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Process optimization in
Polycondensation

Polycondensation is the most important step in polymer resin production. LiquiSonic® provides precise monitoring and analysis of your processes - completely maintenance-free and drift-free.

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Reaction monitoring

Real-time measurement

Maintenance-free & drift-free

Cost-saving

Challenges in polycondensation

Polycondensation is the central step in polymer resin production and is particularly susceptible to process fluctuations. Even minor deviations in the reaction progress can lead either to an excessively high degree of crosslinking or to molecular weight that is too low. The result is brittle, unusable resin with inadequate mechanical properties. To prevent scrap, precise control of viscosity and degree of crosslinking is therefore critical. In addition, precise determination of reaction progress is technically very demanding.

Challenges

  • Precise control of reaction progress required
  • Excessive crosslinking leads to brittle, unusable resins
  • Molecular weight that is too low causes inadequate mechanical properties
  • Laboratory measurements are delayed and do not provide continuous data
  • Narrow process window: even small deviations lead to scrap

Solution: LiquiSonic®

  • Continuous ultrasonic measurement of reaction progress in real time
  • High accuracy through temperature-compensated sound velocity measurement
  • Robust sensor design, individually adaptable to process conditions
  • Automated data acquisition and analysis for seamless process documentation
  • Integration into process control systems via digital and analog interfaces

Your benefits

  • Consistent product quality through real-time monitoring
  • Reduced scrap through precise process control
  • Reduction of time-consuming analyses, higher process efficiency
  • Stable, maintenance-free, drift-free, and cleaning-free sensors
  • Sustainable and cost-effective polymer resin synthesis

Our solution: The LiquiSonic® measurement system

Monitor concentration in real time

LiquiSonic® addresses the key challenges of polycondensation in polymer resin production through continuous and highly precise ultrasonic measurement of reaction progress. Since sound velocity correlates directly with the concentration and properties of the resin, critical deviations can be detected early and corrected immediately. The robust sensor design allows direct installation in reactors or pipelines and provides temperature-compensated real-time data that can be documented automatically and transmitted to the process control system. In this way, reaction parameters can be controlled more effectively, laboratory analyses can be reduced to a minimum, and consistent quality can be ensured. An above-average sensor length is often used, which (as one of many customization options for the measurement system) allows optimal integration into your specific process.

  • Continuous, precise real-time monitoring
  • Robust, temperature-compensating sensor design
  • Flexible customization options

Technical and economic details

Ultrasonic measurement principle

The ultrasonic measurement method from LiquiSonic® is based on highly precise time measurement. From the measured sound transit time and the known distance between transmitter and receiver, the sound velocity is calculated, which correlates directly with the concentration and properties of the polymer resin. This makes it possible to determine reaction progress continuously and in real time during polycondensation - a decisive advantage over laboratory-based methods. Although viscosity measurement is traditionally considered the standard method in polycondensation, it is slower, reacts less sensitively to concentration fluctuations (especially at high concentrations), and leads to fouled sensors in inline measurement. Ultimately, the ultrasonic method provides a more stable measurement and is also completely drift-free, cleaning-free, and maintenance-free.

The ultrasonic method offers additional advantages: robust inline measurement without interruption, high accuracy, temperature compensation, reliable gas bubble detection, and flexible adaptation of sensor length and installation variant to the respective plant geometry. Continuous data acquisition also enables the creation of a "Golden Batch" profile that documents the optimal reaction course. Future batches can be compared with this reference process so that deviations are immediately detected and corrected. In this way, consistently high resin quality is ensured and process control is sustainably optimized.


