How DR3419 Precision Pressure Transmitter Cut Scrap by 20%

Our extruder was producing inconsistent sheet thickness. The melt pressure reading seemed normal, but the product quality told a different story. We traced the issue to a faulty melt pressure sensor that couldn’t handle 400°C. First, the temperature variations caused drift in the readings, leading to unreliable pressure data. Consequently, we were producing off-spec material for weeks before identifying the root cause.

$20,000 in Scrap: How a Faulty Sensor Was Hiding in Plain Sight

Our monthly scrap rate had climbed to 15%, costing us over $20,000 in wasted materials. Initially, we blamed the extruder settings or raw material inconsistencies. However, after extensive troubleshooting, we discovered the melt pressure sensor was the culprit. Specifically, the sensor’s readings drifted by up to 5% during temperature fluctuations, which went unnoticed because the SCADA system averaged the data. As a result, we were making adjustments based on faulty information.

What Our SCADA System Didn’t Tell Us About Thermal Drift

Pressure sensors are temperature sensors first. Without compensation, accuracy claims are meaningless. In fact, temperature fluctuations led to changes in sensor performance, amplifying errors in critical process control. For instance, a 10°C change in melt temperature could shift the sensor output by 2%, which translated to a 20-bar error at 1000 bar. This means our process was running blind. Moreover, the sensor’s diaphragm and fill fluid were not rated for sustained 400°C exposure, causing permanent calibration drift over time.

How DR3419 Solved Our Melt Pressure Inaccuracy

To address this, we installed the DR3419 precision pressure transmitter. This precision pressure transmitter features 0.05% accuracy FS, ensuring reliable readings even at high temperatures. Additionally, its temperature compensation algorithm corrects for thermal effects across the operating range, maintaining accuracy within 0.1% total error band. The sensor also offers excellent long-term stability, so recalibration intervals are extended. Furthermore, the variety of electrical and pressure connections made integration seamless with our existing extruder ports.

20% Scrap Reduction and $20,000 Monthly Savings: Why Temperature Compensation Matters

With the new setup, we saw a significant improvement. Specifically, extruder cycles became more stable, reducing scrap rates by 20%. This means we saved over $20,000 in wasted materials each month. Moreover, the consistent readings allowed us to optimize the process further, increasing throughput by 5%. As a result, the DR3419 paid for itself within the first month.

Key Specifications

• High accuracy 0.05% FS
• Excellent long-term stability
• Temperature compensated
• Low total error band
• Variety of electrical and pressure connections

Closing Question

How do you ensure consistent readings in your critical processes? If you’re relying on uncompensated sensors, you might be losing thousands in scrap. Consider upgrading to a temperature compensated pressure sensor for reliable performance.

Tags: #precisionpressuretransmitter #0.05%accuracy #temperaturecompensatedpressuresensor #DR3419