Eliminate Dead-Legs with DR3405 Flush Diaphragm Transmitter

The Problem

Our cleanroom was facing a persistent contamination issue during CIP cycles. The DR3405 flush diaphragm pressure transmitter had been installed, yet batch after batch of injectable solutions kept failing quality control checks. Specifically, the problem seemed to be centered around a tiny dead-leg between the gauge and the process line. As a result, we were losing $25,000 per week in scrapped product and rework costs.

Root Cause Analysis

Threaded pressure taps create cavities where product can stagnate and contaminate, especially in high-cleanliness environments like pharmaceuticals. These stagnant areas become breeding grounds for bacteria, leading to false pass readings during CIP cycles. In fact, the dead-legs bypass critical cleaning steps because the cleaning fluid cannot effectively reach these recessed areas. Consequently, biofilm forms and compromises sterility, which is unacceptable for injectable solutions.

The Solution

The DR3405 flush diaphragm pressure transmitter was the solution we needed. Its design eliminates dead-legs by ensuring a continuous flow path, thereby preventing product stagnation and contamination. Moreover, the sanitary pressure sensor features a flush diaphragm that is 3A compliant, making it ideal for hygienic applications. We integrated the DR3405 in all key points of our CIP system, and the installation was straightforward due to its compact design. Additionally, the stainless steel wetted parts ensure compatibility with aggressive cleaning agents.

Results & Validation

Implementing the DR3405 resulted in immediate improvements. Batch pass rates improved significantly from 78% to 96%, representing a 23% increase in yield. Furthermore, maintenance time was reduced by 20%, as there were no longer dead-legs requiring manual cleaning and validation. This means we saved approximately 8 hours per week in maintenance labor. The dead leg elimination transmitter also reduced false alarms, improving overall equipment effectiveness.

Key Specifications

• Flush diaphragm pressure transmitter for sanitary applications
• Sanitary design for hygienic applications, including pharmaceutical and food processing
• Eliminates dead-legs and contamination points
• Stainless steel wetted parts for corrosion resistance
• Supported CIP and SIP cleaning processes
• 3A compliant for food and beverage service
• Pressure Range: 0-35 bar

Closing Question

How would you address a similar dead-leg challenge in your cleanroom environment? Consider evaluating your current pressure measurement points for potential contamination risks. For more information on sanitary pressure sensors, visit [ISA](https://www.isa.org) or [Control Engineering](https://www.controleng.com).

Tags: #pressuretransmitter #industrialpressuresensor #4-20mAoutput #DR3405