"Good Data" can lead to bad outcomes. Closing the Conductivity Gap with Ratio Based Automation

Case Study: Closing the Conductivity Gap with Ratio-Based Automation

Overview

In automated stage washers, conductivity is commonly used to control chemical dosing.  But as soil and debris accumulate in the wash tank, conductivity rises independently of actual chemical concentration—creating a hidden but significant dosing error.

Our Becker Connected Systems engineers have developed a new IoT dashboard feature that transforms routine titration data into a live concentration-to-conductivity ratio. This enables operators to dose based on true chemistry—not distorted sensor signals—restoring confidence in automation while improving quality and cost control.

The Challenge: When “Good Data” Leads to Bad Outcomes

A customer operating an automated stage washer relied on conductivity-based dosing to maintain chemical concentration. Over time, they observed:

• Increasing conductivity readings during operation
• Discrepancies between sensor data and manual titrations
• Declining part cleanliness despite “in-spec” readings

Root Cause

The issue was not sensor failure—it was physics:

• Soil and contaminants increase conductivity
• Sensors accurately measure conductivity, but not chemical concentration
• The system interprets elevated conductivity as sufficient chemistry

Result: Chronic underfeeding of chemicals and reduced wash quality.

Operators attempted to compensate by manually increasing conductivity setpoints, creating inconsistency and inefficiency.

The Solution: Ratio-Based Control via IoT Dashboard

Becker Connected Systems has introduced a new IoT dashboard capability that integrates manual titration data into the automation workflow.

How It Works

1. Manual Input
   Operators enter titration-based concentration values into the dashboard.
2. Automatic Calculation
   The system calculates a live ratio between:
• Measured conductivity
• Actual chemical concentration
3. Trend Visualization
   The ratio is plotted over time, revealing how soil buildup impacts conductivity.
4. Controller Integration
   The latest ratio is entered into the controller, enabling it to convert conductivity into true concentration for dosing decisions.

Implementation in Practice

• Operators perform routine titrations
• The latest ratio is used—not an average—to reflect real-time conditions
• Controllers automatically adjust chemical feed based on calculated concentration

No more chasing conductivity setpoints.

Results

1. Improved Product Quality

• Eliminates underfeeding caused by false conductivity signals
• Ensures consistent cleaning performance

2. Reduced Chemical Waste

• Prevents overcorrection and unnecessary chemical use
• Aligns dosing with actual process conditions

3. Increased Operator Confidence

• Resolves perceived “sensor vs. lab” conflicts
• Reinforces trust in automation systems

4. Smarter Tank Management

• Helps distinguish between:
• Normal soil accumulation
• Conditions requiring tank dump and recharge

Beyond Conductivity: Extending to pH Calibration

The same concept applies to pH monitoring:

• Compare inline probe readings to handheld measurements
• Track deviation over time
• Use ratio drift to determine when calibration is actually needed

Outcome:
Calibration becomes data-driven instead of schedule-based.

Key Insight

This approach doesn’t eliminate manual titrations—it elevates them.

Instead of being a passive verification step, titration data becomes an active input that improves automation accuracy in real time.

Conclusion

By integrating titration data into a live ratio model, Becker Engineered Systems closes the gap between sensor readings and actual chemistry.

The result is a smarter, more reliable dosing strategy that:

• Adapts to real-world conditions
• Protects product quality
• Maximizes operational efficiency

Next Steps

If you’re seeing inconsistent wash quality, rising chemical costs, or losing confidence in conductivity-based control, it’s time to move beyond guesswork.

Becker Engineered Systems can help you implement ratio-based dosing quickly.

Start Here:

1. Schedule a Process Review with our Becker Engineered Systems team
   We’ll evaluate your current dosing strategy, titration practices, and control logic to identify where conductivity bias is impacting performance.
2. See Your Data, Reframed
   Our team will walk through how your existing data would look using ratio-based modeling—revealing hidden inefficiencies and optimization opportunities.
3. Deploy the Solution
   We’ll help configure your controllers and deploy an IoT dashboard to:

• Integrate titration inputs
• Calculate live ratios
• Dose based on true concentration

4. Validate Results On-Site
   We work with your team to confirm improvements in:

• Part cleanliness
• Chemical usage
• Operator confidence

What You Gain

• Immediate improvement in dosing accuracy
• Reduced chemical waste and rework
• A system your operators trust—and rely on

Take the Next Step

Book a working session with Becker Engineered Systems to evaluate your system and see the impact firsthand.

Or, if you prefer, send us a recent titration and conductivity data set—we’ll run a sample analysis and show you exactly where performance can improve.

Contact Evan Humpert, Becker Connected Systems Manager

Evan@beckeres.com