{"id":3140,"date":"2026-10-19T11:28:55","date_gmt":"2026-10-19T11:28:55","guid":{"rendered":"https:\/\/www.cybernetik.com\/blog\/?p=3140"},"modified":"2026-10-19T11:30:10","modified_gmt":"2026-10-19T11:30:10","slug":"catalytic-converter-quality-control-in","status":"publish","type":"post","link":"https:\/\/www.cybernetik.com\/blog\/cleantech\/catalytic-converter-quality-control-in\/","title":{"rendered":"Quality Control in Catalytic Converter Manufacturing"},"content":{"rendered":"\n<div class=\"wp-block-group has-white-color has-text-color has-background has-link-color wp-elements-c79a008d5c263c382d601b3580c373c0 is-layout-constrained wp-container-core-group-is-layout-800b4e77 wp-block-group-is-layout-constrained\" style=\"border-top-left-radius:5px;border-top-right-radius:5px;border-bottom-left-radius:5px;border-bottom-right-radius:5px;background-color:#12263a;margin-bottom:20px;padding-top:10px;padding-right:30px;padding-bottom:30px;padding-left:30px\">\n<h2 class=\"wp-block-heading has-white-color has-text-color has-link-color wp-elements-19215f1e6a1396f83f0257af42631315\" style=\"line-height:1.4\">Key takeaways<\/h2>\n\n\n\n<div style=\"height:6px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n<style>.wp-block-kadence-iconlist.kt-svg-icon-list-items3140_575b2e-27:not(.this-stops-third-party-issues){margin-top:0px;margin-bottom:0px;}.wp-block-kadence-iconlist.kt-svg-icon-list-items3140_575b2e-27 ul.kt-svg-icon-list:not(.this-prevents-issues):not(.this-stops-third-party-issues):not(.tijsloc){margin-top:0px;margin-right:0px;margin-bottom:var(--global-kb-spacing-sm, 1.5rem);margin-left:0px;}.wp-block-kadence-iconlist.kt-svg-icon-list-items3140_575b2e-27 ul.kt-svg-icon-list{grid-row-gap:35px;}.wp-block-kadence-iconlist.kt-svg-icon-list-items3140_575b2e-27 .kb-svg-icon-wrap{font-size:10px;color:#ef8e27;}.wp-block-kadence-iconlist.kt-svg-icon-list-items3140_575b2e-27 ul.kt-svg-icon-list .kt-svg-icon-list-item-wrap .kt-svg-icon-list-single{margin-right:10px;}.kt-svg-icon-list-items3140_575b2e-27 ul.kt-svg-icon-list .kt-svg-icon-list-item-wrap, .kt-svg-icon-list-items3140_575b2e-27 ul.kt-svg-icon-list .kt-svg-icon-list-item-wrap a{line-height:1.2em;}.kt-svg-icon-list-items3140_575b2e-27 ul.kt-svg-icon-list .kt-svg-icon-list-level-0 .kt-svg-icon-list-single svg{font-size:20px;}<\/style>\n<div class=\"wp-block-kadence-iconlist kt-svg-icon-list-items kt-svg-icon-list-items3140_575b2e-27 kt-svg-icon-list-columns-1 alignnone kt-list-icon-aligntop\"><ul class=\"kt-svg-icon-list\"><style>.kt-svg-icon-list-item-3140_875641-19 .kt-svg-icon-list-text mark.kt-highlight{background-color:unset;font-style:normal;color:#f76a0c;-webkit-box-decoration-break:clone;box-decoration-break:clone;padding-top:0px;padding-right:0px;padding-bottom:0px;padding-left:0px;}<\/style>\n<li class=\"wp-block-kadence-listitem kt-svg-icon-list-item-wrap kt-svg-icon-list-item-3140_875641-19\"><span class=\"kb-svg-icon-wrap kb-svg-icon-fas_circle kt-svg-icon-list-single\"><svg viewBox=\"0 0 512 512\"  fill=\"currentColor\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\"  aria-hidden=\"true\"><path d=\"M256 8C119 8 8 119 8 256s111 248 248 248 248-111 248-248S393 8 256 8z\"\/><\/svg><\/span><span class=\"kt-svg-icon-list-text\">Quality control in catalytic converter manufacturing must cover every production stage, from incoming substrate inspection to coating, thermal processing and canning, because critical coating properties and precious metal distribution cannot be verified visually in the finished unit.<\/span><\/li>\n\n\n<style>.kt-svg-icon-list-item-3140_d30977-c6 .kt-svg-icon-list-text mark.kt-highlight{background-color:unset;font-style:normal;color:#f76a0c;-webkit-box-decoration-break:clone;box-decoration-break:clone;padding-top:0px;padding-right:0px;padding-bottom:0px;padding-left:0px;}<\/style>\n<li class=\"wp-block-kadence-listitem kt-svg-icon-list-item-wrap kt-svg-icon-list-item-3140_d30977-c6\"><span class=\"kb-svg-icon-wrap kb-svg-icon-fas_circle kt-svg-icon-list-single\"><svg viewBox=\"0 0 512 512\"  fill=\"currentColor\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\"  aria-hidden=\"true\"><path d=\"M256 8C119 8 8 119 8 256s111 248 248 248 248-111 248-248S393 8 256 8z\"\/><\/svg><\/span><span class=\"kt-svg-icon-list-text\">Incoming substrate inspection and washcoat slurry monitoring help prevent chipped or cracked bricks, inconsistent coating pickup, uneven coverage and excessive precious metal consumption.<\/span><\/li>\n\n\n<style>.kt-svg-icon-list-item-3140_3e1610-e1 .kt-svg-icon-list-text mark.kt-highlight{background-color:unset;font-style:normal;color:#f76a0c;-webkit-box-decoration-break:clone;box-decoration-break:clone;padding-top:0px;padding-right:0px;padding-bottom:0px;padding-left:0px;}<\/style>\n<li class=\"wp-block-kadence-listitem kt-svg-icon-list-item-wrap kt-svg-icon-list-item-3140_3e1610-e1\"><span class=\"kb-svg-icon-wrap kb-svg-icon-fas_circle kt-svg-icon-list-single\"><svg viewBox=\"0 0 512 512\"  fill=\"currentColor\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\"  aria-hidden=\"true\"><path d=\"M256 8C119 8 8 119 8 256s111 248 248 248 248-111 248-248S393 8 256 8z\"\/><\/svg><\/span><span class=\"kt-svg-icon-list-text\">Three-stage weight checks and backpressure testing identify undercoating, overcoating and blocked channels, while controlled drying and calcining help ensure coating adhesion and consistent performance.<\/span><\/li>\n\n\n<style>.kt-svg-icon-list-item-3140_0f5906-26 .kt-svg-icon-list-text mark.kt-highlight{background-color:unset;font-style:normal;color:#f76a0c;-webkit-box-decoration-break:clone;box-decoration-break:clone;padding-top:0px;padding-right:0px;padding-bottom:0px;padding-left:0px;}<\/style>\n<li class=\"wp-block-kadence-listitem kt-svg-icon-list-item-wrap kt-svg-icon-list-item-3140_0f5906-26\"><span class=\"kb-svg-icon-wrap kb-svg-icon-fas_circle kt-svg-icon-list-single\"><svg viewBox=\"0 0 512 512\"  fill=\"currentColor\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\"  aria-hidden=\"true\"><path d=\"M256 8C119 8 8 119 8 256s111 248 248 248 248-111 248-248S393 8 256 8z\"\/><\/svg><\/span><span class=\"kt-svg-icon-list-text\">Canning quality depends on correct mat mount density, brick positioning and dimensional control, with push-out, leak and durability tests helping confirm the assembly can withstand vibration and thermal cycling.<\/span><\/li>\n\n\n<style>.kt-svg-icon-list-item-3140_4a03af-4e .kt-svg-icon-list-text mark.kt-highlight{background-color:unset;font-style:normal;color:#f76a0c;-webkit-box-decoration-break:clone;box-decoration-break:clone;padding-top:0px;padding-right:0px;padding-bottom:0px;padding-left:0px;}<\/style>\n<li class=\"wp-block-kadence-listitem kt-svg-icon-list-item-wrap kt-svg-icon-list-item-3140_4a03af-4e\"><span class=\"kb-svg-icon-wrap kb-svg-icon-fas_circle kt-svg-icon-list-single\"><svg viewBox=\"0 0 512 512\"  fill=\"currentColor\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\"  aria-hidden=\"true\"><path d=\"M256 8C119 8 8 119 8 256s111 248 248 248 248-111 248-248S393 8 256 8z\"\/><\/svg><\/span><span class=\"kt-svg-icon-list-text\">Traceability and statistical process control connect each converter to its substrate lot, slurry batch, process settings and test results, helping manufacturers identify process drift early and investigate quality issues efficiently.<\/span><\/li>\n\n\n<style>.kt-svg-icon-list-item-3140_8cc4f5-80 .kt-svg-icon-list-text mark.kt-highlight{background-color:unset;font-style:normal;color:#f76a0c;-webkit-box-decoration-break:clone;box-decoration-break:clone;padding-top:0px;padding-right:0px;padding-bottom:0px;padding-left:0px;}<\/style>\n<li class=\"wp-block-kadence-listitem kt-svg-icon-list-item-wrap kt-svg-icon-list-item-3140_8cc4f5-80\"><span class=\"kb-svg-icon-wrap kb-svg-icon-fas_circle kt-svg-icon-list-single\"><svg viewBox=\"0 0 512 512\"  fill=\"currentColor\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\"  aria-hidden=\"true\"><path d=\"M256 8C119 8 8 119 8 256s111 248 248 248 248-111 248-248S393 8 256 8z\"\/><\/svg><\/span><span class=\"kt-svg-icon-list-text\">Cybernetik integrates washcoat preparation, automated dosing, robotic handling, three-stage weight checks, backpressure testing, barcode tracking and process-data recording into catalytic substrate coating lines for DOC, DPF and SCR components.