- June 10, 2025
How to Choose the Right Pressure Sensor for Industrial Applications
Pressure sensors are foundational to industrial systems, where accuracy, reliability, and resilience in harsh conditions are essential. From monitoring line pressure in food processing to tracking water levels in remote reservoirs, these sensors play a critical role in maintaining safety, performance, and compliance.
For Australian engineers operating in sectors such as water treatment, process automation, and environmental monitoring, choosing the right pressure sensor goes beyond basic measurement. It demands devices that endure tough environments, deliver consistent long-term performance, and integrate seamlessly with today’s control and telemetry systems.
What Is Pressure Sensor and How Does It Work?
A pressure sensor is a transducer that converts pressure into an electrical signal for measurement and control. It detects the force exerted by a fluid (liquid or gas) and converts this mechanical input into a readable output, typically voltage, current (4-20mA), or digital signal (RS485, I2C).
Common working principles include:
- Piezoresistive sensing: Changes in electrical resistance under pressure.
- Capacitive sensing: Measures capacitance changes between two plates under pressure.
- Strain gauge: Deformation in the diaphragm changes resistance.
Most industrial pressure sensors are housed in stainless steel enclosures, designed to endure vibration, temperature changes, and chemical exposure.
Key Features to Consider
When selecting a differential pressure sensor, it’s essential to evaluate key performance and environmental factors to ensure optimal reliability and accuracy. Below are the most important features to consider:
- Measurement Range: Ensure the sensor suits your operational pressure range.
- Output Signal: Choose analog (4–20mA, 0–10V) or digital (Modbus, CANopen).
- Ingress Protection: IP67 or higher for wet or dusty environments.
- Material Compatibility: Media-wetted materials must be resistant to the fluid being measured.
- Temperature Stability: Sensors must operate within the process temperature ranges.
- Accuracy & Repeatability: Critical in regulated or high-precision processes.
Use Cases in Australian Industries
Water and Wastewater:
– Case 1: Pressure sensors in borehole monitoring systems measure groundwater levels across remote pumping sites in Queensland.
– Case 2: Pressure transmitters are deployed in wastewater treatment plants for sludge level control and pumping efficiency.
Environmental Monitoring:
– Case 1: In river systems, submersible sensors track hydrostatic pressure to estimate water depth with high accuracy.
– Case 2: Environmental firms install sensors in piezometers to monitor soil water pressure in flood-prone areas.
Food and Beverage:
– Case 1: Flush-mount pressure sensors ensure hygienic CIP-compliant measurement in dairy processing lines.
– Case 2: CO₂ line pressure is monitored in carbonated beverage manufacturing for process consistency.
Process and Manufacturing:
– Case 1: Differential pressure sensors measure filtration pressure drop in chemical dosing systems.
– Case 2: Compact sensors with high ingress protection monitor compressed air lines in packaging machinery.
Selection Tips & Technology Comparison
| Sensor Type | Best For | Strength | Limitation |
| Gauge Pressure | Open systems, atmospheric references | Simple & cost-effective | Not for sealed environments |
| Absolute Pressure | Vacuum systems, barometric monitoring | True zero reference | Costlier |
| Differential Pressure | Filtration, flow across membranes | Measures across two points | Requires two ports |
| Flush Diaphragm | Hygienic or viscous media | Easy to clean | Higher cost |
| Submersible | Tank level, boreholes | IP68 rated, durable | Limited range |
Tips:
– Use gauge for tank pressure, absolute for vacuum, and differential for filter monitoring.
– Confirm media compatibility with diaphragm material (e.g., 316L stainless steel, ceramic).
– Consider form factors and cable options for retrofit or OEM use.
FAQs
Q1: What is the difference between gauge and absolute pressure sensors?
A: A gauge sensor measures pressure relative to atmospheric pressure, while absolute sensors measure relative to a vacuum.
Q2: How do I know which pressure range to choose?
A: Select a sensor with a full-scale range 1.5 to 2 times higher than your maximum expected pressure.
Q3: Are MeasureX pressure sensors waterproof?
A: Yes, most models are IP67 or IP68 rated and suitable for outdoor or submersible use.
Q4: Can I use one sensor for both gas and liquid?
A: Yes, if the wetted materials are compatible with both media.
Q5: What is the typical lifespan of a pressure sensor?
A: MeasureX sensors are designed for long-term use, often exceeding 5–10 years with proper installation.
Recommended Products
MRB20 – General Purpose Piezoresistive Pressure Transmitter:
Compact, cost-effective sensor for embedded or mobile applications. Excellent thermal stability and wide signal options.
MRB21 – Low Power Pressure Transmitter:
IP67-rated stainless steel sensor ideal for harsh conditions. Suitable for pumps, valves, and general automation.
MRL21 – Submersible Level Transmitter:
Fully sealed and IP68-rated. Designed for groundwater, tank, or reservoir level monitoring in environmental and water industries.
Looking for a pressure sensor built for Australian standard?
Talk to our experts at MeasureX today to specify the right sensor for your application.
Why Choose MeasureX?
- Local Technical Support across Australia
- Custom Configuration for OEM and industrial applications
- Short Lead Times for standard and custom products
- Engineering Expertise to support specification and integration
