A critical review of analytical methods in the electroplating industry: Workflow, methods and limits

Process control in electroplating industry requires rapid analytical response and methodological robustness of highly concentrated, multi-component chemical matrices. This critical review provides a comprehensive evaluation of the analytical workflows governing the electrodeposition sector, categorizing methodologies into preventative monitoring of the electrolytic solution and the characterization of the resulting metal coatings. We critically evaluate the figures of merit, operational limitations, and matrix tolerances of both state-of-the-art instrumental techniques and classical wet chemical approaches, still widely used. Despite the rapid evolution of high-performance instrumentation, traditional titrations and semi-quantitative tools, such as the Hull cell, remain the practical standards in the industry due to their simplicity and their cost-effectiveness. Rather than indicating technological immobility, this persistence exposes a significant knowledge gap between academic analytical innovation and the robustness required for on-site industrial applications. This work highlights the intrinsic vulnerabilities of current monitoring protocols and delineates future research trajectories, emphasizing the need for next-generation, process-integrated, and calibration-free analytical methodologies tailored for the surface finishing industry.