<\/span><\/li>\n<\/ul><\/div>\n<\/div>\n\n\n\n<h2 class=\"wp-block-heading has-link-color wp-elements-0ef3e866544da72790468da05b12d878\"><strong>Quality Control in Catalytic Converter Manufacturing<\/strong><\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">A catalytic converter is an unusual part to inspect. Most of what makes it work is invisible: a thin coating spread across thousands of channels, carrying small amounts of precious metal that cannot be seen or easily measured on the finished unit. By the time the brick is sealed in its steel can, the only way to check most of it is to have recorded it on the way through.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Quality control in catalytic converter manufacturing means checking each stage where a defect can be created: the incoming substrate, the washcoat slurry, the coating step, drying and calcining, the coated part, and canning. Weight checks and backpressure tests catch most coating faults on every part, while performance and durability tests are run on samples. Traceability ties each unit to its process data, because the finished converter cannot be opened to check what went inside.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\"><strong>Why Quality Control Here Is Different<\/strong><\/h3>\n\n\n\n<p class=\"has-link-color wp-elements-4a2017afcb833a1f39e70bec10dd9494 wp-block-paragraph\">Three things make catalytic converters harder to control than most components.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><\/p>\n\n\n<style>.wp-block-kadence-iconlist.kt-svg-icon-list-items3140_692cfa-69:not(.this-stops-third-party-issues){margin-top:0px;margin-bottom:0px;}.wp-block-kadence-iconlist.kt-svg-icon-list-items3140_692cfa-69 ul.kt-svg-icon-list:not(.this-prevents-issues):not(.this-stops-third-party-issues):not(.tijsloc){margin-top:0px;margin-right:0px;margin-bottom:var(--global-kb-spacing-sm, 1.5rem);margin-left:0px;}.wp-block-kadence-iconlist.kt-svg-icon-list-items3140_692cfa-69 ul.kt-svg-icon-list{grid-row-gap:35px;}.wp-block-kadence-iconlist.kt-svg-icon-list-items3140_692cfa-69 .kb-svg-icon-wrap{font-size:10px;color:#ef8e27;}.wp-block-kadence-iconlist.kt-svg-icon-list-items3140_692cfa-69 ul.kt-svg-icon-list .kt-svg-icon-list-item-wrap .kt-svg-icon-list-single{margin-right:10px;}.kt-svg-icon-list-items3140_692cfa-69 ul.kt-svg-icon-list .kt-svg-icon-list-item-wrap, .kt-svg-icon-list-items3140_692cfa-69 ul.kt-svg-icon-list .kt-svg-icon-list-item-wrap a{line-height:1.2em;}.kt-svg-icon-list-items3140_692cfa-69 ul.kt-svg-icon-list .kt-svg-icon-list-level-0 .kt-svg-icon-list-single svg{font-size:20px;}<\/style>\n<div class=\"wp-block-kadence-iconlist kt-svg-icon-list-items kt-svg-icon-list-items3140_692cfa-69 kt-svg-icon-list-columns-1 alignnone kt-list-icon-aligntop\"><ul class=\"kt-svg-icon-list\"><style>.kt-svg-icon-list-item-3140_701a69-0d .kt-svg-icon-list-text mark.kt-highlight{background-color:unset;font-style:normal;color:#f76a0c;-webkit-box-decoration-break:clone;box-decoration-break:clone;padding-top:0px;padding-right:0px;padding-bottom:0px;padding-left:0px;}<\/style>\n<li class=\"wp-block-kadence-listitem kt-svg-icon-list-item-wrap kt-svg-icon-list-item-3140_701a69-0d\"><span class=\"kb-svg-icon-wrap kb-svg-icon-fas_circle kt-svg-icon-list-single\"><svg viewBox=\"0 0 512 512\"  fill=\"currentColor\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\"  aria-hidden=\"true\"><path d=\"M256 8C119 8 8 119 8 256s111 248 248 248 248-111 248-248S393 8 256 8z\"\/><\/svg><\/span><span class=\"kt-svg-icon-list-text\"><strong>The cost sits in the coating. <\/strong>Platinum, palladium and rhodium are among the most expensive materials in the vehicle. Applying slightly too much on every part across a year of production is a large cost, and applying too little risks failing emissions limits.<\/span><\/li>\n\n\n<style>.kt-svg-icon-list-item-3140_af4918-25 .kt-svg-icon-list-text mark.kt-highlight{background-color:unset;font-style:normal;color:#f76a0c;-webkit-box-decoration-break:clone;box-decoration-break:clone;padding-top:0px;padding-right:0px;padding-bottom:0px;padding-left:0px;}<\/style>\n<li class=\"wp-block-kadence-listitem kt-svg-icon-list-item-wrap kt-svg-icon-list-item-3140_af4918-25\"><span class=\"kb-svg-icon-wrap kb-svg-icon-fas_circle kt-svg-icon-list-single\"><svg viewBox=\"0 0 512 512\"  fill=\"currentColor\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\"  aria-hidden=\"true\"><path d=\"M256 8C119 8 8 119 8 256s111 248 248 248 248-111 248-248S393 8 256 8z\"\/><\/svg><\/span><span class=\"kt-svg-icon-list-text\"><strong>The important features cannot be seen. <\/strong>Coating thickness, precious metal distribution and adhesion inside the channels are not visible from outside, so they are controlled through process data rather than final inspection.<\/span><\/li>\n\n\n<style>.kt-svg-icon-list-item-3140_dd3859-66 .kt-svg-icon-list-text mark.kt-highlight{background-color:unset;font-style:normal;color:#f76a0c;-webkit-box-decoration-break:clone;box-decoration-break:clone;padding-top:0px;padding-right:0px;padding-bottom:0px;padding-left:0px;}<\/style>\n<li class=\"wp-block-kadence-listitem kt-svg-icon-list-item-wrap kt-svg-icon-list-item-3140_dd3859-66\"><span class=\"kb-svg-icon-wrap kb-svg-icon-fas_circle kt-svg-icon-list-single\"><svg viewBox=\"0 0 512 512\"  fill=\"currentColor\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\"  aria-hidden=\"true\"><path d=\"M256 8C119 8 8 119 8 256s111 248 248 248 248-111 248-248S393 8 256 8z\"\/><\/svg><\/span><span class=\"kt-svg-icon-list-text\"><strong>Performance shows up later. <\/strong>A converter that is marginal when new may pass every check and still fail after aging in service. That is why durability testing and conformity checks matter as much as day-one results.<\/span><\/li>\n<\/ul><\/div>\n\n\n\n<p class=\"wp-block-paragraph\">The practical result is that quality is built in at each step rather than tested at the end. Final inspection matters, but it cannot recover information that was never recorded.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\"><strong>The Control Points<\/strong><\/h2>\n\n\n\n<figure class=\"wp-block-table\"><table class=\"has-fixed-layout\"><thead><tr><th><strong>Stage<\/strong><\/th><th><strong>What is checked<\/strong><\/th><th><strong>Why it matters<\/strong><\/th><\/tr><\/thead><tbody><tr><td>Incoming substrate<\/td><td>Dimensions, cell defects, chipped edges, strength and porosity<\/td><td>A flawed brick wastes coating and precious metal later<\/td><\/tr><tr><td>Washcoat slurry<\/td><td>Solids content, viscosity, particle size, density and pH<\/td><td>Slurry properties decide how much coating each part picks up<\/td><\/tr><tr><td>Coating<\/td><td>Dose weight, coat length and coverage<\/td><td>This is where precious metal loading is set<\/td><\/tr><tr><td>Drying and calcining<\/td><td>Temperature profile and time at temperature<\/td><td>Fixes the coating and decides how well it adheres<\/td><\/tr><tr><td>Coated part checks<\/td><td>Weight gain, backpressure and blocked channels<\/td><td>Catches overcoating, undercoating and closed channels<\/td><\/tr><tr><td>Canning<\/td><td>Mat mount density, brick position, can welds and dimensions<\/td><td>Holds the brick for life without crushing it<\/td><\/tr><tr><td>Final and sample testing<\/td><td>Traceability marking, leak checks, conversion and durability tests<\/td><td>Confirms the finished part performs and can be traced<\/td><\/tr><\/tbody><\/table><\/figure>\n\n\n\n<div style=\"height:25px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<figure class=\"wp-block-image