Implementing Total Dissolved Solids Automation in the 1st Leaching Station  for Rubber Glove Manufacturing

Nattapong Chotipan; Ratta Chotipan

Authors

Nattapong Chotipan Department of Industrial Enginerring, Faculty Engineering, Princess of Naradhiwas University, Mueang, Narathiwat 96000, Thailand.
Ratta Chotipan Department of Industrial Enginerring, Faculty Engineering, Princess of Naradhiwas University, Mueang, Narathiwat 96000, Thailand.

Keywords:

total dissolved solids (TDS), SCADA systems, leaching process, real-time, monitoring, quality control and downtime, return on investment (ROI)

Abstract

This research implemented a Total Dissolved Solids (TDS) automation control system to regulate TDS levels and water flow rates in the first leaching tank. The integration of TDS sensors enables real-time monitoring of dissolved solids in the water an essential component of automation that can be incorporated into a Supervisory Control and Data Acquisition (SCADA) system.The implementation of this system has improved glove quality while optimizing water usage in the production process. Prior to its deployment, the company experienced unplanned downtime due to ineffective TDS control, leading to defects such as sludge accumulation (SD), dirt contamination (D), and discoloration (DC) in the gloves. High concentrations of dissolved solids, including minerals, salts, and heavy metals, were identified as key contributors to these defects.The objectives of this study were to install a TDS automation system, regulate water flow rates, and record TDS and flow rate data through SCADA integration. This approach aimed to minimize non-value-added processes, reduce water consumption, and prevent unplanned downtime caused by TDS-related glove defects. The findings demonstrate that the system effectively reduces water consumption by approximately 5 liters per minute (a 25% reduction) and eliminates unplanned downtime associated with water quality issues at the leaching tank by improving TDS automation control by nearly 100%. The implementation of this system has led to significant cost savings, including reductions in non-value-added costs, water expenses, and unplanned downtime, totaling approximately 308,457.78 baht per month. The return on investment (ROI) was achieved within 0.33 months, highlighting the system’s effectiveness in enhancing operational efficiency and reducing production costs.

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