In pharmaceutical manufacturing, ensuring the integrity and safety of processes is paramount. This application story highlights a solution for wirelessly monitoring pressure within large powder containers used in tumbling operations, addressing the critical need for preventing container over-pressurization. By implementing a specialized flush diaphragm pressure transmitter coupled with an industrial wireless transmitter and a single-channel receiver, manufacturers can achieve precise, real-time pressure measurement without the complexities and costs associated with traditional wired installations.
- Application: Monitoring pressure in 1500kg powder totes during tumbling in pharmaceutical manufacturing.
- Challenge: Detecting powder expansion to prevent over-pressurization and requiring a robust, hygienic measurement solution.
- Solution: A DMP 331P series flush diaphragm pressure transmitter integrated with an IWmAT series industrial wireless transmitter and an IWR-1 series single-channel wireless receiver.
- Key Benefit: Enables wireless, hygienic, and accurate pressure monitoring in challenging industrial environments.
A pharmaceutical manufacturing facility sought a robust and reliable solution for monitoring pressure within 1500kg totes filled with powder during tumbling operations. The primary concern was to detect any expansion of the powder, which could lead to an undesirable increase in pressure within the totes. Traditional wired sensor installations presented several challenges, including the potential for cable damage during tumbling, the difficulty and expense of routing cables in a dynamic industrial environment, and the necessity for hygienic design in a pharmaceutical setting. The customer required a measurement system that could withstand the presence of alkaline media, meet stringent food-grade requirements, and provide a clear output for process control. Specifically, the pressure range of interest was 0 to 250 mbar Gauge.
To address these critical requirements, a solution was proposed featuring a DMP 331P series flush diaphragm pressure transmitter, an IWmAT series industrial wireless 4-20mA transmitter, and an IWR-1 series single-channel wireless receiver. The DMP 331P pressure transmitter was selected for its hygienic design, featuring a flush welded stainless steel diaphragm (1.4435 (316L)) and a Clamp 1″ DN25 (DIN 32676), 3A process connection, which are crucial for applications involving powders and ensuring ease of cleaning-in-place (CIP) and sterilization-in-place (SIP). The use of a food-compatible oil (FDA) as the diaphragm filling fluid further underscored its suitability for pharmaceutical processes, where media compatibility is paramount. Its accuracy of 0.35% FSO according to IEC 60770 provides precise pressure readings for critical process monitoring.
The IWmAT series industrial wireless transmitter serves as a cable replacement, wirelessly transmitting the 4-20 mA output from the DMP 331P pressure transmitter. This eliminated the need for complex and potentially vulnerable cable runs in the tumbling application, offering a significant advantage in terms of installation cost and flexibility. Powered by a user-replaceable Lithium C cell battery with a five-year life at a 10-second update rate, the IWmAT provides a long-term, low-maintenance solution for remote data acquisition. Its 2.4 GHz ISM band transmission frequency and integral 0 dBi antenna allow for a line-of-sight range of up to 500 meters, ensuring reliable communication from the moving totes to a central receiving point.
Completing the wireless measurement loop, the IWR-1 series single-channel wireless receiver provides user-selectable 1-5V or 4-20 mA output, mirroring the calibrated range of the pressure transmitter, making it compatible with existing control systems. The receiver also includes 5A rated changeover contacts for alarm functionality, enabling immediate alerts for conditions such as process over-pressurization, low battery, or loss of signal, critical for maintaining process safety and operational efficiency. Its simple DIL switch pairing with the IWmAT transmitter ensures a “plug and play” setup, minimizing configuration effort. The IWR-1‘s ability to be DIN rail or wall mounted offers versatile installation options within the facility. This integrated wireless solution provides an accurate, hygienic, and highly practical method for monitoring powder expansion within pharmaceutical totes, enhancing both safety and operational efficiency.
DMP331P Hygienic Flush Pressure Transmitter
- Part No: 500-2500-1-5-100-C61-1-0-2-000
- Pressure Range: 0 to 250 mbar
- Range Type: Positive Gauge (atm to +P)
- Output Signal: 4-20mA (2 wire)
- Accuracy: 0.5% FS
- Electrical Connection: DIN43650A plug IP65
- Process Connection: Clamp 1″ DN25 (DIN 32676), 3A
- Process Connector Material: Stainless steel 316L
- Diaphragm Material: Stainless Steel 316L
- Media & Temperature: Food grade, 125degC max
IWmAT 4-20mA Signal Input to Wireless Transmitter
- Part No: IWmAT
- Input: 4-20mA
- Supply: User replaceable Lithium C Cell battery
- Transmission Frequency: 2.4GHz using ISM bands
- Transmit Power: 18 dBm
- Antenna: Integral 0dBi
- Operating Temperature Range: -20 to +50°C
IWR-1 Single Channel Wireless Sensor to 4-20mA Output Signal Receiver
- Part No: IWR-1
- Output: User-selectable 1-5V or 4-20 mA
- Power Supply: 12-32V dc
- Transmission Range: Up to 500 m line-of-site range
- Accuracy: <±0.25% FS BFSL end to end
- LED indication of the wireless link
- Installation: DIN rail or wall mounting kits available