size-full has-custom-border\"><img fetchpriority=\"high\" decoding=\"async\" width=\"1585\" height=\"931\" src=\"https:\/\/www.cybernetik.com\/blog\/wp-content\/uploads\/2026\/10\/Coating-Lines-from-Cybernetik.webp\" alt=\"\" class=\"wp-image-3177\" style=\"border-top-left-radius:5px;border-top-right-radius:5px;border-bottom-left-radius:5px;border-bottom-right-radius:5px\" srcset=\"https:\/\/www.cybernetik.com\/blog\/wp-content\/uploads\/2026\/10\/Coating-Lines-from-Cybernetik.webp 1585w, https:\/\/www.cybernetik.com\/blog\/wp-content\/uploads\/2026\/10\/Coating-Lines-from-Cybernetik-300x176.webp 300w, https:\/\/www.cybernetik.com\/blog\/wp-content\/uploads\/2026\/10\/Coating-Lines-from-Cybernetik-1024x601.webp 1024w, https:\/\/www.cybernetik.com\/blog\/wp-content\/uploads\/2026\/10\/Coating-Lines-from-Cybernetik-768x451.webp 768w, https:\/\/www.cybernetik.com\/blog\/wp-content\/uploads\/2026\/10\/Coating-Lines-from-Cybernetik-1536x902.webp 1536w\" sizes=\"(max-width: 1585px) 100vw, 1585px\" \/><\/figure>\n\n\n\n<p class=\"wp-block-paragraph\"><\/p>\n\n\n\n<h2 class=\"wp-block-heading\"><strong>Incoming Substrate Inspection<\/strong><\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">Coating a flawed substrate wastes the most expensive material in the process, so the brick is checked before anything is applied to it.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Dimensional checks cover diameter, length and the squareness of the end faces, since these affect how the brick sits in the coating fixture and later in the can. The faces are inspected for chipped edges, cracked cells and debris in the channels. For ceramic substrates, suppliers usually provide strength and porosity data for each lot, and the porosity matters because it affects how much slurry the walls absorb during coating.<\/p>\n\n\n\n<p class=\"has-link-color wp-elements-00eac1fc8db99d3d268fe946ca347705 wp-block-paragraph\">Thin-walled substrates make this inspection more important rather than less, because they chip more easily in transit and handling. How substrates are made, and the difference between ceramic and metallic types, is covered in the article on <a href=\"https:\/\/www.cybernetik.com\/blog\/cleantech\/catalytic-converter-substrate\/\">catalytic converter substrates<\/a>.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\"><strong>Washcoat Slurry Control<\/strong><\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">The slurry is where many coating problems begin, and it changes over time even when nothing is added to it.<\/p>\n\n\n\n<figure class=\"wp-block-table\"><table class=\"has-fixed-layout\"><thead><tr><th><strong>Slurry property<\/strong><\/th><th><strong>What drifts if it is not controlled<\/strong><\/th><\/tr><\/thead><tbody><tr><td>Solids content<\/td><td>How much coating a part takes up for the same dose, and therefore precious metal loading<\/td><\/tr><tr><td>Viscosity<\/td><td>How far the slurry travels up the channels and how evenly it coats them<\/td><\/tr><tr><td>Particle size<\/td><td>Coating adhesion, surface area and how readily channels block<\/td><\/tr><tr><td>Density<\/td><td>A quick daily check that solids content has not moved<\/td><\/tr><tr><td>pH<\/td><td>Slurry stability, and whether particles start clumping in the tank<\/td><\/tr><tr><td>Age and temperature<\/td><td>Properties change as a batch sits, so time since mixing is tracked<\/td><\/tr><\/tbody><\/table><\/figure>\n\n\n\n<p class=\"wp-block-paragraph\">Solids content and viscosity are the two that most directly affect the part. If solids drift upward, every part picks up more coating for the same dose, and precious metal loading rises across the whole run without anyone changing a setting. If viscosity drifts, the coating travels a different distance up the channels, changing the coat profile. Regular checks against set limits, with adjustments recorded, keep the coating step predictable.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\"><strong>Controlling the Coating Step<\/strong><\/h2>\n\n\n\n<h3 class=\"wp-block-heading\"><strong>Dose and pick-up<\/strong><\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">Most modern lines dose a measured volume of slurry into each part, either by pushing it up from below or drawing it through with vacuum. The dose sets how much coating the part receives, and the amount actually retained, called the pick-up, depends on the dose, the slurry properties and the substrate porosity. Controlling all three is what keeps pick-up consistent.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\"><strong>Coat length<\/strong><\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">Many converters are coated from both ends, sometimes with different formulations on each half. The coating has to reach the intended depth from each end, so the two zones meet or overlap as designed. Coat length is checked on samples, often by cutting a part open, because it cannot be measured on a finished brick.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\"><strong>Clearing the channels<\/strong><\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">After dosing, excess slurry is removed, usually with an air blast or vacuum. If clearing is weak or uneven, channels can be left partly closed, which raises backpressure and wastes surface area. This step is one of the main defenses against blocked channels.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\"><strong>Drying and Calcining<\/strong><\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">Drying removes water from the coating, and calcining at high temperature fixes it to the substrate and prepares the active sites. Both steps can create defects if they are not controlled.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Drying too fast can move coating toward the channel ends or crack it, giving an uneven layer. Calcining at the wrong temperature or for the wrong time affects adhesion and the surface area of the coating. Temperature profiles are monitored and recorded for each batch, since a furnace that has drifted may produce parts that look normal and perform poorly.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\"><strong>Weight Checks: The Workhorse of Coating Quality<\/strong><\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">Weighing is simple, fast and done on every part, and it answers the most important question on the line: how much coating did this part actually receive?<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">The usual method is to weigh the bare substrate, weigh again after coating and drying, and weigh once more after calcining. The difference between the bare and final weights is the coating mass, and comparing it with the target shows whether the part is within limits. Where parts are coated from both ends, a weight after each coat shows whether one side took more than the other.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Weight data also shows trends before they become rejects. A slow upward drift across a shift usually points to slurry solids rising, and catching it early saves a run of overcoated parts.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\"><strong>Backpressure and Blockage Checks<\/strong><\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">Weight shows how much coating went on. It does not show where it went. A part can be the right weight overall and still have a cluster of blocked channels, which raises restriction and reduces working surface.