Enhancing Flow Measurement with Air Bubble Detection
Achieving better process stability and quality
In bioprocessing, reliable flow measurement is essential to ensure product quality, process stability, and efficient production operations. Air bubbles can affect measurement accuracy and filling precision, as well as disrupt processes such as chromatography. Advanced air bubble detection plays a key role in protecting equipment, maintaining stable process conditions, and ensuring consistent process performance.
Benefits for Lab and GMP Bioprocessing
Upstream Bioprocessing
- Media and buffer preparation
Batch reproducibility through airless and stable liquid flow, as well as precise mixing and dosing. - Single-use bioprocessing systems
Safe, automated operation without process interruptions due to incomplete priming and unintended air ingress. - Fermentation and cell culture transfer
Gentle product handling and stable transfer conditions as air bubbles may increase shear stress and affect cell viability. - Pump protection and monitoring
Rapid response to abnormal conditions or dry running to maintain an airfree liquid stream for stable flow rates.
Downstream Bioprocessing
- Sampling and dosing systems
Airless dosing for higher precision in sampling and better process control. - Chromatography systems
Column protection and process stability for consistent purification results, as well as reduced downtime. - Filtration and Tangential Flow Filtration
Improved filtration efficiency and performance, as well as consistent and bubble-free operation conditions. - Filling and dosing applications
Higher accuracy through airless filling and dosing, as well as minimized product loss or rejected batches.
Why flow meters with integrated bubble detection enhance your bioprocessing jobs?
- Enhanced product quality and batch consistency
Detecting bubbles in real-time helps maintain stable operating conditions and supports consistent batch-to-batch performance. - Faster automation and alarm handling
Advanced communication interfaces enable direct integration into PLCs or process control platforms allowing automatic alarms or process adjustments without operator intervention. - Additional process intelligence
Process engineers can correlate flow variations with bubble events, which improves data analysis, process optimization, and data-driven manufacturing strategies.
Working with the Bubble Detection Feature
The bubble feature has been developed specifically for the SONOFLOW CO.55 V3.0 flow meter series. To configure the bubble detection, users need the SONOTEC Flow Monitor Software and a SONOTEC USB Data Converter, which is available in various models.
The integrated bubble detection feature transforms the SONOFLOW CO.55 V3.0 from a high accuracy flow meter into a more comprehensive process monitoring solution by enhancing quality assurance, automation, safety, and overall process stability.
Sensor Configuration
SONOFLOW CO.55 V3.0 flow meters are preset with a fixed threshold value for bubble detection. Depending on mounting orientation and operating conditions, bubbles with a minimum size of approx. 1/3 of the inner diameter of the tubing can be detected.
Adjustments to the detection threshold and related parameters can be made in the advanced access mode of the SONOTEC Flow Monitor Software by the SONOTEC Customer Service or by particularly trained users.
By default, the bubble detection feature is disabled. With only one click in the SONOTEC Flow Monitor Software, the bubble detection can be activated. Once activated, the sensor starts detecting bubbles according to the default threshold - also indicated on the sensor’s touch display.
Interfaces
Bubble events are available digitally via the RS485 serial interface or analog via the switching output.
By using the serial interface, a number of variables are available for data retrieval. Thus, further data analysis about bubble events and their effects can be performed. Users can choose between the SONOTEC protocol and the Modbus protocol.
The analog signal via the switching output can be easily configured in the SONOTEC Flow Monitor Software. Select the Bubble Alarm from the available options and choose between the configuration type, e.g., PNP or NPN.
The sensor offers additional configuration options, particularly when using the serial interface. Contact our service team so that we can set up the optimal configuration for application-specific settings.
Measurement Principle
Bubble Detection | Ultrasonic Transmission
SONOFLOW CO.55 V3.0 flow meters detect air bubbles and obstructions by means of dynamic amplitude monitoring. Depending on the sound impedance of the adjacent media, reflection and transmission take place at the interface. When an air bubble passes the sensor channel, the signal level of the transmitted sound wave drops. The higher the drop of the signal level, the larger the bubble size.
Benefit from Our Clamp-On Flow Meters
More Information about Ultrasonic Flow Meters
Do you have any questions?
Feel free to contact us! We will be happy to help you.
SONOTEC US Inc.
SONOTEC US Inc.
10 Newton Pl., Ste. 100
Hauppauge, New York 11788