Software for Process Control


Chemical Process Control
Are you using spreadsheets, yesterday’s software, or paper logs to maintain control of your chemical solutions? If so, you are spending too much time, too much effort and too much money. ChemTrak is modern software designed for metal finishing process control and to facilitate conformance to AC7108. Bath concentrations and additions are automatically computed to stay within your control limits. All tank parameters, all analysis methods, and all documentation are all in one place and instantly accessible. And with ChemTrak’s statistical analysis tools and extensive reporting, you can defend your continuous improvement to any auditor. ChemTrak has been in use at large and small shops for many years, and is continually upgraded and improved as we respond to customer requests and suggestions. ChemTrak embeds years of experience with plating and anodizing chemistry in real-world metal finishing environments. Now there is a new option for ChemTrak users. The Anoplex ChemScreen product uses the ChemTrak database to support visible test scheduling and quality control. ChemScreen drives an HDTV monitor to show rolling control charts for all process tanks and to accumulate lists of tanks that need testing or have had recent tests outside of control range. ChemScreen reduces statistical complexity to a simple red-light, green-light display that is guaranteed to get your production and chemistry departments working together.
Getting Started with ChemTrak
ChemTrak comes with a library of ready-to-use chemistries from ABrite, Atotech, Enthone, Henkel, MacDermid, MetalChem, OMG Fidelity, Rohm & Haas, Technic, Chemetall-Oakite, Clariant, Coral, Stone Chemical, McGean-Rohco, Metalast, Stellar, SurTec, Umicore, US Specialties and others. These baths can be easily copied from the library list and pasted into your shop selection grid. Library baths are preset with vendor operating specifications and analysis methods. All you do is put in your tank volume, unique tank name, and tank description. The ChemTrak library currently offers over 200 commercial chemistries and generic baths and more are added each month. Scroll down to the bottom of this page to see a partial list of available chemistries.
Ready-to-use baths are placed into your shop selection grid with a single click. You can then select the tank in your grid and click on the Tank Setup tab to put in your tank name, volume, etc.; you may also customize the specification limits and tests to meet your needs. ChemTrak’s analysis versatility is unsurpassed. There is built-in support for every metal finishing analysis you will ever need: two-step titrations for Watts and sulfamate nickel, two-step titrations for acid concentration and dissolved aluminum in anodizing baths, and two-step titrations for caustic and dissolved aluminum in alkaline etch baths. Stalagmometer surface tension analysis is also included.
For electroless nickel baths, ChemTrak offers metal turn tracking, calculations for hypophosphite concentration, and calculation of both nickel and reducer additions from a nickel titration. ChemTrak supports printed circuit board and other plastic plating processes with slope-intercept equations that can convert specific gravity readings or refractometer readings into chemical concentrations for etch and catalyst baths. It also supports two-step titrations for formaldehyde in electroless copper baths. Two additions can be calculated from any titration to handle multiple acids for mixed acid baths and proportional brightener adds. Anodize dye baths and other baths requiring analysis by spectrophotometry are easy with ChemTrak because standard-based absorption curves can be stored and bath samples quickly analyzed using the stored curves. Most metal finishing shops will use a small fraction of the ChemTrak tools, but it is good to know that they are there if you need them. Titration instructions are also online for easy reference. The ChemTrak library includes the vendor-recommended titrations, but you are free to modify them to meet your needs: tools are provided to help with addition conversions, changes from metric to Imperial and back again, or just adjusting reagent normality or sample sizes to match your procedures.
Any questions about makeup, analysis, troubleshooting or other chemistry questions? No problem. Click the Tank Data tab and the vendor’s technical data sheet will open in the ChemTrak PDF viewer giving you instant access to all the data you need. The ChemTrak PDF viewer may be used as a way to keep all of your tank documentation on-line and accessible. With Acrobat, you can create your own tank documents from Word or Excel files. You can also combine your own tank documentation with the vendor’s technical data sheet.
Using ChemTrak in Production
After a chemistry is copied from the library, it shows up in your selection grid when you click the Select Your Tank tab. The tank list may be sorted by your Tank name, by the Description or by the Tank Type. To select a tank, simply point and click in the grid and then click a test button. This will switch to the Select Test tab for entering titration results or checking SPC data. It is easy to see if any scheduled testing is due. As shown in the screenshot, tanks with tests due show up with a pink background.
All required tests show up as command buttons in the upper-left part of the screen on the ChemTrak data entry dashboard. A red button shows that a test is due, while a green button shows that the test is up-to-date. When a test button is clicked, the titration calculator, test results table, and SPC data are shown below the dashboard. When the titrant amount is entered into the ChemTrak titration calculator, concentration and additions are computed. The screen shot here shows an ENi bath tracking metal turns from nickel adds, one more tedious and error prone calculation that your chemists will not need to do any longer.
