At-line Measurement

Introduction to At-line measurement

At-line measurement is an important process in metrology that differs from inline, online and offline measurements. In at-line measurement, samples are taken and analyzed outside the running process in another measuring room or laboratory. By comparison, inline measurement takes place directly on the production line during the ongoing process.

At-Line measurement plays an important role in process analysis and production monitoring, as it provides fast measurement results and enables flexible sampling. The integration of at-line measurement into the production process supports process control and optimization.

Advantages of At-line measurement

At-line measurement in a separate laboratory offers a number of advantages that make it a valuable procedure in metrology:

  • Speed: At-line measurement gives you measurement results in seconds or a few minutes. This allows you to react quickly to process deviations and optimize production efficiently.
  • Flexibility: At-line measurement allows sampling outside the running process. This gives the possibility to take samples at different points to analyze specific parameters. This ensures high flexibility in parameter determination and monitoring.
  • Sample preparation: Thorough sample preparation has a direct influence on the accuracy of the measurement results. Suitable sample preparation techniques can improve the quality of the measurements. An accurate and representative sample provides reliable information about product properties.
  • Continuous monitoring: At-line measurements provide you with information about product quality and process status very quickly. This enables continuous monitoring and optimization of production processes. By detecting deviations in time, corrective measures can be taken to ensure high product quality.

With its advantages such as fast measurement results, flexibility in sampling, careful sample preparation and continuous monitoring, at-line measurement supports the effective control and optimization of production processes.



ZEISS BOSELLO MAX can be easily integrated both at-line or off-line. As a result of its robust design, small footprint, easy transportation and simple installation, it can be placed almost anywhere in your production environment.

Measuring instruments for At-line measurements

Special measuring devices such as at-line spectrometers or analyzers are used for at-line measurements. These devices are designed to analyze samples outside the process and provide precise measurement results.

The measuring devices for at-line measurements are often versatile and can be adapted to different parameters. They allow the measurement of parameters such as concentrations, compositions, physical properties and many other relevant quantities. The flexibility in customization allows them to be used in a variety of industries and applications.

The quality and accuracy of measurement results are critical to the reliability of at-line measurement. Measuring instruments used should be of high quality and have appropriate calibrations and validations. Regular maintenance and calibration can ensure high accuracy of measurements. The measurement results serve as the basis for sound decisions in the production process and for ensuring product quality.

Measuring systems from ZEISS meet any requirements for at-line measuring equipment. This allows you to measure and inspect small to large components to optimize your processes and ensure high product quality easily and quickly.

What is important in sampling and sample preparation for At-line measurements?

Production sampling is a crucial step in at-line measurement. There are several important aspects to consider in order to obtain representative samples. These include selecting the correct sampling point, determining the appropriate sampling strategy, and considering potential interfering factors that could affect the sample.

Sample preparation also plays a critical role in the accuracy of at-line measurement results. Appropriate preparation ensures that the sample is homogeneous and that any interfering factors are minimized. Choosing the right sample size, mixing or homogenizing the sample and using specific sample preparation techniques are important aspects to achieve reliable and reproducible results.

More specifically, the sample should be large enough to capture a sufficient amount of the parameter to be analyzed while maintaining an appropriate ratio to the process volume. Homogeneity of the sample is critical to ensure uniform distribution of the parameter being analyzed. This can be achieved by thoroughly mixing or stirring the sample. In addition, appropriate sample preparation techniques should be used to minimize any matrix effects or interfering factors.

Applications of At-line measurement

  • A car body is measured at-line in a separate measuring room.

At-line measurement is used in a wide range of applications in production. It enables the determination of various parameters to ensure the quality of products and optimize production processes.

At-line measurement is used in various industries, including car body construction, medical technology, additive manufacturing or aerospace. But other industries such as the food or chemical industry also use at-line measurements, for example to determine nutrient contents, control impurities or analyze chemical parameters.

By applying at-line measurement in various industries, manufacturers can ensure the quality of their products, improve the efficiency of their production processes and ensure compliance with quality standards.

Integration of At-line measurements into the production process

By regularly performing measurements, relevant information about the current state of the process can be obtained. The measurement results serve as a basis for targeted measures to improve quality and increase efficiency.

The integration of the at-line measurements into the production process enables the integration of the measurement results into the automated control of production plants. Continuous measurements allow process parameters to be adjusted and optimized to ensure high product quality. This can include, for example, the automatic adjustment of dosing quantities, temperatures or pressure values.

Successful integration requires close cooperation between measurement technology experts and process engineers. Measurement technology experts are responsible for selecting and configuring the appropriate measurement devices and provide support in implementing the measurement systems. Process engineers use the measurement results obtained to optimize and monitor the production process. The regular exchange of information and findings ensures effective collaboration. With the integration of the measurement results into the automated control system, continuous monitoring and adjustment of the process can take place.

Challenges of At-line measurement

At-line measurement, despite its advantages, must also overcome some challenges that should be considered:

  • Measurement accuracy and speed: Although at-line meters provide fast measurement results sometimes in a few seconds, the accuracy of the measurements can be affected by several factors such as sample preparation, sample size and sampling procedure. It is important to consider these aspects carefully in order to obtain reliable results.
  • Selection of appropriate measurement parameters and methods: Depending on the application and the parameter to be determined, appropriate measurement equipment and analysis techniques must be selected. It is important to understand the requirements of the specific application and apply the correct measurement parameters and methods to obtain meaningful results.
  • Cost and maintenance requirements of at-line measurement equipment: Specialized measurement equipment can require a significant investment, both in terms of purchase and maintenance. Regular calibrations, validations, and maintenance are necessary to maintain high performance and accuracy of measurements.

It is important to consider these limitations and challenges of at-line measurement in order to have realistic expectations and interpret measurement results correctly. However, through careful planning, selection of appropriate measurement equipment and methods, and regular maintenance and calibration, high quality and accuracy of measurements can be achieved.

At-Line measurements in summary and an outlook on future developments

At-line measurement offers a fast, flexible and reliable method for analyzing production samples in process analytics and production monitoring. By taking samples outside the process and using specialized measuring equipment such as at-line spectrometers, accurate measurement results can be achieved. Integrating at-line measurement into the production process enables efficient process control and optimization.

Several advantages of at-line measurement have been highlighted, such as the speed of measurement results, flexibility in sampling, importance of sample preparation and continuous monitoring of product properties. The application areas of at-line measurement range from metrology to the food industry to the chemical industry, where it is used for quality control and process optimization.

Future developments in at-line measurement technology promise further potential and trends. Advances in miniaturization and sensor technology could enable the development of more compact measuring devices. In addition, greater integration of at-line measurements into production plant automation systems is expected to enable seamless control and monitoring. The integration of artificial intelligence and machine learning into data analysis will lead to advanced methods of parameter determination and monitoring.

With measurement systems from ZEISS, your at-line measurements are always state-of-the-art and ensure precise measurement results, high quality assurance and maximum efficiency. ZEISS also has the right solution for special applications, as many measuring devices can be specially adapted and programmed to your requirements. High-quality inline measurements can also be individually implemented with ZEISS measuring devices. We will be happy to advise you on this!

Share this page