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">A backpressure check passes a set flow of air through the coated part and measures the pressure drop. Parts above the limit are rejected. Reading weight and backpressure together separates the usual problems: high weight with high backpressure points to overcoating, normal weight with high backpressure points to blocked channels, and low weight with normal backpressure points to undercoating<\/p>\n\n\n\n<div style=\"height:25px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<div class=\"wp-block-group is-nowrap is-layout-flex wp-container-core-group-is-layout-7387b849 wp-block-group-is-layout-flex\">\n<p class=\"has-text-align-left wp-block-paragraph\" style=\"font-size:29px\"><img decoding=\"async\" class=\"wp-image-503\" style=\"width: 65px\" src=\"https:\/\/www.cybernetik.com\/blog\/wp-content\/uploads\/2026\/05\/Frame-1.svg\" alt=\"\"><strong>&#8220;Complete traceability connects each catalytic converter to its process and test data. This visibility helps manufacturers investigate quality issues, identify process variations, and strengthen production control.&#8221;<\/strong><\/p>\n<\/div>\n\n\n\n<div class=\"wp-block-group has-luminous-vivid-amber-color has-text-color has-link-color has-medium-font-size wp-elements-6bc6b22d4811b996eac9b48d6a42bdf4 is-horizontal is-content-justification-left is-nowrap is-layout-flex wp-container-core-group-is-layout-e8523bbf wp-block-group-is-layout-flex\" style=\"text-decoration:none\">\n<div class=\"wp-block-group is-content-justification-left is-layout-constrained wp-container-core-group-is-layout-d9c85f36 wp-block-group-is-layout-constrained\">\n<figure class=\"wp-block-image alignwide size-thumbnail\" style=\"margin-top:0;margin-right:0;margin-bottom:0;margin-left:0\"><img decoding=\"async\" width=\"150\" height=\"150\" src=\"https:\/\/www.cybernetik.com\/blog\/wp-content\/uploads\/2026\/05\/minus-2-150x150.png\" alt=\"\" class=\"wp-image-898\" srcset=\"https:\/\/www.cybernetik.com\/blog\/wp-content\/uploads\/2026\/05\/minus-2-150x150.png 150w, https:\/\/www.cybernetik.com\/blog\/wp-content\/uploads\/2026\/05\/minus-2-300x300.webp 300w, https:\/\/www.cybernetik.com\/blog\/wp-content\/uploads\/2026\/05\/minus-2.webp 512w\" sizes=\"(max-width: 150px) 100vw, 150px\" \/><\/figure>\n<\/div>\n\n\n\n<p class=\"wp-block-paragraph\"><a href=\"https:\/\/cleantech.cybernetik.com\/\" data-type=\"link\" data-id=\"https:\/\/cleantech.cybernetik.com\/\">Cybernetik Cleantech Automation Team<\/a><\/p>\n<\/div>\n\n\n\n<div class=\"wp-block-group is-layout-constrained wp-block-group-is-layout-constrained\">\n<h2 class=\"wp-block-heading\" style=\"font-size:34px\">See it in action<\/h2>\n\n\n\n<figure class=\"wp-block-embed is-type-video is-provider-youtube wp-block-embed-youtube wp-embed-aspect-16-9 wp-has-aspect-ratio\"><div class=\"wp-block-embed__wrapper\">\n<iframe title=\"Motorcycle Catalytic Converter | Cybernetik Substrate Coating Automation\" width=\"800\" height=\"450\" src=\"https:\/\/www.youtube.com\/embed\/6qNmDxS2bR0?feature=oembed\" frameborder=\"0\" allow=\"accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture; web-share\" referrerpolicy=\"strict-origin-when-cross-origin\" allowfullscreen><\/iframe>\n<\/div><\/figure>\n<\/div>\n\n\n\n<div style=\"height:25px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<h2 class=\"wp-block-heading\"><strong>Canning Quality<\/strong><\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">The coated brick is wrapped in a mat and pressed into a steel can. The mat has to hold the brick firmly through years of vibration and heat cycling without crushing it, and that depends on how tightly it is compressed.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Mount density, the compression of the mat between brick and can, is the key measure. Too low and the brick can move or the mat can erode; too high and a thin-walled substrate can crack. Lines control this by measuring each brick and selecting or forming the can to suit, so the gap is right for that individual part. Can welds, outer dimensions and inlet and outlet positions are checked, and some assemblies are leak tested. Push-out testing on samples confirms the brick is held with enough force.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\"><strong>Common Defects and Where They Are Caught<\/strong><\/h2>\n\n\n\n<figure class=\"wp-block-table\"><table class=\"has-fixed-layout\"><thead><tr><th><strong>Defect<\/strong><\/th><th><strong>Usual cause<\/strong><\/th><th><strong>Where it is caught<\/strong><\/th><\/tr><\/thead><tbody><tr><td>Undercoated part<\/td><td>Low dose, low slurry solids or poor coat depth<\/td><td>Weight check after coating and after calcining<\/td><\/tr><tr><td>Overcoated part<\/td><td>High dose or slurry too thick<\/td><td>Weight gain and backpressure test<\/td><\/tr><tr><td>Blocked channels<\/td><td>Coating bridging the openings or debris<\/td><td>Backpressure and blockage check<\/td><\/tr><tr><td>Short or uneven coat length<\/td><td>Wrong dose or slurry viscosity drift<\/td><td>Coat length check on samples, often by sectioning<\/td><\/tr><tr><td>Poor adhesion<\/td><td>Drying too fast or wrong calcining profile<\/td><td>Adhesion testing on samples<\/td><\/tr><tr><td>Chipped or cracked substrate<\/td><td>Rough handling or thermal shock<\/td><td>Visual inspection at load and before canning<\/td><\/tr><tr><td>Loose brick in the can<\/td><td>Low mat mount density or wrong can size<\/td><td>Gap and mount density checks, push-out testing on samples<\/td><\/tr><\/tbody><\/table><\/figure>\n\n\n\n<h2 class=\"wp-block-heading\"><strong>Performance and Durability Testing<\/strong><\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">Some properties can only be confirmed by testing the converter as a catalyst, which is destructive or slow, so it is done on samples rather than every part.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><\/p>\n\n\n<style>.wp-block-kadence-iconlist.kt-svg-icon-list-items3140_0900ee-83:not(.this-stops-third-party-issues){margin-top:0px;margin-bottom:0px;}.wp-block-kadence-iconlist.kt-svg-icon-list-items3140_0900ee-83 ul.kt-svg-icon-list:not(.this-prevents-issues):not(.this-stops-third-party-issues):not(.tijsloc){margin-top:0px;margin-right:0px;margin-bottom:var(--global-kb-spacing-sm, 1.5rem);margin-left:0px;}.wp-block-kadence-iconlist.kt-svg-icon-list-items3140_0900ee-83 ul.kt-svg-icon-list{grid-row-gap:35px;}.wp-block-kadence-iconlist.kt-svg-icon-list-items3140_0900ee-83 .kb-svg-icon-wrap{font-size:10px;color:#ef8e27;}.wp-block-kadence-iconlist.kt-svg-icon-list-items3140_0900ee-83 ul.kt-svg-icon-list .kt-svg-icon-list-item-wrap .kt-svg-icon-list-single{margin-right:10px;}.kt-svg-icon-list-items3140_0900ee-83 ul.kt-svg-icon-list .kt-svg-icon-list-item-wrap, .kt-svg-icon-list-items3140_0900ee-83 ul.kt-svg-icon-list .kt-svg-icon-list-item-wrap a{line-height:1.2em;}.kt-svg-icon-list-items3140_0900ee-83 ul.kt-svg-icon-list .kt-svg-icon-list-level-0 .kt-svg-icon-list-single svg{font-size:20px;}<\/style>\n<div class=\"wp-block-kadence-iconlist kt-svg-icon-list-items kt-svg-icon-list-items3140_0900ee-83 kt-svg-icon-list-columns-1 alignnone kt-list-icon-aligntop\"><ul class=\"kt-svg-icon-list\"><style>.kt-svg-icon-list-item-3140_a2008c-20 .kt-svg-icon-list-text mark.kt-highlight{background-color:unset;font-style:normal;color:#f76a0c;-webkit-box-decoration-break:clone;box-decoration-break:clone;padding-top:0px;padding-right:0px;padding-bottom:0px;padding-left:0px;}<\/style>\n<li class=\"wp-block-kadence-listitem kt-svg-icon-list-item-wrap kt-svg-icon-list-item-3140_a2008c-20\"><span class=\"kb-svg-icon-wrap kb-svg-icon-fas_circle kt-svg-icon-list-single\"><svg viewBox=\"0 0 512 512\"  fill=\"currentColor\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\"  aria-hidden=\"true\"><path d=\"M256 8C119 8 8 119 8 256s111 248 248 248 248-111 248-248S393 8 256 8z\"\/><\/svg><\/span><span class=\"kt-svg-icon-list-text\"><strong>Light-off testing. <\/strong>A sample is heated in a gas stream to find the temperature at which conversion starts, which matters most for cold-start emissions.