Precisely measure ethanol concentration
for maximum process efficiency
for maximum process efficiency
Our maintenance-free ultrasonic sensors enable continuous inline measurement of ethanol-water mixtures.
Measurement results with the highest accuracy and without sampling, for example in the pharmaceutical, chemical, or food industry.
Real-time measurement
Continuous monitoring without delay
Maintenance-free
No moving parts or wear components
Highest accuracy
Precise measurement even under difficult conditions
Cost savings
Reduction of operating costs and waste
Why is ethanol concentration measurement
a challenge?
a challenge?
In the pharmaceutical industry, ethanol-water mixtures for disinfectants must have a concentration zwischen 70–80 % aufweisen, um eine zuverlässige antimikrobielle Wirkung zu erzielen. Besonders 70 % Ethanol gilt als optimal wirksam gegen Bakterien, Viren und Pilze. Konzentrationen unter 60 % verlieren deutlich an Effektivität und sind unterhalb von 50 % kaum noch wirksam. Daher ist die präzise Kontrolle der Ethanolkonzentration essenziell for medizinische und hygienische Anwendungen.
Typical challenges:
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Volume contraction in ethanol-water mixtures
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Continuous process monitoring
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Quick response to deviations
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Reliable measurement even with temperature changes
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Documentation for quality assurance
Consequences of inadequate monitoring:
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Faulty batches
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Quality problems
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Inefficient distillation processes
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Rework or waste
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Insufficient cleaning validation
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Compliance issues
Conventional measurement methods unsuitable:
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Manuelle Probenentnahme: Zeitaufwändig, fehleranfällig and sicherheitskritisch
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Laboratory analyses: Measurement results often available only after hours
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Conductivity measurement: Methanol as an organic solvent is not conductive
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Density measurement: Installation and calibration very complex
Our solution for ethanol concentration measurement
LiquiSonic® Measuring systems revolutionize ethanol concentration measurement through innovative ultrasonic technology. Our maintenance-free inline sensors enable continuous process monitoring without sampling.
Technical details and backgrounds
Ultrasonic transit time measurement
The SensoTech LiquiSonic® system is based on the precise measurement of the ultrasonic transit time between transmitter and receiver. The sound speed is calculated from the measured transit time and the known distance of the sensor.
Physical principles
The sound speed in liquids depends on their density and compressibility. In ethanol-water mixtures, the sound speed changes almost linearly with concentration.
A measurement frequency of 4 MHz enables the rapid detection of concentration fluctuations. The integrated temperature measurement automatically compensates for temperature-related fluctuations in sound speed.
This characteristic dependence enables the precise determination of ethanol concentration by calibration with reference solutions.
Economic benefit
Economic benefit
Cost savings
✔ Save on laboratory costs
✔ Less personnel effort
✔ Reduction of waste
✔ Save energy
Rapid amortization
✔ Typische Amortisationszeit < 1 Jahr
✔ Low maintenance effort
✔ Betriebszeit > 99 % Verfügbarkeit
✔ High durability
More productivity
✔ Real-time data
✔ Quality improvement
✔ Compliance
✔ Flexibility
Individual adjustments
Individual adjustments
Installation options:
- Sensor lengths up to 3000 mm
- All common process connections
- Pressure resistance up to 500 bar
- Explosion protection for Zone 1 and Zone 2
Material options:
Since ethanol-water mixtures generally do not have special material requirements, standard stainless steel sensors can be used. For special requirements, SensoTech offers comprehensive customization options.