As with all Anoplex tools, the focus is on SPC. ChemTrak has unique features to help with chemical bath process control: these features include detailed analysis of the distributions at the upper and lower control limits to increase the accuracy of Cpk estimates and to give you insight into addition accuracy, analysis procedures, and adequacy of control limits and testing frequency. ChemTrak statistical analysis is designed specifically for metal finishing process control.
ChemTrak provides reports to help with audits, reviews and lab supervision. The figure to the right shows a page from the Chemical Control Trends Report. This report was the result of a customer request following a Nadcap audit. The auditor wanted to know how the company could get an overall picture of control trends when the company had such a large number of tanks and processes. ChemTrak allows any test parameter on any tank to be pulled up instantly online, but it would take quite a while to bring up almost 200 tests. With the Control Trends Report, control charts can be printed for 200 tests in less than five minutes. Try that with separate spreadsheet files! The complete spreadsheet file for all tests had 47 individual worksheets, each with 4 control charts. The charts may be quickly reviewed by clicking through the spreadsheet, and any chart can be copied and pasted into Powerpoint presentations and Word documents or saved as PDF files. The Control Trends Report is a great tool for process control as well as audits and customer presentations.
Other ChemTrak reports include daily Add Sheets for individual tanks or for all tanks in the shop. These Add Sheets include add-by-add check offs and signature places. There is also a new Chemical Usage Report that sums and prints all additions over a given period of time. If this report is run with a start date at the time of the last physical inventory, the report will show current usages and can compute current inventory levels. To help meet Nadcap requirements, there is a report that shows all tests scheduled between a start date and end date, whether the test was done on time, late, or not done. This report also shows the test results, highlights tests that show out of control limits, and shows whether additions were done. This is the ideal report for oversight and checking as required by AC7108 ¶ 4.5.1. There is a place for sign off on the report, and, like all Anoplex reports, it can be formatted to meet your company’s unique requirements. The sample report shown on the right is the SPC report for an individual tank and test. This report is similar to the control chart and distribution chart available online as test results are entered; however, since this SPC Report is an Excel spreadsheet, it can be marked up, printed, emailed, converted to PDF, posted, etc.
The ChemTrak database and executable program are normally installed on a network server allowing company-wide access. Shortcuts are placed on client PCs, and the shortcut properties insure that the program runs on the client PC instead of on the server; however, it’s easy to make the program run on the server if you have a couple of older PCs around the shop. Users are assigned usernames, passwords and privilege levels to control access. The ChemTrak license allows installation on all PCs at your site so users in all departments have access to real-time data and reports, and no one has to deal with software that is locked down to a particular PC. ChemTrak includes an option for automatic backups to disks anywhere on your network.
ChemTrak is in use at small shops with as few as 10 tanks and large shops with over 100 tanks. Although every chemist and technician has his or her own way of doing things, it does not take long for them to appreciate the value of ChemTrak. They don’t like to spend their days doing repetitive calculations, and the long-term users of ChemTrak report that titration times are cut in half - that is significant time savings in a week of ENi testing or a month of anodize tank testing. That means more time to run the AA for impurity analysis, more time for new process development, and more time for lunch.
The following is a partial list of chemistries in the ChemTrak Library. We are continually adding new chemistries for old and new customers. If you don't see what you need, send an email to support@anoplex.com, attach a TDS, and we will quickly update the library.
Acid Activator	Generic Nitric AB	Acid Copper	Enthone Udylite UBAC WP
Acid Copper	Rohm-Hass Copper Gleam	Acid Dip	Atotech Quatrasid
Acid Gold Strike	Enthone Aurobond TCL	Acid Gold Strike	Technic ACR40
Acid Hard Gold	Technic E-74	Acid Hard Gold	Technic E-94
Acid Pickle	Enthone Actane 70	Acidic Activator	MacDermid Isoprep 192
Acidic Al Etch	Enthone Actane E-10	Acidic Cleaner	MacDermid Isoprep 190
Activator	Enthone Actane 342	Alballoy	Umicore Miralloy 2800
Alkaline Cleaner	Clariant Anodal NFO	Alkaline Cleaner	MacDermid Isoprep 49L
Alkaline Cleaner	Fidelity 1143	Alkaline Cleaner	Fidelity 3152
Aluminum Deox	Chemetall Oakite Deox LNC	Aluminum Deox	Stone Chemical AN650L
Aluminum Etch	Chemetall Oakite 160	Anodize II	Anodize Type II
Anodize III	Anodize Type III	Anodize Strip	Miles SA-200 Strip
Bright Acid Tin	MacDermid TinMAC	Bright Dip	Sulfuric/Nitric
Cadmium Plate	Atotech ROHCO 20-XL	Catalyst Modifier	Rohm-Haas Accelerator 19
Caustic Etch	Enthone Enprep 14	Caustic Etch	Clariant Anodal Etch Add B
Chromate	MacDermid Iridite 14	Chromate	MacDermid Iridite 14-2
Chromate Clear	Henkel Alodine 1000L	Chromate Clear	Henkel Alodine 1500
Chromate Gold	Henkel Alodine 600	Chromate Gold	Henkel Alodine 1200S
Clear Zinc Chromate	Atotech RODIP Zn25	Olive Drab Chromate	Atotech RODIP O.D.