<\/span><\/li>\n\n\n<style>.kt-svg-icon-list-item-3140_33858c-f0 .kt-svg-icon-list-text mark.kt-highlight{background-color:unset;font-style:normal;color:#f76a0c;-webkit-box-decoration-break:clone;box-decoration-break:clone;padding-top:0px;padding-right:0px;padding-bottom:0px;padding-left:0px;}<\/style>\n<li class=\"wp-block-kadence-listitem kt-svg-icon-list-item-wrap kt-svg-icon-list-item-3140_33858c-f0\"><span class=\"kb-svg-icon-wrap kb-svg-icon-fas_circle kt-svg-icon-list-single\"><svg viewBox=\"0 0 512 512\"  fill=\"currentColor\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\"  aria-hidden=\"true\"><path d=\"M256 8C119 8 8 119 8 256s111 248 248 248 248-111 248-248S393 8 256 8z\"\/><\/svg><\/span><span class=\"kt-svg-icon-list-text\"><strong>Conversion efficiency. <\/strong>Measured on a synthetic gas bench or an engine to confirm the converter removes pollutants as designed.<\/span><\/li>\n\n\n<style>.kt-svg-icon-list-item-3140_b82a6c-9e .kt-svg-icon-list-text mark.kt-highlight{background-color:unset;font-style:normal;color:#f76a0c;-webkit-box-decoration-break:clone;box-decoration-break:clone;padding-top:0px;padding-right:0px;padding-bottom:0px;padding-left:0px;}<\/style>\n<li class=\"wp-block-kadence-listitem kt-svg-icon-list-item-wrap kt-svg-icon-list-item-3140_b82a6c-9e\"><span class=\"kb-svg-icon-wrap kb-svg-icon-fas_circle kt-svg-icon-list-single\"><svg viewBox=\"0 0 512 512\"  fill=\"currentColor\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\"  aria-hidden=\"true\"><path d=\"M256 8C119 8 8 119 8 256s111 248 248 248 248-111 248-248S393 8 256 8z\"\/><\/svg><\/span><span class=\"kt-svg-icon-list-text\"><strong>Aged performance. <\/strong>Samples are aged at high temperature to simulate service life, then tested again, since a converter must still meet limits after aging.<\/span><\/li>\n\n\n<style>.kt-svg-icon-list-item-3140_1df0bf-24 .kt-svg-icon-list-text mark.kt-highlight{background-color:unset;font-style:normal;color:#f76a0c;-webkit-box-decoration-break:clone;box-decoration-break:clone;padding-top:0px;padding-right:0px;padding-bottom:0px;padding-left:0px;}<\/style>\n<li class=\"wp-block-kadence-listitem kt-svg-icon-list-item-wrap kt-svg-icon-list-item-3140_1df0bf-24\"><span class=\"kb-svg-icon-wrap kb-svg-icon-fas_circle kt-svg-icon-list-single\"><svg viewBox=\"0 0 512 512\"  fill=\"currentColor\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\"  aria-hidden=\"true\"><path d=\"M256 8C119 8 8 119 8 256s111 248 248 248 248-111 248-248S393 8 256 8z\"\/><\/svg><\/span><span class=\"kt-svg-icon-list-text\"><strong>Precious metal verification. <\/strong>Sample parts or coating material are analyzed to confirm the actual metal content matches the specification.<\/span><\/li>\n\n\n<style>.kt-svg-icon-list-item-3140_cfe2ae-fe .kt-svg-icon-list-text mark.kt-highlight{background-color:unset;font-style:normal;color:#f76a0c;-webkit-box-decoration-break:clone;box-decoration-break:clone;padding-top:0px;padding-right:0px;padding-bottom:0px;padding-left:0px;}<\/style>\n<li class=\"wp-block-kadence-listitem kt-svg-icon-list-item-wrap kt-svg-icon-list-item-3140_cfe2ae-fe\"><span class=\"kb-svg-icon-wrap kb-svg-icon-fas_circle kt-svg-icon-list-single\"><svg viewBox=\"0 0 512 512\"  fill=\"currentColor\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\"  aria-hidden=\"true\"><path d=\"M256 8C119 8 8 119 8 256s111 248 248 248 248-111 248-248S393 8 256 8z\"\/><\/svg><\/span><span class=\"kt-svg-icon-list-text\"><strong>Mechanical durability. <\/strong>Hot vibration and thermal shock tests confirm the brick and mount survive real operating conditions.<\/span><\/li>\n<\/ul><\/div>\n\n\n\n<p class=\"wp-block-paragraph\">In India, emissions components are also subject to conformity of production checks under the vehicle type approval system, where production parts are tested against the approved design. A plant that controls each stage and keeps the records is far better placed for these checks than one relying on final inspection alone.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\"><strong>Traceability<\/strong><\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">Because so much of a converter\u2019s quality is invisible in the finished part, the records are part of the product. Each unit is marked, and its identity is linked to the substrate lot, slurry batch, coating parameters, weights, backpressure result, furnace profile and canning data.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">That record earns its value later. If a vehicle maker raises a field issue or a conformity check finds a problem, traceability narrows the investigation to the parts and process conditions involved instead of an entire production period. It also lets a plant find patterns, such as a particular slurry batch or furnace that tends to produce parts near the limit.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\"><strong>Statistical Process Control<\/strong><\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">Checking each part against limits catches defects. Watching how the measurements move catches them before they happen.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Plotting coating weight, backpressure and slurry properties over time shows drift long before parts start failing. A gradual rise in coating weight, a slowly widening spread in backpressure or a viscosity reading creeping toward its limit are all signals to adjust the process while parts are still good. Plants that act on trends rather than rejects use less precious metal and scrap fewer parts.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\"><strong>Why Automation Helps<\/strong><\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">Many of the quality risks in converter manufacturing come from variation that people find hard to control by hand. Dosing by hand is less consistent than a metered doser. Manual handling chips substrates and puts debris into channels. Readings written on paper are slower to trend and easier to lose.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Automated lines address all three: metered dosing for consistent pick-up, robotic handling to reduce chipping, and weights and test results captured directly against each part\u2019s identity. The aim is not to remove people from quality control but to give them consistent parts and complete data.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\"><strong>Coating Lines from Cybernetik<\/strong><\/h2>\n\n\n\n<p class=\"has-link-color wp-elements-52cfef53eaed34285361431f66752d74 wp-block-paragraph\">Cybernetik builds <a href=\"https:\/\/cleantech.cybernetik.com\/solutions\/catalytic-converter-substrate-coating.html\">substrate coating systems<\/a> for heavy truck, passenger car and motorcycle catalytic converters, with quality checks built into the line rather than added at the end. Lines have been built for DOC, DPF and SCR catalysts, including metallic substrates coated with a rotary coater, fixed volume doser and air stripper.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Several of the controls in this article are part of that line:<\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><\/p>\n\n\n<style>.wp-block-kadence-iconlist.kt-svg-icon-list-items3140_90775c-59:not(.this-stops-third-party-issues){margin-top:0px;margin-bottom:0px;}.wp-block-kadence-iconlist.kt-svg-icon-list-items3140_90775c-59 ul.kt-svg-icon-list:not(.this-prevents-issues):not(.this-stops-third-party-issues):not(.tijsloc){margin-top:0px;margin-right:0px;margin-bottom:var(--global-kb-spacing-sm, 1.5rem);margin-left:0px;}.wp-block-kadence-iconlist.kt-svg-icon-list-items3140_90775c-59 ul.kt-svg-icon-list{grid-row-gap:35px;}.wp-block-kadence-iconlist.kt-svg-icon-list-items3140_90775c-59 .kb-svg-icon-wrap{font-size:10px;color:#ef8e27;}.wp-block-kadence-iconlist.kt-svg-icon-list-items3140_90775c-59 ul.kt-svg-icon-list .kt-svg-icon-list-item-wrap .kt-svg-icon-list-single{margin-right:10px;}.kt-svg-icon-list-items3140_90775c-59 ul.kt-svg-icon-list .kt-svg-icon-list-item-wrap, .kt-svg-icon-list-items3140_90775c-59 ul.kt-svg-icon-list .kt-svg-icon-list-item-wrap a{line-height:1.2em;}.kt-svg-icon-list-items3140_90775c-59 ul.kt-svg-icon-list .kt-svg-icon-list-level-0 .kt-svg-icon-list-single svg{font-size:20px;}<\/style>\n<div class=\"wp-block-kadence-iconlist kt-svg-icon-list-items kt-svg-icon-list-items3140_90775c-59 kt-svg-icon-list-columns-1 alignnone kt-list-icon-aligntop\"><ul class=\"kt-svg-icon-list\"><style>.kt-svg-icon-list-item-3140_245cae-6c .kt-svg-icon-list-text mark.kt-highlight{background-color:unset;font-style:normal;color:#f76a0c;-webkit-box-decoration-break:clone;box-decoration-break:clone;padding-top:0px;padding-right:0px;padding-bottom:0px;padding-left:0px;}<\/style>\n<li class=\"wp-block-kadence-listitem kt-svg-icon-list-item-wrap kt-svg-icon-list-item-3140_245cae-6c\"><span class=\"kb-svg-icon-wrap kb-svg-icon-fas_circle kt-svg-icon-list-single\"><svg viewBox=\"0 0 512 512\"  fill=\"currentColor\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\"  aria-hidden=\"true\"><path d=\"M256 8C119 8 8 119 8 256s111 248 248 248 248-111 248-248S393 8 256 8z\"\/><\/svg><\/span><span class=\"kt-svg-icon-list-text\"><strong>Three-stage weight checks, <\/strong>showing how much coating each part received at each step.