Economic benefits

In addition to the technical advantages, the use of LiquiSonic® also offers significant economic potential:

  • Reduction of scrap through immediate detection of incorrect mixtures
  • Optimized raw material consumption thanks to precise dosing and optimized final concentrations

  • Faster response times in the event of process deviations, thereby minimizing downtime

  • Savings in energy and operating costs through more efficient process control
  • Reliable documentation through automatic data storage
  • Higher plant availability through robust, drift-free, cleaning-free, and maintenance-free sensors
  • Fast ROI through reduced operating costs and greater process stability


Application example

Polycondensation is the most important step in polymer resin production. Only with the correct viscosity can the polymer resin be used for the desired application. The LiquiSonic® measurement system continuously monitors concentration via ultrasonic measurement and detects even the smallest deviations in real time. This makes it possible to avoid incorrect mixtures and precisely control material usage. The robust plug-and-play sensor design enables direct integration into the process. Sensor length and connection variant can be individually adapted to the process so that polycondensation progress can be monitored continuously. All measured values are automatically documented and are available for subsequent analyses or audits. In this way, ecological responsibility is combined with economic efficiency.

Success stories and references:

You can obtain detailed case studies and customer references from our sales team. Feel free to contact us for specific application examples!

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The most important benefits at a glance

Consistent quality

Real-time monitoring prevents excessive or insufficient crosslinking and ensures consistent product quality.

Cost savings

Less scrap, reduced raw material and energy consumption - with consistent product quality and process stability.

Maximum efficiency

Real-time data enables faster decisions and optimized workflows.

Robust sensors

Completely maintenance-free, drift-free, and cleaning-free sensors that do not require consumables.

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Frequently asked questions

What is SensoTech?

SensoTech GmbH is a leading company in the field of process measurement technology based in Barleben, near Magdeburg, Germany. We develop and manufacture 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.

How does LiquiSonic® respond to temperature fluctuations?

Since the speed of sound is affected by temperature, all our LiquiSonic® sensors are equipped with highly precise temperature sensors. This allows the influence of temperature on the measurement to be directly compensated for this reason, it is not necessary to integrate additional temperature sensors during polymer resin production  integration.

Which process conditions can be covered?

Our sensors operate reliably within a temperature range of -40 °C to 200 °C and pressures up to 500 bar. Thanks to various material options such as stainless steel, Hastelloy, or PFA coatings, aggressive media can also be measured. Explosion protection for Zones 1 and 2 is also available.

Can extreme operating ranges also be covered?

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, such as optional explosion protection. Each sensor is individually according to your requirements configured.

Can multiple components be monitored simultaneously?

Yes, by combining sound velocity measurement with additional physical variables (e.g., conductivity), multiple components gleichzeitig bestimmt werden. So lassen sich auch Zusatzstoffe bei der polymer resin production  überwachen.

What distinguishes LiquiSonic® from conventional measurement technology?

Unlike optical methods, which are affected 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. Compared to viscosity measurement, the method is also less sluggish, does not require sampling, and responds more sensitively to concentration fluctuations.  The LiquiSonic® measurement technology also contains neither moving parts nor components that can wear out or be consumed. After installation, the measurement system is therefore completely maintenance-free and drift-free. The sensors offer digital signal transmission up to 1000 m and enable continuous inline measurement without sampling.

How is integration into existing automation systems carried out?

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.

What maintenance is required for reliable polycondensation?

There are no mechanical wear parts, seals, or optical windows that could be attacked or become fouled during inline measurement. Regular calibration is not required—the sensors remain stable for years. Compared to viscosity measurement, our ultrasonic method ultimately delivers a more stable measurement and is also completely drift-free, cleaning-free, and maintenance-free.

How quickly do you receive measurement results during polymer resin production?

The system provides results in real time. Based on these measurements, you receive an up-to-date measured value every second. This fast response time enables effective process control and early detection of unwanted deviations during polycondensation.

Further applications


Blending of resins

During blending, various resins, additives, or solvents are mixed to achieve specific properties and a homogeneous composition.

Formaldehyde production

Formaldehyde production places high demands on process control, since even small deviations in methanol oxidation have noticeable effects on efficiency and product quality.

Polymerization

Polymerization is a chemical process in which smaller molecules (monomers) combine to form larger molecules (polymers). This process is fundamental to the production of many plastics and other materials.

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