Copper Etch	Enthone Entek ME-1020	Copper Plate	Generic Acid Copper
Copper Strike	Cyanide Copper	Cyanide Copper	Technic Techni-Copper C
Cyanide Silver	Enthone Silvrex 3	Desmutter	Generic Nitric AB
Electrocleaner	Chemetall Oakite 90	Electrocleaner	MacDermid Isoprep 172
Electrocleaner	MadDermid Metex 662SE	Electrocleaner	MacDermid Anodex NP-2
Electrocleaner	MacDermid Metalex W	Electroless Copper	MacDermid E-Copper 22
Electroless Copper	OMG-Fidelity 1120	ENi Boron	MacDermid Niklad 752
ENi Hi-Phos	Atotech 5100	ENi Hi-Phos	Coventya H15
ENi Hi-Phos	Coventya EF583R	ENi Hi-Phos	Enthone Enplate ADP-300
ENi Hi-Phos	MacDermid Vand-Aloy 4200	ENi Hi-Phos	MetalChem MetaPlate 2500
ENi Hi-Phos	OMG-Fidelity 5023	ENi Hi-Phos	OMG-Fidelity 9961
ENi Mid-Phos	Atotech 2500	ENi Mid-Phos	Enthone Enplate EN-7601
ENi Mid-Phos	MacDermid Vand-Aloy 5000	ENi Mid-Phos	MacDermid Niklad 767
ENi Mid-Phos	MacDermid Niklad 787	ENi Mid-Phos	MetaPlate Platinum Plus
ENi Mid-Phos	OMG-Fidelity 9189	ENi Mid-Phos	OMG-Fidelity 9012
ENi Mid-Phos	Rohm-Haas Duraposit 88	ENi Mid-Phos	Coventya EF592
ENi Bright Mid-Phos	MacDermid Niklad 768	ENi Bright Mid-Phos	MacDermid Vand-Aloy 6000
ENi Lo-Phos	OMG-Fidelity 9045	ENi Lo-Phos	Enthone Enplate NI-429
ENi Lo-Phos	MacDermid Niklad 797	ENi Lo-Phos	MetalChem MetaPlate 3500
ENi Strike	Enthone Enplate AL-100	ENi Strike	OMG-Fidelity 4009
ENi Strip - CuSteel	Enthone Enstrip EN-86	Alkaline Cleaner	Americlene 8
ENi Teflon	MacDermid NiFlor	ENi Teflon	MetalChem MetaPlate 8500T
ENi Teflon	OMG-Fidelity 9013	General Strip	ROSTRIP M-10
Hard Gold	Enthone BDT510	Fluoride Glass Etch	Rohm-Haas Neutralizer 3313
Hard Gold	Technic Orosene 999	HCl Acid Dip	Generic HCl-15%
HCl Etch	Generic HCl-50%	HF Activator	Generic HF-30%
Matte Acid Tin	Rohm-Hass SatTin	Ni Acetate Seal	Clariant Anodal MS-1L
Nickel Plate	Generic Woods Strike	Nickel Plate	Generic Watts Nickel
Nickel Plate	Generic Sulfamate Nickel	Nickel Sulfamate	Technic Techni-Nickel S
Nickel Watts	Technic MX-5	Nickel Strip	Fidelex 3136
Nickel Strip	Fidelex 3701	Nickel Strip	Fidelex 3702
Nickel Sulfamate	MacDermid Barrett SN	Nitric Activator	HNO3-25%
Nitric Etch	HNO3-40%	Passivate T2	HNO3 w Na2Cr2O7
Passivate T6	HNO3 25-45%	Plastic Prep	Rohm-Haas Conditioner 211A
Plastic Prep	Rohm-Haas Conditioner 3320	Plastic Prep	Rohm-Haas Promoter 3308
Plastic Catalyst	Rohm-Haas Catalyst 44	Plastic Catalyst	Rohm-Haas Pre-dip 404
Platinum	Technic Platinum TP	Rhodium	Technic Rhodium TS
Seal - Na2Cr2O7	Sodium Dichromate Seal	Silver Plate	Rohm-Hass Bright Silver
Silver Plate	Rohm-Hass Matte Silver	Silver Plate	Technic Silversene DW
Silver Strike	Rohm-Hass Silver Strike	Silver Strike	Techni-Silver Strike
Soft Gold	Technic ACR414	Sonic Cleaner	Brulin 815 GD
Steel Descaler	Enthone Enprep 114	Steel Descaler	Enthone Enprep 214
Sulfuric Acid Dip	Generic H2SO4-10%	Sulfuric Etch	Generic H2SO4-35%
Zincate	Atotech AlumSeal 2000	Zincate	Enthone Alumon EN
Zincate	Enthone Alumon 5825	Zincate	MacDermid Metex 6811
Zincate	MetalChem MetaMate Zincate 40	Zincate	OMG-Fidelity 3116M
Added December 2010 ...