<\/span><\/li>\n\n\n<style>.kt-svg-icon-list-item-3140_9f3e2f-d8 .kt-svg-icon-list-text mark.kt-highlight{background-color:unset;font-style:normal;color:#f76a0c;-webkit-box-decoration-break:clone;box-decoration-break:clone;padding-top:0px;padding-right:0px;padding-bottom:0px;padding-left:0px;}<\/style>\n<li class=\"wp-block-kadence-listitem kt-svg-icon-list-item-wrap kt-svg-icon-list-item-3140_9f3e2f-d8\"><span class=\"kb-svg-icon-wrap kb-svg-icon-fas_circle kt-svg-icon-list-single\"><svg viewBox=\"0 0 512 512\"  fill=\"currentColor\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\"  aria-hidden=\"true\"><path d=\"M256 8C119 8 8 119 8 256s111 248 248 248 248-111 248-248S393 8 256 8z\"\/><\/svg><\/span><span class=\"kt-svg-icon-list-text\"><strong>A back pressure checking station, <\/strong>catching blocked or overcoated parts after calcining.<\/span><\/li>\n\n\n<style>.kt-svg-icon-list-item-3140_0765f3-47 .kt-svg-icon-list-text mark.kt-highlight{background-color:unset;font-style:normal;color:#f76a0c;-webkit-box-decoration-break:clone;box-decoration-break:clone;padding-top:0px;padding-right:0px;padding-bottom:0px;padding-left:0px;}<\/style>\n<li class=\"wp-block-kadence-listitem kt-svg-icon-list-item-wrap kt-svg-icon-list-item-3140_0765f3-47\"><span class=\"kb-svg-icon-wrap kb-svg-icon-fas_circle kt-svg-icon-list-single\"><svg viewBox=\"0 0 512 512\"  fill=\"currentColor\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\"  aria-hidden=\"true\"><path d=\"M256 8C119 8 8 119 8 256s111 248 248 248 248-111 248-248S393 8 256 8z\"\/><\/svg><\/span><span class=\"kt-svg-icon-list-text\"><strong>Barcode marking and scanning, <\/strong>which confirms whether a part is due its first or second coat before coating begins.<\/span><\/li>\n\n\n<style>.kt-svg-icon-list-item-3140_fc7d1f-0f .kt-svg-icon-list-text mark.kt-highlight{background-color:unset;font-style:normal;color:#f76a0c;-webkit-box-decoration-break:clone;box-decoration-break:clone;padding-top:0px;padding-right:0px;padding-bottom:0px;padding-left:0px;}<\/style>\n<li class=\"wp-block-kadence-listitem kt-svg-icon-list-item-wrap kt-svg-icon-list-item-3140_fc7d1f-0f\"><span class=\"kb-svg-icon-wrap kb-svg-icon-fas_circle kt-svg-icon-list-single\"><svg viewBox=\"0 0 512 512\"  fill=\"currentColor\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\"  aria-hidden=\"true\"><path d=\"M256 8C119 8 8 119 8 256s111 248 248 248 248-111 248-248S393 8 256 8z\"\/><\/svg><\/span><span class=\"kt-svg-icon-list-text\"><strong>Robotic accept and reject, <\/strong>moving parts between stages and removing failures automatically after critical steps.<\/span><\/li>\n\n\n<style>.kt-svg-icon-list-item-3140_6c9d47-45 .kt-svg-icon-list-text mark.kt-highlight{background-color:unset;font-style:normal;color:#f76a0c;-webkit-box-decoration-break:clone;box-decoration-break:clone;padding-top:0px;padding-right:0px;padding-bottom:0px;padding-left:0px;}<\/style>\n<li class=\"wp-block-kadence-listitem kt-svg-icon-list-item-wrap kt-svg-icon-list-item-3140_6c9d47-45\"><span class=\"kb-svg-icon-wrap kb-svg-icon-fas_circle kt-svg-icon-list-single\"><svg viewBox=\"0 0 512 512\"  fill=\"currentColor\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\"  aria-hidden=\"true\"><path d=\"M256 8C119 8 8 119 8 256s111 248 248 248 248-111 248-248S393 8 256 8z\"\/><\/svg><\/span><span class=\"kt-svg-icon-list-text\"><strong>Washcoat preparation automation, <\/strong>with premix, brewing and activation tanks for consistent slurry.<\/span><\/li>\n\n\n<style>.kt-svg-icon-list-item-3140_757ab3-7a .kt-svg-icon-list-text mark.kt-highlight{background-color:unset;font-style:normal;color:#f76a0c;-webkit-box-decoration-break:clone;box-decoration-break:clone;padding-top:0px;padding-right:0px;padding-bottom:0px;padding-left:0px;}<\/style>\n<li class=\"wp-block-kadence-listitem kt-svg-icon-list-item-wrap kt-svg-icon-list-item-3140_757ab3-7a\"><span class=\"kb-svg-icon-wrap kb-svg-icon-fas_circle kt-svg-icon-list-single\"><svg viewBox=\"0 0 512 512\"  fill=\"currentColor\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\"  aria-hidden=\"true\"><path d=\"M256 8C119 8 8 119 8 256s111 248 248 248 248-111 248-248S393 8 256 8z\"\/><\/svg><\/span><span class=\"kt-svg-icon-list-text\"><strong>Data tracking, <\/strong>recording process data against each part for monitoring and later investigation.<\/span><\/li>\n<\/ul><\/div>\n\n\n\n<p class=\"wp-block-paragraph\">Drying runs at 150 to 200 degrees Celsius and calcining at 600 to 650 degrees Celsius, with a flip-over unit allowing parts to be coated from both ends. Projects are delivered by one team through design, factory acceptance testing, installation and commissioning.<\/p>\n\n\n\n<div style=\"height:25px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<div class=\"wp-block-group has-white-color has-text-color has-background has-link-color wp-elements-ac152bf2f15fc4c7252137b9076b5ae4 is-content-justification-space-between is-layout-flex wp-container-core-group-is-layout-bcf883e7 wp-block-group-is-layout-flex\" style=\"border-top-left-radius:5px;border-top-right-radius:5px;border-bottom-left-radius:5px;border-bottom-right-radius:5px;background-color:#12263a;margin-bottom:20px;padding-top:20px;padding-right:30px;padding-bottom:30px;padding-left:30px\">\n<h3 class=\"wp-block-heading has-white-color has-text-color has-link-color wp-elements-f22099acdeda5e510eedec4b07580a36 wp-container-content-29dca9c1\" style=\"font-size:34px;font-style:normal;font-weight:400;line-height:1.4\">Want to know more about our solution?<\/h3>\n\n\n\n<div class=\"wp-block-buttons wp-container-content-69bc4bdf is-content-justification-right is-layout-flex wp-container-core-buttons-is-layout-88867f99 wp-block-buttons-is-layout-flex\" style=\"border-style:none;border-width:0px;border-top-left-radius:0px;border-top-right-radius:0px;border-bottom-left-radius:0px;border-bottom-right-radius:0px;margin-top:0;margin-bottom:0;padding-top:6;padding-right:6;padding-bottom:6;padding-left:6\">\n<div class=\"wp-block-button has-custom-width wp-block-button__width-100 is-style-fill\"><a class=\"wp-block-button__link has-white-color has-text-color has-background has-link-color has-text-align-right wp-element-button\" href=\"https:\/\/meetings-eu1.hubspot.com\/anand-gaikar\" style=\"background-color:#ee8d26;padding-top:10px;padding-right:20px;padding-bottom:10px;padding-left:20px\">Book a call<\/a><\/div>\n<\/div>\n<\/div>\n\n\n\n<div style=\"height:25px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<h2 class=\"wp-block-heading has-large-font-size\"><strong>Frequently asked questions<\/strong><\/h2>\n\n\n<style>.kt-accordion-id3140_005f90-af .kt-accordion-inner-wrap{column-gap:var(--global-kb-gap-md, 2rem);row-gap:14px;}.kt-accordion-id3140_005f90-af .kt-accordion-panel-inner{border-top:0px solid transparent;border-right:0px solid transparent;border-bottom:0px solid transparent;border-left:0px solid transparent;background:#ffffff;padding-top:var(--global-kb-spacing-md, 