How DR3419 Saved a Pharma Facility $25,000

When Normal Pressure Readings Were Not Enough

A critical step in our pharmaceutical production process depends on precise pressure measurement to maintain product consistency and process safety. Recently, our hydraulic press began cycling more slowly than expected. The pressure gauge showed normal readings, yet the finished parts were increasingly falling outside specification.

At first, we suspected the hydraulic system itself. The equipment appeared to reach the required pressure, but the production results told a different story. After reviewing the press, control system, and pressure measurement equipment, we discovered that measurement stability was becoming a significant part of the problem.

The Hidden Problem Behind Pressure Measurement Errors

Pressure sensors can be affected by changes in temperature. As operating and ambient temperatures change, the sensing element and electronics can experience changes that affect zero and span performance. If these effects are not adequately compensated, a pressure reading can shift even when the actual system pressure remains stable.

This was particularly important for our application because the hydraulic press operated under changing environmental conditions. A pressure reading that looked correct during one inspection could change as the equipment warmed up. That made it difficult for our engineers to determine whether the hydraulic system was actually changing or whether the measurement itself was drifting.

For a pharmaceutical production process, this uncertainty can quickly become expensive. Inconsistent pressure data can lead to incorrect process adjustments, rejected parts, repeated testing, and unnecessary downtime.

The Solution: DR3419

After evaluating the application and discussing our requirements with FANDESENSOR engineers, we selected the DR3419 High-Accuracy Pressure Transmitter.

The DR3419 provides accuracy options down to ±0.05% FS and incorporates digital compensation and nonlinear correction technology. These features were particularly important for our application because we needed a pressure measurement solution that could provide consistent results as operating conditions changed.

We installed the DR3419 on the hydraulic press and configured it for the required pressure range. The objective was not simply to obtain a more precise pressure value at room temperature. We needed a measurement signal that remained dependable throughout the actual operating environment.

Why 0.05% Accuracy Matters

For general pressure monitoring, a small measurement error may have little practical impact. However, the situation changes when pressure is directly related to product quality, test results, or equipment control.

A 0.05% accuracy pressure transmitter can provide significantly finer pressure measurement than a standard transmitter intended for general process monitoring. This can be valuable when engineers need to identify small pressure changes, verify equipment performance, or maintain tight process tolerances.

In our hydraulic press application, better measurement accuracy gave the control system a more dependable pressure signal. It also helped our engineers distinguish actual process changes from measurement-related variations.

Temperature Compensation for Changing Conditions

Accuracy at a single reference temperature is only part of the measurement equation. Real industrial equipment rarely operates under perfectly constant environmental conditions.

The DR3419 provides digital temperature compensation for zero and span characteristics, with a compensated temperature range of -10°C to +80°C. Its specified working temperature range is -30°C to +70°C.

This compensation helps reduce the effect of temperature-related sensor changes on the pressure output. As a result, engineers can have greater confidence that changes in the transmitter signal represent changes in actual pressure rather than simply changes in the surrounding temperature.

For our application, this was one of the most important differences between the DR3419 and the previous pressure sensor.

The Results

After installing the DR3419, pressure measurements became considerably more consistent throughout the hydraulic press operating cycle. The press returned to its expected performance, while the number of non-conforming parts decreased significantly.

The improved measurement stability allowed our engineers to make process adjustments based on more reliable pressure data. Instead of repeatedly investigating whether a pressure variation was caused by the hydraulic system or the sensor, the team had a much more stable measurement reference.

Most importantly, we eliminated approximately $25,000 in losses associated with non-conforming production. The improvement also reduced troubleshooting time and gave the production team greater confidence in the pressure data used for process decisions.

DR3419 Key Specifications

The DR3419 is designed for applications where pressure accuracy, stability, and repeatability are important.

• Accuracy options down to ±0.05% FS
• Digital temperature compensation
• Nonlinear correction technology
• Excellent long-term stability
• 4–20 mA output options
• 0/1–5/10 V DC output options
• Pressure ranges from -1 bar to 1000 bar
• Gauge, absolute, and sealed gauge pressure options
• Stainless steel construction options
• Suitable for precision measurement and OEM applications

For complete pressure ranges, electrical outputs, process connections, and ordering options, refer to the DR3419 product specifications.

More Than Just a Pressure Reading

Our experience with the hydraulic press highlighted an important lesson: a pressure reading can appear normal while still being unsuitable for a precision production process.

When measurement accuracy and stability are critical, engineers need to consider more than the nominal pressure range. Sensor accuracy, temperature effects, long-term stability, and compensation technology can all influence the reliability of the final measurement.

The DR3419 0.05% accuracy pressure transmitter combines high measurement accuracy with digital compensation and correction technology to provide a more stable pressure signal for demanding applications. This makes it suitable for hydraulic equipment, test benches, OEM machinery, laboratory equipment, calibration systems, and other applications where pressure measurement directly influences process decisions.

Why Measurement Stability Affects Production Costs

The original problem did not immediately look like a sensor problem. The hydraulic press was operating, the pressure gauge showed values within the expected range, and there were no obvious equipment failures.

However, small measurement errors can become expensive when they affect a production process repeatedly. An inaccurate or unstable pressure signal can cause engineers to adjust the wrong parameter, resulting in additional testing, rejected parts, and wasted production time.

By improving the quality of the pressure measurement, we were able to eliminate one of the hidden variables affecting the process. The result was not only better pressure data but also more predictable production performance.

Conclusion

The $25,000 loss initially appeared to be a hydraulic press problem. After investigating the entire measurement chain, we found that pressure measurement stability was contributing to the inconsistent production results.

Replacing the previous sensor with the DR3419 gave us a more reliable pressure measurement reference. Its ±0.05% FS accuracy, digital compensation, and temperature-related correction helped improve measurement consistency under changing operating conditions.

For manufacturers using pressure data for quality control, hydraulic testing, OEM machinery, or precision process control, selecting a transmitter based only on pressure range is not enough. Accuracy, temperature performance, and long-term stability should also be considered.

Could pressure measurement error be hiding the real cause of inconsistent results in your production process?

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