➔ Starting Situation:

A manufacturer of polyurethane (PU) with 2 reactors at one site and a production volume of 3600 t/year achieves a gross profit margin of €7 million/year.m

 ➔ Savings Potential: Analysis Costs

To simplify, a consistent production is expected over the whole year. On average, 3 samples are taken per reactor per day. Laboratory analysis is maintained and needed for calibration preparation and regular checks. The effort can be reduced by an estimated 80%.

Analysis costs: determination of NCO, acid number and viscosity → 50 € / sample.

365 days x 3 analyses x 2 reactors x 50 € = 109.500 €/a

Savings: 109,500 €/a x 80 % = 87,600 €/a

➔ Savings Potential: Raw Material and Disposal Costs

In the past, there was an average of 3 faulty batches per reactor (approx. 4 % of batches/a). With PAT, the number of faulty batches could be reduced to 1 per reactor (1.3 %).

Due to faulty batches, production time is also lost. Other costs such as personnel, equipment or energy costs are neglected in this example.

➔ Savings Potential: Production Time

Thanks to online analytics, the process time of the individual batches could be reduced. Approx. 3% more batches can now be produced.

Additional output: 3% x 3600 t/a x 1,000 €/t = 108,000 €/a

➔ As an example, the following PAT investment is anticipated:

• Spectrometer, 2 probes and optical fibers:100,000 €
• Installation, connection to process control system: 30,00 €
• Setup/test of 3 calibration models: 30,000 €

Total costs: 160,000 €

➔ Comparison of total costs / savings

➔ Calculation Return on Invest (ROI):

160,000 € / 339,600 €/a = 0.47 a = 5.7 Monate
 

Conclusion: The initially "supposedly" high PAT investment pays off after only 5.7 months.