2rem);padding-right:var(--global-kb-spacing-sm, 1.5rem);padding-bottom:0px;padding-left:var(--global-kb-spacing-sm, 1.5rem);}.kt-accordion-id3140_005f90-af > .kt-accordion-inner-wrap > .wp-block-kadence-pane > .kt-accordion-header-wrap > .kt-blocks-accordion-header{border-top:0px solid #949494;border-right:0px solid #949494;border-bottom:1px solid #abb8c3;border-left:0px solid #949494;border-top-left-radius:0px;border-top-right-radius:0px;border-bottom-right-radius:0px;border-bottom-left-radius:0px;background:#ffffff;font-size:var(--global-kb-font-size-md, 1.25rem);line-height:1.5em;letter-spacing:-0.1px;font-weight:400;text-transform:capitalize;color:#12263a;padding-top:14px;padding-right:10px;padding-bottom:16px;padding-left:16px;}.kt-accordion-id3140_005f90-af:not( .kt-accodion-icon-style-basiccircle ):not( .kt-accodion-icon-style-xclosecircle ):not( .kt-accodion-icon-style-arrowcircle )  > .kt-accordion-inner-wrap > .wp-block-kadence-pane > .kt-accordion-header-wrap .kt-blocks-accordion-icon-trigger:after, .kt-accordion-id3140_005f90-af:not( .kt-accodion-icon-style-basiccircle ):not( .kt-accodion-icon-style-xclosecircle ):not( .kt-accodion-icon-style-arrowcircle )  > .kt-accordion-inner-wrap > .wp-block-kadence-pane > .kt-accordion-header-wrap .kt-blocks-accordion-icon-trigger:before{background:#12263a;}.kt-accordion-id3140_005f90-af:not( .kt-accodion-icon-style-basic ):not( .kt-accodion-icon-style-xclose ):not( .kt-accodion-icon-style-arrow ) .kt-blocks-accordion-icon-trigger{background:#12263a;}.kt-accordion-id3140_005f90-af:not( .kt-accodion-icon-style-basic ):not( .kt-accodion-icon-style-xclose ):not( .kt-accodion-icon-style-arrow ) .kt-blocks-accordion-icon-trigger:after, .kt-accordion-id3140_005f90-af:not( .kt-accodion-icon-style-basic ):not( .kt-accodion-icon-style-xclose ):not( .kt-accodion-icon-style-arrow ) .kt-blocks-accordion-icon-trigger:before{background:#ffffff;}.kt-accordion-id3140_005f90-af > .kt-accordion-inner-wrap > .wp-block-kadence-pane > .kt-accordion-header-wrap > .kt-blocks-accordion-header:hover, \n\t\t\t\tbody:not(.hide-focus-outline) .kt-accordion-id3140_005f90-af .kt-blocks-accordion-header:focus-visible{color:#12263a;background:#ffffff;border-top-color:#474747;border-top-style:solid;border-right-color:#474747;border-right-style:solid;border-bottom-color:#474747;border-bottom-style:solid;border-left-color:#474747;border-left-style:solid;}.kt-accordion-id3140_005f90-af:not( .kt-accodion-icon-style-basiccircle ):not( .kt-accodion-icon-style-xclosecircle ):not( .kt-accodion-icon-style-arrowcircle ) .kt-accordion-header-wrap .kt-blocks-accordion-header:hover .kt-blocks-accordion-icon-trigger:after, .kt-accordion-id3140_005f90-af:not( .kt-accodion-icon-style-basiccircle ):not( .kt-accodion-icon-style-xclosecircle ):not( .kt-accodion-icon-style-arrowcircle ) .kt-accordion-header-wrap .kt-blocks-accordion-header:hover .kt-blocks-accordion-icon-trigger:before, body:not(.hide-focus-outline) .kt-accordion-id3140_005f90-af:not( .kt-accodion-icon-style-basiccircle ):not( .kt-accodion-icon-style-xclosecircle ):not( .kt-accodion-icon-style-arrowcircle ) .kt-blocks-accordion--visible .kt-blocks-accordion-icon-trigger:after, body:not(.hide-focus-outline) .kt-accordion-id3140_005f90-af:not( .kt-accodion-icon-style-basiccircle ):not( .kt-accodion-icon-style-xclosecircle ):not( .kt-accodion-icon-style-arrowcircle ) .kt-blocks-accordion-header:focus-visible .kt-blocks-accordion-icon-trigger:before{background:#ff6900;}.kt-accordion-id3140_005f90-af:not( .kt-accodion-icon-style-basic ):not( .kt-accodion-icon-style-xclose ):not( .kt-accodion-icon-style-arrow ) .kt-accordion-header-wrap .kt-blocks-accordion-header:hover .kt-blocks-accordion-icon-trigger, body:not(.hide-focus-outline) .kt-accordion-id3140_005f90-af:not( .kt-accodion-icon-style-basic ):not( .kt-accodion-icon-style-xclose ):not( .kt-accodion-icon-style-arrow ) .kt-accordion-header-wrap .kt-blocks-accordion-header:focus-visible .kt-blocks-accordion-icon-trigger{background:#ff6900;}.kt-accordion-id3140_005f90-af:not( .kt-accodion-icon-style-basic ):not( .kt-accodion-icon-style-xclose ):not( .kt-accodion-icon-style-arrow ) .kt-accordion-header-wrap .kt-blocks-accordion-header:hover .kt-blocks-accordion-icon-trigger:after, .kt-accordion-id3140_005f90-af:not( .kt-accodion-icon-style-basic ):not( .kt-accodion-icon-style-xclose ):not( .kt-accodion-icon-style-arrow ) .kt-accordion-header-wrap .kt-blocks-accordion-header:hover .kt-blocks-accordion-icon-trigger:before, body:not(.hide-focus-outline) .kt-accordion-id3140_005f90-af:not( .kt-accodion-icon-style-basic ):not( .kt-accodion-icon-style-xclose ):not( .kt-accodion-icon-style-arrow ) .kt-accordion-header-wrap .kt-blocks-accordion-header:focus-visible .kt-blocks-accordion-icon-trigger:after, body:not(.hide-focus-outline) .kt-accordion-id3140_005f90-af:not( .kt-accodion-icon-style-basic ):not( .kt-accodion-icon-style-xclose ):not( .kt-accodion-icon-style-arrow ) .kt-accordion-header-wrap .kt-blocks-accordion-header:focus-visible .kt-blocks-accordion-icon-trigger:before{background:#ffffff;}.kt-accordion-id3140_005f90-af .kt-accordion-header-wrap .kt-blocks-accordion-header:focus-visible,\n\t\t\t\t.kt-accordion-id3140_005f90-af > .kt-accordion-inner-wrap > .wp-block-kadence-pane > .kt-accordion-header-wrap > .kt-blocks-accordion-header.kt-accordion-panel-active{color:#12263a;background:#ffffff;border-top-color:#abb8c3;border-top-style:solid;border-right-color:#abb8c3;border-right-style:solid;border-bottom-color:#abb8c3;border-bottom-style:solid;border-left-color:#abb8c3;border-left-style:solid;}.kt-accordion-id3140_005f90-af:not( .kt-accodion-icon-style-basiccircle ):not( .kt-accodion-icon-style-xclosecircle ):not( .kt-accodion-icon-style-arrowcircle )  > .kt-accordion-inner-wrap > .wp-block-kadence-pane > .kt-accordion-header-wrap > .kt-blocks-accordion-header.kt-accordion-panel-active .kt-blocks-accordion-icon-trigger:after, .kt-accordion-id3140_005f90-af:not( .kt-accodion-icon-style-basiccircle ):not( .kt-accodion-icon-style-xclosecircle ):not( .kt-accodion-icon-style-arrowcircle )  > .kt-accordion-inner-wrap > .wp-block-kadence-pane > .kt-accordion-header-wrap > .kt-blocks-accordion-header.kt-accordion-panel-active .kt-blocks-accordion-icon-trigger:before{background:#ff6900;}.kt-accordion-id3140_005f90-af:not( .kt-accodion-icon-style-basic ):not( .kt-accodion-icon-style-xclose ):not( .kt-accodion-icon-style-arrow ) .kt-blocks-accordion-header.kt-accordion-panel-active .kt-blocks-accordion-icon-trigger{background:#ff6900;}.kt-accordion-id3140_005f90-af:not( .kt-accodion-icon-style-basic ):not( .kt-accodion-icon-style-xclose ):not( .kt-accodion-icon-style-arrow ) .kt-blocks-accordion-header.kt-accordion-panel-active .kt-blocks-accordion-icon-trigger:after, .kt-accordion-id3140_005f90-af:not( .kt-accodion-icon-style-basic ):not( .kt-accodion-icon-style-xclose ):not( .kt-accodion-icon-style-arrow ) .kt-blocks-accordion-header.kt-accordion-panel-active .kt-blocks-accordion-icon-trigger:before{background:#ffffff;}@media all and (max-width: 1024px){.kt-accordion-id3140_005f90-af .kt-accordion-panel-inner{border-top:0px solid transparent;border-right:0px solid transparent;border-bottom:0px solid transparent;border-left:0px solid transparent;}}@media all and (max-width: 1024px){.kt-accordion-id3140_005f90-af > .kt-accordion-inner-wrap > .wp-block-kadence-pane > .kt-accordion-header-wrap > .kt-blocks-accordion-header{border-top:0px solid #949494;border-right:0px solid #949494;border-bottom:1px solid #abb8c3;border-left:0px solid #949494;}}@media all and (max-width: 1024px){.kt-accordion-id3140_005f90-af > .kt-accordion-inner-wrap > .wp-block-kadence-pane > .kt-accordion-header-wrap > .kt-blocks-accordion-header:hover, \n\t\t\t\tbody:not(.hide-focus-outline) .kt-accordion-id3140_005f90-af .kt-blocks-accordion-header:focus-visible{border-top-color:#474747;border-top-style:solid;border-right-color:#474747;border-right-style:solid;border-bottom-color:#474747;border-bottom-style:solid;border-left-color:#474747;border-left-style:solid;}}@media