Introduction To Industry Scenarios
The fine chemical/pharmaceutical chemical industry is characterized by small batches, multiple varieties, high purity, cleanliness/sterility, low/medium temperature, normal/low pressure, strong corrosion, high hygiene requirements, and strict parameter control. The process covers reaction vessels (synthesis/crystallization/fermentation), distillation/purification, sterile storage tanks, batching/mixing, filtration/drying, clean workshops, and wastewater/solvent recovery.
Typical measuring points:
Reactor: precise liquid level, reaction pressure, temperature, pH/acid-base level, solvent level (sterile/sanitary grade)
Distillation/Purification Tower: Tower kettle/distillate liquid level, reflux pressure, vacuum degree
Aseptic storage tank: API/purified water/injection water level, pressure, temperature (sanitary grade, no dead corners)
Ingredients/Mixing Tank: Raw Material/Solvent Level, Proportioning Pressure, Mixing Level
Cleanroom: pure water pipe network pressure, circulating water level, sterile air pressure
Explosion proof/anti-corrosion area: organic solvent tank, reaction kettle (Ex d/Ex ia, anti-corrosion PTFE)
Adapt to Core Products
QDY30A sanitary input type liquid level transmitter (316L/PTFE, no dead corners, easy to clean IP68、 Aseptic adaptation)
QDW90A-3051 sanitary single flange liquid level transmitter (sanitary clamp/flange, polished surface, high temperature resistance of 150 ℃, easy to crystallize/viscous medium)
QDKG sanitary/anti-corrosion pressure switch/transmitter (316L/Hastelloy, sanitary grade diaphragm, anti-corrosion coating, vacuum/low pressure, explosion-proof)
GLG series signal isolator/RS485 isolator (clean room anti-interference, explosion-proof area signal isolation, GMP compliant data traceability)
S803/SS803 Sanitary/Explosion proof Digital Display Instrument (Stainless Steel Shell, Clean Display, Alarm Interlock, GMP Compliance Communication)
Product Function
QDY30A sanitary type+QDW90A-3051 sanitary flange liquid level class
Liquid level of reaction kettle/crystallization tank: 0.2 level high-precision, hygienic design (316L/PTFE, no dead corners, easy to clean and sterilize), precise control of reaction/crystallization liquid level, ensuring batch consistency, stable purity, and compliance with GMP.
Aseptic storage tank (purified water/injection water/raw materials): IP68 protection, fully enclosed structure, no microbial contamination, no residue, easy CIP/SIP cleaning, long-term stable monitoring of liquid level, supporting accurate measurement of inventory and ingredients.
Viscous/easily crystallizable medium (ointment/resin/salt solution): hygienic single flange, high temperature resistance of 150 ℃, anti crystallization adhesion, long-term stable measurement, no need for frequent cleaning.
Solvent/acid-base tank (ethanol/acetone/hydrochloric acid/caustic soda): PTFE anti-corrosion probe, resistant to strong corrosion, organic solvents, and does not contaminate the medium.
QDKG sanitary/anti-corrosion pressure switch/transmitter
Reaction kettle/distillation tower pressure/vacuum degree: 0.075 level high-precision, sanitary diaphragm, temperature resistance of 150 ℃, precise control of reaction pressure and distillation vacuum degree, ensuring reaction rate and product purity (≥ 99.9%).
Pure water pipeline network/clean steam pressure: hygienic design, no dead corners, monitoring water/steam supply pressure, stabilizing process parameters, and preventing pollution.
Explosion proof area (organic solvent tank/reactor): Ex d II CT6 explosion-proof certification, suitable for flammable solvent environments, eliminating spark risks.
Differential pressure of filtration/drying equipment: Monitor the differential pressure of filter cartridges/drying towers, warn of blockages, and replace them in advance to ensure filtration efficiency and product quality.
GLG signal isolator/RS485 isolator
Strong interference in clean workshop (mixer/centrifuge/frequency converter): 2500V isolation, suppresses common mode interference, prevents signal drift, ensures stable DCS/PLC data, and complies with GMP data integrity.
Explosion proof area → clean area signal transmission: intrinsically safe isolation, energy limitation, explosion-proof safety, while avoiding pollution of the clean environment.
Multi parameter synchronous transmission (liquid level/pressure/temperature): RS485+Modbus, data synchronization, no packet loss, traceability, meeting GMP audit tracking requirements.
S803/SS803 Sanitary/Explosion proof Digital Display Instrument
Clean area on-site display: 304 stainless steel shell, dustproof and waterproof, high brightness LED, suitable for sterile workshops, easy to clean, convenient for inspection and on-site operation.
Alarm/Interlock Output: Upper and lower limit alarms, relay outputs, linked feed/discharge valves, mixing start/stop, emergency shutdown to prevent overheating, overpressure, and batch scrap.
GMP compliant communication: Supports Modbus, automatic data upload, full traceability, tamper proof, meeting the GMP audit requirements of the pharmaceutical industry.
Addressing Industry Issues
The product quality requirements are extremely high, and batch consistency is difficult to control: fluctuations in liquid level/pressure lead to purity not meeting standards, low yield, large batch differences, and high scrap rates (fine chemical scrap losses can reach 120000 yuan/month).
The risk of cleanliness/sterility is prominent
Ordinary instruments have blind spots, are prone to residue, difficult to sterilize, breed microorganisms, contaminate raw materials/preparations, and violate GMP.
Strong corrosion/organic solvent erosion
Acid alkali and organic solvent corrosion of ordinary instruments, probe damage, medium contamination, measurement failure.
Strict parameter control and large manual errors
With multiple varieties and small batches, manual batching/adjustment errors are large, inefficient, and prone to errors, affecting quality and delivery time.
Dual pressure of explosion-proof safety and GMP compliance
Organic solvents are flammable and explosive, while ordinary instruments are prone to explosions; Data cannot be traced and non-compliance may result in production suspension fines.
Direct Customer Benefits
Quality and yield benefits (core)
Accurate liquid level/pressure control, stable product purity ≥ 99.9%, improved batch consistency ≥ 95%, reduced scrap rate ≥ 80%, and reduced annual scrap losses ≥ 1.5 million yuan.
The reaction/distillation parameters are stable, the yield is increased by 2% -5%, the utilization rate of raw materials is improved, and the annual cost savings of raw materials are ≥ 2 million yuan.
Cleanliness and compliance benefits
Hygiene grade design (no dead corners, easy CIP/SIP), eliminates microbial contamination, 100% meets GMP sterile requirements, and avoids production stoppage fines.
Explosion proof instruments and isolators eliminate the risk of organic solvent explosions, reducing the safety accident rate by ≥ 95%.
The data is traceable and tamper proof, and through GMP auditing, it enhances the company's qualifications and market competitiveness.
Efficiency and Cost Benefit
Automatic control+precise measurement, reducing manual batching/adjustment by ≥ 70%, lowering labor costs, and increasing production efficiency by ≥ 50%.
Anti corrosion/hygiene design extends instrument lifespan by 2-3 times, reduces failure rate by ≥ 80%, and reduces maintenance costs by ≥ 60%.
Quick alarm+interlock, accident response time ≤ 1 second, reducing batch scrap and downtime losses.
Brand and Market Revenue
Stable and compliant product quality, improved customer satisfaction, increased order volume, and enhanced brand premium capability.
Intelligent monitoring and data tracing meet the requirements of high-end customers in the pharmaceutical/fine chemical industry, expanding the high-end market.
