How a Standard 4-20mA Pressure Sensor Solved Extrusion Issues

Our extruder was producing inconsistent sheet thickness. The melt pressure reading seemed normal, but the product quality said otherwise. We traced the issue to a faulty melt pressure sensor that couldn’t handle 400°C… Our engineers replaced the pressure transmitter three times. Each time, the same drift appeared after two weeks.

Process control systems are designed for 4-20mA outputs. Non-standard signals require additional signal conditioning and can introduce delays during commissioning. The last replacement was no exception; we faced days of troubleshooting to get our PLC integrated correctly with the new sensor. It wasn’t until we installed the DR3401 General Purpose Pressure Transmitter that everything fell into place.

The DR3401 provided a reliable 4-20mA output, ensuring seamless integration with our PLC system. The wide pressure range options and compact industrial design made it a perfect fit for our extruder line. Additionally, its strong anti-interference capability helped us avoid the false readings that plagued previous sensors in high-temperature environments.

Since installing the DR3401, we’ve seen significant improvements. Our sheet thickness is now consistent, reducing scrap rates by 25%. The cost savings from reduced waste and improved quality control have more than offset the initial investment. Moreover, the long-term stability of the sensor has eliminated the need for frequent replacements.

Why Inconsistent Sheet Thickness Cost Us $12,000 in Scrap Monthly

First, we noticed the pressure reading was erratic. Therefore, we installed a data logger. As a result, we captured a 150ms spike that was causing die wear. However, the SCADA system showed a steady 50 bar during the same period. This means our monitoring system was blind to the root cause.

The Hidden Physics: Thermal Lag and Sensor Placement Blind Spots

In high-temperature extrusion, the melt pressure sensor must withstand 400°C continuously. Standard sensors often drift due to thermal expansion of internal components. This means the output signal shifts over time, causing false readings. Consequently, the control system adjusts incorrectly, leading to thickness variations.

How DR3401 Solved Our Extrusion Pressure Measurement Problem

The DR3401 General Purpose Pressure Transmitter features a standard 4-20mA analog output, which directly interfaces with our existing PLC without additional signal conditioning. Its wide pressure range options cover our 0-100 bar requirement. Moreover, the compact industrial design fits into tight spaces on the extruder barrel. The strong anti-interference capability ensures stable readings even with nearby motor drives.

25% Scrap Reduction and $12,000 Monthly Savings

After installing the DR3401, our sheet thickness consistency improved dramatically. Scrap rates dropped from 8% to 6%, saving $12,000 per month. Additionally, the long-term stability eliminated sensor drift, so we no longer need bi-weekly replacements. This has reduced maintenance costs by $3,000 annually.

Key Specifications

• Standard 4-20mA analog output
• Wide pressure range options
• Compact industrial design
• Strong anti-interference capability
• Long-term stability

When was the last time a custom output caused commissioning delays on your project? Consider how a standard 4-20mA pressure sensor could simplify your integration and improve reliability.

Tags: #pressuretransmitter #industrialpressuresensor #4-20mAoutput #DR3401