all and (max-width: 1024px){.kt-accordion-id3140_005f90-af .kt-accordion-header-wrap .kt-blocks-accordion-header:focus-visible,\n\t\t\t\t.kt-accordion-id3140_005f90-af > .kt-accordion-inner-wrap > .wp-block-kadence-pane > .kt-accordion-header-wrap > .kt-blocks-accordion-header.kt-accordion-panel-active{border-top-color:#abb8c3;border-top-style:solid;border-right-color:#abb8c3;border-right-style:solid;border-bottom-color:#abb8c3;border-bottom-style:solid;border-left-color:#abb8c3;border-left-style:solid;}}@media all and (max-width: 767px){.kt-accordion-id3140_005f90-af .kt-accordion-inner-wrap{display:block;}.kt-accordion-id3140_005f90-af .kt-accordion-inner-wrap .kt-accordion-pane:not(:first-child){margin-top:14px;}.kt-accordion-id3140_005f90-af .kt-accordion-panel-inner{border-top:0px solid transparent;border-right:0px solid transparent;border-bottom:0px solid transparent;border-left:0px solid transparent;}.kt-accordion-id3140_005f90-af > .kt-accordion-inner-wrap > .wp-block-kadence-pane > .kt-accordion-header-wrap > .kt-blocks-accordion-header{border-top:0px solid #949494;border-right:0px solid #949494;border-bottom:1px solid #abb8c3;border-left:0px solid #949494;}.kt-accordion-id3140_005f90-af > .kt-accordion-inner-wrap > .wp-block-kadence-pane > .kt-accordion-header-wrap > .kt-blocks-accordion-header:hover, \n\t\t\t\tbody:not(.hide-focus-outline) .kt-accordion-id3140_005f90-af .kt-blocks-accordion-header:focus-visible{border-top-color:#474747;border-top-style:solid;border-right-color:#474747;border-right-style:solid;border-bottom-color:#474747;border-bottom-style:solid;border-left-color:#474747;border-left-style:solid;}.kt-accordion-id3140_005f90-af .kt-accordion-header-wrap .kt-blocks-accordion-header:focus-visible,\n\t\t\t\t.kt-accordion-id3140_005f90-af > .kt-accordion-inner-wrap > .wp-block-kadence-pane > .kt-accordion-header-wrap > .kt-blocks-accordion-header.kt-accordion-panel-active{border-top-color:#abb8c3;border-top-style:solid;border-right-color:#abb8c3;border-right-style:solid;border-bottom-color:#abb8c3;border-bottom-style:solid;border-left-color:#abb8c3;border-left-style:solid;}}<\/style>\n<div class=\"wp-block-kadence-accordion alignnone\"><div class=\"kt-accordion-wrap kt-accordion-id3140_005f90-af kt-accordion-has-19-panes kt-active-pane-0 kt-accordion-block kt-pane-header-alignment-left kt-accodion-icon-style-none kt-accodion-icon-side-right\" style=\"max-width:none\"><div class=\"kt-accordion-inner-wrap\" data-allow-multiple-open=\"false\" data-start-open=\"0\">\n<div class=\"wp-block-kadence-pane kt-accordion-pane kt-accordion-pane-1 kt-pane3140_cf7399-6f\"><div class=\"kt-accordion-header-wrap\"><button class=\"kt-blocks-accordion-header kt-acccordion-button-label-show\" type=\"button\"><span class=\"kt-blocks-accordion-title-wrap\"><span class=\"kt-blocks-accordion-title\">What are the main quality checks in catalytic converter manufacturing?<\/span><\/span><span class=\"kt-blocks-accordion-icon-trigger\"><\/span><\/button><\/div><div class=\"kt-accordion-panel kt-accordion-panel-hidden\"><div class=\"kt-accordion-panel-inner\">\n<p class=\"wp-block-paragraph\">Incoming substrate inspection, washcoat slurry control, coating dose and coat length, drying and calcining profiles, weight checks, backpressure and blockage tests, canning checks, and sample-based performance and durability testing.<\/p>\n<\/div><\/div><\/div>\n\n\n\n<div class=\"wp-block-kadence-pane kt-accordion-pane kt-accordion-pane-2 kt-pane3140_beb9d4-6f\"><div class=\"kt-accordion-header-wrap\"><button class=\"kt-blocks-accordion-header kt-acccordion-button-label-show\" type=\"button\"><span class=\"kt-blocks-accordion-title-wrap\"><span class=\"kt-blocks-accordion-title\">Why are weight checks so important?<\/span><\/span><span class=\"kt-blocks-accordion-icon-trigger\"><\/span><\/button><\/div><div class=\"kt-accordion-panel kt-accordion-panel-hidden\"><div class=\"kt-accordion-panel-inner\">\n<p class=\"wp-block-paragraph\">Weighing before and after coating shows how much coating, and therefore precious metal, each part received. It is fast enough to do on every part, and trends in the data show slurry or dosing drift before parts start failing.<\/p>\n<\/div><\/div><\/div>\n\n\n\n<div class=\"wp-block-kadence-pane kt-accordion-pane kt-accordion-pane-3 kt-pane3140_854c49-e5\"><div class=\"kt-accordion-header-wrap\"><button class=\"kt-blocks-accordion-header kt-acccordion-button-label-show\" type=\"button\"><span class=\"kt-blocks-accordion-title-wrap\"><span class=\"kt-blocks-accordion-title\">How are blocked channels detected?<\/span><\/span><span class=\"kt-blocks-accordion-icon-trigger\"><\/span><\/button><\/div><div class=\"kt-accordion-panel kt-accordion-panel-hidden\"><div class=\"kt-accordion-panel-inner\">\n<p class=\"wp-block-paragraph\">With a backpressure check that measures the pressure drop across the coated part at a set air flow. A part with normal weight but high backpressure usually has blocked channels rather than too much coating.<\/p>\n<\/div><\/div><\/div>\n\n\n\n<div class=\"wp-block-kadence-pane kt-accordion-pane kt-accordion-pane-11 kt-pane3140_c954a1-7e\"><div class=\"kt-accordion-header-wrap\"><button class=\"kt-blocks-accordion-header kt-acccordion-button-label-show\" type=\"button\"><span class=\"kt-blocks-accordion-title-wrap\"><span class=\"kt-blocks-accordion-title\">Is every catalytic converter performance tested?<\/span><\/span><span class=\"kt-blocks-accordion-icon-trigger\"><\/span><\/button><\/div><div class=\"kt-accordion-panel kt-accordion-panel-hidden\"><div class=\"kt-accordion-panel-inner\">\n<p class=\"wp-block-paragraph\">No. Light-off, conversion efficiency and aged performance tests are slow or destructive, so they are run on samples. Every part receives the weight, backpressure and canning checks instead.<\/p>\n<\/div><\/div><\/div>\n\n\n\n<div class=\"wp-block-kadence-pane kt-accordion-pane kt-accordion-pane-18 kt-pane3140_d8641c-32\"><div class=\"kt-accordion-header-wrap\"><button class=\"kt-blocks-accordion-header kt-acccordion-button-label-show\" type=\"button\"><span class=\"kt-blocks-accordion-title-wrap\"><span class=\"kt-blocks-accordion-title\">Why does traceability matter for catalytic converters?<\/span><\/span><span class=\"kt-blocks-accordion-icon-trigger\"><\/span><\/button><\/div><div class=\"kt-accordion-panel kt-accordion-panel-hidden\"><div class=\"kt-accordion-panel-inner\">\n<p class=\"wp-block-paragraph\">Because most of the quality is invisible in the finished part. Linking each unit to its substrate lot, slurry batch, coating data and test results lets a plant narrow down any field or conformity issue quickly.<\/p>\n<\/div><\/div><\/div>\n<\/div><\/div><\/div>\n\n\n\n<p class=\"has-white-color has-text-color has-link-color wp-elements-c645e628e62f8fbab9d9726851472d16 wp-block-paragraph\"><\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><\/p>\n","protected":false},"excerpt":{"rendered":"<p>A catalytic converter is an unusual part to inspect. Most of what makes it work is invisible: a thin coating spread across thousands of channels, carrying small amounts&#8230;.<\/p>\n","protected":false},"author":4,"featured_media":3176,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[9],"tags":[29],"class_list":["post-3140","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-cleantech","tag-cleantech"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v28.1 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>Quality Control in Catalytic Converter Manufacturing | Cybernetik<\/title>\n<meta name=\"description\" content=\"Quality control in catalytic converter manufacturing: substrate inspection, slurry control, weight and backpressure checks, canning, testing and traceability.\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, 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