continuously circulating refining liquor. The company needed to replace an aging, manually intensive in-house analyser with a modern, automated solution capable of accelerating throughput, reducing operating costs, and operating in a 24/7 environment with minimal human intervention.

The company engaged Elevate Controls to develop a next-generation multi-analysis titration system—one that could achieve four times the sample throughput of its predecessor, at half the scale-up cost, while maintaining laboratory-grade accuracy and reliability.

The Challenge

Designing a high-performance, automated titration system for continuous operation required overcoming several challenges:

  • Unattended 24/7 operation:
    The system had to function dependably without manual oversight during varying shifts and production cycles.
  • High throughput:
    It needed to process four times more samples than the previous system, ensuring rapid and continuous chemical monitoring.
  • Cost and footprint efficiency:
    The solution had to be cost-positive and compact, enhancing performance at half the cost and space requirements.
  • Lab integration:
    Compatibility with standard laboratory equipment and direct communication with the Laboratory Information Management System (LIMS) were essential.
  • Quality control:
    The automated titration system needed to deliver consistent and accurate results with real-time monitoring of data integrity and process deviations.

The Solution

Elevate Controls designed and delivered the ALIAN—a powerful, PC-based automated titration system customised for industrial-scale, multi-point chemical analysis.

Key Features and Benefits

  • Advanced automation & parallel processing
  • ALIAN integrates effortlessly with industry-standard laboratory instruments, including Gilson Auto Samplers, Mettler, and Metrohm Titrators.

Fully automated scheduling and sample handling
Custom-engineered titration vessels and a modular pump/switching system for fluid routing
Simultaneous analysis of up to four auto-titrators, enabling unmatched efficiency

LabVIEW-Based Control Interface

Built with National Instruments DAQ boards and LabVIEW software, the system provides precise control, data acquisition, and method flexibility.

  • Intuitive GUI for easy titration setup and analysis configuration
  • Support for multiple calculation models and user-scriptable methods
  • Easy adaptability for future analytical requirements

Real-Time integration and quality assurance

ALIAN connects directly with LIMS for data transfer and result archiving.

  • Integrated Statistical Process Control (SPC) tools monitor result trends and flag anomalies.s
  • Maintains high result fidelity and traceability across all analysis cycles

Compact, scalable architecture

The system occupied half the bench space of its predecessor. Its compact size optimised the lab’s real estate and supported broader analytical capabilities.

The Outcome

The ALIAN system exceeded all key performance benchmarks. It provided a 24/7 automated operation solution with zero manual intervention. It quadrupled sample throughput and halved the build cost and physical footprint compared to the original analyser.

The system’s modular design, advanced automation, and easy integration into our clients laboratory ecosystem delivered transformational improvements in chemical analysis throughput and reliability. Engineers gained real-time insights with total data traceability. The benefited from a reduced operational strain.

ALIAN’s innovative design and process control impact were recognised industry-wide, earning it Finalist status at NI Week 2000 for “Best Applications Paper” in Test and Quality.

By adopting this advanced titration system, our client improved its process monitoring capabilities, supporting more responsive, data-driven control in one of the most demanding industrial environments.

 

Our Approach

Every control, monitoring, or test system project is unique. Elevate Controls follows a consistent development process that adapts to the unique requirements of your project and delivers a quality outcome every time. We use industry-standard tool chains that ensure consistent and efficient application of resources across every stage.

We offer a full-cycle development service from concept to deployment, and every stage in between. Whether you’re starting from a blank page or optimising an existing system, our team brings deep industrial experience, technical know-how, and a problem-solving mindset to every project.

Our Services

Elevate Controls offers full-cycle development of embedded controllers. Our consistent development process adapts to the unique requirements of your project and ensures a quality outcome every time. We use industry standard tool chains that ensure efficient use of resources, and design protect to allow for future variation and scalability.

We supply custom measurement and automation systems for application in technology-based industries including mining & materials handling, renewable energy & power, transport, and manufacturing.

Our systems deliver superior performance for demanding applications that push the limits of traditional data loggers and PC/PLC controllers.

We are expert integrators of the Mathworks MATLAB/Simulink software toolchain for system modelling, simulation and control design of complex engineering applications.

We design, develop, validate and certify high-volume Vehicle/Engine Control Units.

We are a proven partner for VCU/ECU development with over 100,000 units currently in service.

Elevate Controls can partner with you to develop your control, measurement, or automation product. We can manage the entire process to the point of handover or work as an embedded part of your product development team.

We develop products using fully documented industry-standard processes and toolsets that ensure that your product can be maintained, evolved, and supported for it’s projected commercial life.

We employ a consistent development methodology that delivers successful outcomes every time.

Elevate Controls develops custom test systems that are integral to every successful industrial or manufacturing business. Test guides and validates product development, tracks and maintains product quality, and is an essential element of post-production support and warranty management.

Elevate Controls specialises in custom solutions to industrial automation challenges that push the limits of traditional PLC/SCADA systems. We target challenging industrial R&D or test applications, specialised sub-systems within a traditional DCS, and process control for niche or pilot-scale manufacturing.

We have supplied systems to industries that include mining and materials handling, electrical power, transport, manufacturing, process industries, agribusiness, and engineering services.

We do not compete directly in the large-scale DCS or SCADA space.

Traditional data management lags behind the exponential growth in the volume and variety of data collected in modern engineering workplaces.

Elevate Controls’ Engineering Data Management Solution is designed to meet the needs of small to medium-sized engineering groups that must manage, analyse, and report large quantities of mixed-signal data.

Elevate Controls is an NI Systems Integration Partner with over 30 years’ experience deploying NI-based systems into Australian industry.

We are one of Australia’s most awarded integrators of NI systems at leading industry events.

We have hands-on experience with all NI’s current & legacy hardware lines, and all NI software applications & frameworks. We are one of Australia’s leading LabVIEW software development houses, having worked with every version of LabVIEW since its initial release.

Fibre Optic Measurement delivers some unique benefits that complement the functionality of traditional electro-mechanical sensing systems.

Elevate Controls can deliver measurement and automation systems that seamlessly integrate Fibre Optic Measurement into traditional electro-mechanical sensing systems. This can address issues that may be challenging or impossible to meet with electro-mechanical sensors alone.

Contact Us

Our solutions leverage industry-leading platforms, including National Instruments hardware and software, ensuring reliability, scalability, and faultless integration with your existing infrastructure.

We partner with clients throughout the entire project lifecycle—from proof of concept to system development, deployment, and long-term support— with the added flexibility to integrate at any phase of your project.

Elevate Controls helps businesses accelerate innovation while optimising performance and cost.

Contact us today to discuss your specific requirements and discover how Elevate Controls drives efficiency, accuracy, and competitive advantage in your operations.



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