The Most Common Applications for Thermocouples

Dpstar began operations since the 90’s and has become one of the largest manufacturers in Southeast Asia. We provide comprehensive product line and solutions to meet unique customer specifications and applications. Our Maltec sensors can be found on equipment and in process applications for different industry. We are the experts in the field of manufacturing and calibration of temperature sensors, working in partnership with our customers to ensure we exceed their expectations.

Thermocouples are the most widely used temperature sensors in process industry applications due to their combination of wide temperature capabilities, ruggedness, and low cost. Thermocouples are the most economical elements for measuring temperature and also provide the highest ranges. Depending on the application, different types of metals can be used to produce the required voltage. This allows for the thermocouples to be provided in different calibrations to meet various application temperature requirements.

Thermocouples for Food & Beverage Industry

Thermocouples can be used for a wide variety of applications in the food and beverage industry. The food industry temperature sensor plays a crucial role in providing consistent readings for precise cooking, heading or frying, and ensuring food is properly cooked. Primarily in various commercial restaurant applications uses food industry thermocouples. Most common uses of thermocouples in the food industry are cooking equipment. Thermocouples can be found in large food cooking systems used for mass production to small scale, low volume, restaurant grade appliances. Typical cooking type equipment to use our temperature sensing probes include; ovens, warmers, fryers, toasters, and grills.  Traditionally, temperature sensors for the food industry thermocouple need to provide consistent temperature readings to ensure precise cooking, frying or heating to protect food from being overcooked as well as undercooked.

Thermocouples for Plastic Industry

Plastics manufacturing and other plastics related activities requires temperature control. Thermocouples are needed in the plastics processing industry at different places for temperature monitoring. Whether for temperature measurement on surfaces, at injection and diecasting moulds or for measuring the melting temperature in injection nozzles. The uses of thermocouples in plastic industries can be divided into two categories. The first category is that of measurement, where the thermocouple is used to determine the heat-transfer functions of plastics based on their cross-section. The thermocouple’s job is to determine the dissimilarity of the applied force for its orientation and velocity. The other uses of thermocouples in plastic industries are related to the designing of products. The second category of uses of thermocouples in plastic industries is that of engineering and product designing. A thermocouple is used in product engineering to calculate the changes in temperature of various materials during the product’s life. It allows engineers to choose the right kind of thermocouple that best suits the material they want to use in their products. They can also use these thermocouples to test the performance of their design and make any necessary changes before going on with production.

Thermocouples for Glass Industry

Temperature plays a vital role in glass-forming process as the viscosity of glass completely depends on the thermal uniformity and any change in this particular factor will results in problems in the next stages of the glass forming process. Good temperature management is essential in the glass manufacturing industry to ensure that the process remains reliable producing final products of a high standard. Measurement and control of temperature improve the refractory life of the glass industry and controls the overall quality and consistency of the glass products. The most widespread use of precious metal thermocouples can be found in the glass industry, but it is in the continuous melting facilities where they play the most important role. In these installations, the control of the process is very dependent on computers and accurate temperature measurement is essential. Our sensors are widely used in all applications in the glass industry, accurate temperature measurement is supported by well-designed and constructed thermocouples that can survive the severe temperature and corrosive conditions found in glass manufacturing furnaces.

Thermocouples for Metal Industry

Accurate temperature measurement is essential to controlling and analysing the temperature of the molten metal ensuring the final product is high quality and free from defects. Measuring the temperature of molten metal is difficult due to the high temperature and severe conditions encountered. For these reasons, Type K and N base metal and Types R, S and B platinum thermocouples are the only choice for contact measurements. When base-metal thermocouples are used, the wires typically are large diameter 8 or 14 AWG solid wires with ceramic insulators as well as ceramic or metal protection tubes. The large diameter of the Type K or N wires degrade more slowly to allow time for measurements before the high temperature conditions degrade the wires. Platinum thermocouple wires typically are on the order of 20 to 30 AWG solid. Unlike base-metal Type K and N wires that deteriorate due to oxidation or corrosion, the platinum wires become soft due to long-term annealing. They eventually fail due to grain growth.

Thermocouples for Cement Industry

The process condition in cement manufacturing sites are extremely harsh like high temperature, direct falling of hot molten material, coating collapse and corrosive gas, abrasive surroundings etc, there is also the risk of fire and potential explosions caused by dust particles.Since cement manufacturing processes involves harsh environments, it is important that the sensors deployed are capable of withstanding strong temperatures. Dpstar provides temperature measurement solutions for most various measuring points and also attends complex measuring tasks. Thermocouples for cement industry are available in standard and special models. The choice of the protection tube material and style of construction depends on the thermal, chemical and mechanical conditions on site. Our experience in the past would be handy on material selection and tube construction for a given application and its surroundings.

Thermocouples for Oil & Gas Industry

Oil and gas production is heavy-duty work for man and machine, which takes place under extreme conditions like enormous forces, massive vibrations and explosive gases. The oil/gas industry has several critical requirements to the process in order to prevent moisture, overheating, corrosion, and inefficient fuel usage. Some important and largely produced petrochemicals are ethylene, propylene, benzene, methanol etc. Cracking furnace, reactors, reformers, vessels, tanks are engaged in producing these Petrochemicals. Temperature measurement and control are very important and critical in petrochemical processing. Gases & liquids flow at high velocity & pressure and many of them have corrosion & erosion properties. Petrochemicals are highly Flammable. Therefore, Hazardous area protection is essential. Flame Proof, Explosion proof (Ex d) and Intrinsically safe (Ex i) sensor assemblies are required to be used. Dpstar offers a number of temperature sensors for the many different processes in the extraction, production, refining and distribution of oil, gas and other petrochemicals.

Thermocouples for Ceramic Industry

Within the Ceramic Manufacturing Industry, precise temperature measurement in the sintering process is essential to ensuring the final product is of a robust and high standard. This standard of quality can only be achieved with adequate temperature control. From porcelain, ceramic tiles, to additive manufacturing, our bespoke-made temperature sensors ensure the highest levels of accuracy and reliability within the hostile, high-temperature environments they will encounter in the furnace, oven, or kiln. Temperature sensors used for monitoring the temperature in kilns, ovens or furnaces when firing green ceramics to form sintered ceramics. These temperatures are normally very high and can range from 1000° C to 1600° C. There are a few different thermocouple types available to suit your ceramic manufacturing process. For example, depending on the firing temperature and how robust the thermocouple needs to be, will determine whether a base metal or mineral insulated thermocouple is best suited to your process.

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Dpstar Group
No 35, Jalan OP ½, Pusat Perdagangan One Puchong,
Off Jalan Puchong, 47160 Puchong,
Selangor Darul Ehsan, Malaysia.
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