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Read BlogThe future of mass balance: Innovation and emerging technologies
In a time where sustainability is a prime concern, mass balance has become a crucial tool for industries striving to develop sustainable solutions. Through diligent tracking and balancing of material inputs and outputs, mass balance facilitates companies in achieving more efficient and transparent management of sustainable materials. However, with the increasing complexity of supply chains and heightened sustainability demands, the traditional mass balance approach is being stretched to its breaking point. In this blog, we explore the future of mass balance, focusing on the innovations and technologies that promise to revolutionize this essential practice.
Already adopted in various industries with complex supply chains, the mass balance approach is a flexible and scalable method. It is a well-established chain of custody model that evolves as a promising way to advance circularity. Innovation and emerging technologies have swiftly become important topics in the sustainability space, especially in the petrochemical and plastic industries.
What is mass balance: A brief overview
Within a production system, mass balance is a method used to manage and track the flow of materials, making sure that the inputs (raw material) and the outputs (finished products) are balanced. The concept of mass balance, at its core, is a principle rooted in the law of conservation of mass as it ensures that the mass entering and the mass exiting remains the same, whether in the form of products, by-products, or waste.
In the chemical industry, manufacturers often replace a portion of fossil-based feedstocks with recycled or bio-based materials without making any changes to the existing setup, showcasing a practical application of mass balance. This strategy ensures an accountable approach to tracking how much of the final product is derived from sustainable sources, even when raw materials are mixed during the production process.
The need for innovation
While the core principles of mass balance remain unchanged, the environment in which they are applied has evolved dramatically. Supply chains have become more complicated, with materials often traveling across multiple continents and passing through various stages. Moreover, the rising consumers’ demand has also put immense pressure on companies to provide accurate and verifiable mass balance data. These above-mentioned challenges highlight the need for innovation in mass balance methodologies, especially in the fields of data integration, sustainability, and automation.
Limitations and obstacles in current mass balance approaches
In the present complex industrial landscape, the traditional mass balance approach, while effective in simpler systems, faces significant challenges. Traditional methods employ manual interventions, making it difficult for companies to respond swiftly to changes in production or supply chain conditions. One of the prominent challenges is the dependency on manual data collection and processing, which leads to inconsistencies, errors, and delays.
Another significant limitation is the difficulty in integrating mass balance with other critical business systems, such as Enterprise Resource Planning (ERP) systems. In the absence of seamless integration, companies may struggle to automate mass balance for scaling sustainable portfolios, limiting its value as a tool for strengthening efficiency and sustainability.
The role of automation in simplifying mass balance calculations
The recurring challenge of human error in the areas of maintaining consistency and accuracy in mass balance calculations can be significantly reduced by automating data collection and processing. The transformative potential of automation will play a critical role in surmounting these challenges. Automated systems are capable of handling large volumes of data in a much more efficient manner as compared to manual methods, enabling real-time reporting and monitoring.
To illustrate, artificial intelligence can read supplier declarations for transferring inbound credits and create sustainable declarations to share with customers. By integrating with ERP, costly errors and delays such as conversion factor calculation and overallocation can also be avoided, reducing time spent in managing mass balance bookkeeping.
Reduction of human error and improved consistency
Human error reduction stands as the most significant benefit of adopting improved automation solutions in mass balance. In overwhelming setups like large and complex systems where the sheer volume of manual data entry and calculations can lead to human mistakes. Automation effectively eliminates this risk by making sure that data is collected, processed, and reported in a standardized and consistent method.
For example, one of the research demonstrates that 74% of users adopting automation tools in their operations experience a 20-25% boost in data accuracy. According to 90% of IT users, automation considerably boosted their satisfaction with cross-departmental collaboration.
Benefits of linking mass balance with ERP for better decision-making
Combining mass balance data with ERP systems indicates a significant step towards leveraging this meticulous data for strategic decision-making. Incorporating mass balance data can help companies gain a more detailed understanding of their material flows and resource usage.Inbound material can automatically be added to sustainability credits and be utilized for transferring to customers with appropriate conversion factors.
The role of emerging technologies in the future of mass balance
Technologies such as artificial intelligence (AI) and advanced analytics are expected to play a key role in the future of mass balance. This is particularly crucial in industries like chemicals and plastics, where traceability is key to maintaining product safety and adhering to regulations. AI helps companies to extract data from supplier files, validate authenticity and identify patterns to make more informed decisions. AI algorithms analyze historical mass balance data to forecast future material needs, optimize their supply chains, and lessen waste.
Challenges: Data privacy, adoption barriers, and cost implications
One of the key challenges linked to the expanding use of automation and digital technologies in mass balance is ensuring privacy and security. With the overwhelming data and information stored electronically, the risk of cyber-attacks and data breaches becomes more prominent. In the future, companies will need to prioritize robust security measures to protect their mass balance data besides adhering to data privacy regulations.
To sum up
Undoubtedly, the future of mass balance looks promising, with innovations and emerging technologies ready to reshape how companies manage and monitor material flows. As the mass balance landscape continues to evolve, companies that embrace these cutting-edge technologies will be well-positioned to succeed in a world where sustainability is paramount. The key to thriving will be staying informed about the latest trends and innovations and being willing to invest wisely in the tools and technologies that will drive the future of mass balance.
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