Measure ethanol concentration precisely
for maximum process efficiency
for maximum process efficiency
Our maintenance-free ultrasonic sensors enable continuous inline measurement of ethanol-water mixtures.
Measurement results with 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 between 70 to 80 wt% to achieve a reliable antimicrobial effect. Especially 70 wt% ethanol is considered optimally effective against bacteria, viruses, and fungi. Concentrations below 60 wt% significantly lose effectiveness and are hardly effective below 50 wt%. Therefore, precise control of ethanol concentration is essential for medical and hygienic applications.
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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Classical sampling often time-consuming, error-prone, and safety-critical
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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® Measurement systems revolutionize ethanol concentration measurement through innovative ultrasonic technology. Our maintenance-free inline sensors enable continuous process monitoring without sampling.
Technical details and background
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 high measurement frequency allows for the quick detection of concentration fluctuations. The integrated temperature measurement automatically compensates for temperature-related fluctuations in sound speed.
This characteristic dependence allows for precise determination of ethanol concentration through calibration with reference solutions.
Economic benefit
Economic benefit
Cost savings
✔ Save on laboratory costs
✔ Less personnel effort
✔ Scrap reduction
✔ Save energy
Quick amortization
✔ Typische Amortisationszeit < 1 Jahr
✔ Low maintenance effort
✔ Permanent availability
✔ Long service life
More productivity
✔ Real-time data
✔ Quality improvement
✔ Compliance
✔ Flexibility
Individual adaptations
Individual adaptations
Installation options:
- Sensor lengths up to 3000 mm
- All common process connections
- Pressure resistance up to 500 bar
- Ex protection for Zone 1 and Zone 2
Material options:
Since ethanol-water mixtures generally do not pose any special material requirements, standard stainless steel sensors can be used. For special requirements, SensoTech offers comprehensive customization options.
Quality assurance:
- Complete documentation of all measured values
- Continuous process validation
- Automatic alerting in case of deviations
- Traceability of all batches
- Reduced out-of-specification results
- Simplified cleaning validation
Technical specifications:
Measuring ranges (ethanol in water) | 0-15 wt% / 90-100 wt% (others on request) |
Measurement accuracy | typically ±0.05 wt% |
Repeatability | ±0.02 m/s |
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 explosion 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
Since 1990, SensoTech has been a leading provider of inline measurement technology 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 customized 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 method is independent of these influences.
The LiquiSonic® measuring technology also contains no moving parts or components that can wear out or be consumed. Therefore, after installation, the measurement system is completely maintenance-free and drift-free.
The sensors offer digital signal transmission up to 1000 m and enable continuous inline measurement without sample extraction.
Our system uses ultrasonic transit time measurement to determine the speed of sound in the liquid. The speed of sound directly correlates with the 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. You receive an updated measurement value every second of your ethanol concentration. This fast response time enables effective process control and early detection of deviations.
Since the speed of sound, like other physical quantities, is influenced by temperature, all our LiquiSonic® sensors are equipped with high-precision temperature sensors. This way, 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 seamless via standardized protocols.
Our sensors operate reliably within a temperature range of -40 °C to 200 °C and pressures up to 500 bar. Through various material options such as stainless steel, Hastelloy, or PFA coatings, aggressive media can also be measured. Explosion 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 customizations 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), several components can be determined simultaneously. This allows monitoring of additional additives besides the ethanol concentration.
Yes, SensoTech manufactures sensors individually according to customer requirements. All standard flanges, any installation lengths, various threads, and special geometries for crystallization vessels or small pipelines are available.
The system is completely maintenance-free. There are no mechanical wear parts, seals, or optical windows that could be affected. Regular calibration is not required - the sensors remain stable for years.