Aluminum Deox	Henkel Deoxidizer6/16	Degreaser	Super Bee 300LF
Aluminum Deox	Haviland Deox CR#1	Zincate	Haviland AlumaGuard XP
Acid Etch	Haviland Acidsalt	Chrome Catalyst	Haviland Catalyst 430
Alkaline Cleaner	Haviland ASC	Electrocleaner	Haviland Electrocleaner-73
Chromate Conversion	Haviland HavaCoat AL-Y	Nickel Stripper	Haviland HavaStrip NI
Bright Nickel	Haviland Performa HD	Bright Acid Copper	Haviland Sapphire Elite
Alkaline ENi Strike	OMG Fidelity 4009	Plastic Catalyst	MacDermid Niklad 262
Added May 2011 ...
Trivalent Chemfilm	Metalast TCP-HP	Electro-Color	Clariant Anodal TS-2
Anodize Dye	Sanodye Green AEN	Anodize Dye	Sanodye Blue G
Anodize Dye	Sanodure Black BK	Anodize Dye	Sanodal Turquoise PLW
Anodize Dye	Sanodye Yellow D	Anodize Dye	US Specialty Bordeaux R
Anodize Dye	US Specialty Brown BL	Anodize Dye	US Specialty Gold S
Anodize Dye	US Specialty Copper BF	Anodize Dye	US Specialty Orange RLW
Anodize Dye	US Specialty Grey BL	Anodize Dye	US Specialty Grey NLN
Anodize Dye	US Specialty Neon Pink	Anodize Dye	US Specialty Violet MRB
Anodize Dye	US Specialty Olive Drab	Aluminum Deox	Stone AN675L
Electro-Color	Stone AN400L	Soak Cleaner	Coral Al Clene 75R
Aluminum Deox	Coral Deox IT 22L	Aluminum Etch	Coral Cor Etch
Anodize Sealer	Coral Corak 777	Chromate Conversion	Coral CorCoat MSP1-3
Added Sept 2011 ...
ENi Hi-Phos	MacDermid Niklad ELV 811 HS	ENi Hi-Phos	Enthone Enplate EN-623
ENi Hi-Phos	Enthone ENfinity 12	ENi Mid-Phos	Enthone Enplate EN-807
ENi Boron	OMG Fidelity 9164	Teflon Coating	USS RO 59tm8
Hard Chrome	Atotech Unichrome CR-844	Black Chrome	Atotech EconoChrome BK
Soak Cleaner	MacDermid Buff Off	Citric Passivation	Generic Citric Acid 8%
Citric Passivation	CitriSurf 2250	Citric Passivation	CitriSurf 2550
Steel Electrocleaner	Enthone Enprep 808E	Matte Acid Tin	MacDermid StanTek BMAT
Anodize Dye	Sanodure Gold S	Anodize Dye	Sanodure Deep Black MLW
Added Oct 2011 ...
Cadmium Plate	ABrite CadGlo 50	Cadmium Plate	Generic Cynanide Cad
Black Chromate	ABrite PitchBlack	Black Chromate	Haviland Havablack
Yellow Chromate	ABrite Yellow 2LC	Chromate Seal	ABrite RP-90
Cadmium Stripper	ABrite Stripper 80	Alkaline Descaler	ABrite My T Kleen
Anodize Dye	Sanodure Grey R	Anodize Dye	Sanodure Blue 4A
Aluminum Etch	Henkel Etchant 33	Alkaline Cleaner	Henkel Ridoline 298
Aluminum Deox	Henkel Turco Smut-Go