Quality assurance:
- Complete documentation of all measurements
- Continuous process validation
- Automatic alerting in case of deviations
- Traceability of all batches
- Reduced out-of-specification results
- Simplified cleaning validation
Technical specifications:
Measurement ranges (ethanol in water) | 0-15 wt% / 90-100 wt% (others on request) |
Measurement accuracy | typically ±0.05 wt% |
Repeatability | ±0.02 m/s |
Measurement frequency | 4 MHz |
Temperature range | -40 °C to 200 °C |
Pressure range | Up to 500 bar |
Sensor length | Up to 3000 mm |
Material & coating | Stainless steel, Hastelloy, PFA, PVDF, ETFE, ... |
Digital transmission | Up to 1,000 m (more on request) |
Interfaces | 4-20 mA, Profibus, Ethernet, Modbus, Fieldbus, ... |
Protection class | IP65/67/68 and Ex protection available |
Calibration | One-time factory calibration |
Maintenance | Completely maintenance-free |
Practical examples and applications
Pharmaceutical industry
Continuous monitoring of ethanol concentration in the production of disinfectants. Ensuring optimal ethanol concentration for best possible antimicrobial efficacy.
Beverage industry
Precise alcohol content measurement in spirits and alcoholic beverages. Quality control during distillation and dilution for consistent product quality.
Chemical industry
Process optimization in ethanol purification and processing. Inline monitoring of distillation columns and rectification systems for maximum efficiency.
Over 35 years of experience in concentration measurement
Over 35 years of experience in concentration measurement
SensoTech has been a leading provider of inline measurement technology since 1990 and has established itself as a specialist in precise concentration and density measurements.
Our systems are used worldwide, even in critical applications.
35+
1000+
50+
ISO 9001
Quality certified
Do you need further references or a custom feasibility study?
Frequently asked questions
SensoTech GmbH is a leading company in the field of process measurement technology based in Barleben, near Magdeburg, Germany. We develop and produce innovative solutions for monitoring and optimizing industrial processes. Our specialization lies in the precise measurement of concentrations, densities, and other parameters in liquids – in real-time and directly during the process.
Unlike optical methods, which are influenced by color or turbidity, conductivity-based methods, which are sensitive to electrical conductivity, or density-based methods, which can be disturbed by temperature or gas bubbles, our Ultrasonic process independent of these influences.
The LiquiSonic® measurement technology also contains neither moving parts nor components that can wear out or be consumed. Therefore, after installation, the measuring system is completely maintenance-free and drift-free.
The sensors offer digital signal transmission up to 1000 m and enable continuous inline measurement without sampling.
Our system uses ultrasonic transit time measurement to determine the speed of sound in the liquid. The speed of sound directly correlates with ethanol concentration and enables measurement accuracies of ±0.05 wt%. The integrated temperature compensation ensures stable results even under fluctuating process conditions.
The system delivers results in real-time. With a frequency of 4 MHz 32 measurements per second are performed. Based on these measurements, you receive a current measurement value every second. This fast response time enables effective process control and early detection of deviations.
Since the speed of sound, like all other physical quantities, is affected by temperature, all our LiquiSonic® sensors are equipped with high-precision temperature sensors. Thus, the influence of temperature on the measurement can be directly compensated Therefore, it is not necessary to integrate additional temperature sensors.
The system offers various digital interfaces (e.g., Profibus, Ethernet/IP, Foundation Fieldbus) as well as analog 4-20 mA outputs. The integration is carried out smoothly via standardized protocols.
Our sensors operate reliably in a temperature range from -40 °C to 200 °C and pressures up to 500 bar. Through various material options such as stainless steel, Hastelloy, or PFA coatings, even aggressive media can be measured. Ex-protection for Zone 1 and 2 is also available.
Yes, our sensors are designed for extreme conditions. In addition to the extended temperature and pressure range, we offer custom adaptations such as sensor lengths up to 3000 mm, special alloys for corrosive media, and various protection types, for example, optional explosion protection. Each sensor is individually configured according to your requirements configured.
Yes, by combining sound velocity measurement with additional physical quantities (e.g., conductivity), multiple components can be determined simultaneously. This also allows for monitoring additional substances.
Yes, SensoTech manufactures sensors individually according to customer requirements. All standard flanges, any installation lengths, various threads, and special geometries for crystallization containers or small pipes are available.
The system is completely maintenance-free. There are no mechanical wear parts, seals, or optical windows that could be compromised. Regular calibration is not required - the sensors remain stable for years.