Mettler Toledo Single-Use pH Sensors: Transforming Biopharmaceutical Manufacturing

Understanding Single-Use pH Sensors in Modern Bioprocessing

The biopharmaceutical industry is continuing to move toward single-use technologies (SUTs) that dramatically reduce contamination risks while increasing operational flexibility. Single-use pH sensors provide accurate pH measurement in bioprocess bags and other devices, with reliable measurement performance that helps optimize processes for the production of monoclonal antibodies, vaccines, and components for cell and gene therapies.

Unlike traditional reusable sensors that require cleaning, sterilization, and recalibration between batches, single-use pH sensors are directly integrated into the single-use process device by the device supplier and cannot be taken out and replaced. The complete SUB assembly, including the single-use pH sensor, is gamma irradiated and shipped pre-sterilized to the biopharmaceutical producer.

Why Analog Disposable pH Sensors Matter

Analog disposable pH sensors represent a critical advancement in bioprocess monitoring. These sensors must withstand gamma sterilization while maintaining measurement accuracy throughout extended batch processes. These single-use format pH sensors are designed for long-term stability in single-use bioreactor bag applications.

Traditional approaches required operators to insert reusable sensors into single-use bags, creating potential contamination points and requiring complex sterilization procedures. Single-use sensors eliminate these risks by arriving pre-sterilized and factory-calibrated, ready for immediate deployment.

Mettler Toledo's Game-Changing Solution: InSUS 310i and InSUS H30i

The InSUS 310i: First Digital Single-Use pH Sensor

The InSUS 310i from METTLER TOLEDO is the world's first disposable pH sensor in digital format. Analog, disposable pH sensors integrated into single-use bioreactors do not offer the same reliable measurement performance, convenient operation, and electronic documentation features as reusable digital sensors.

Key advantages of the InSUS 310i include:

• Extended Shelf Life: The InSUS 310 single-use pH sensor is designed for integration into single-use bags. Its 30-month shelf life enables enhanced bag inventory control at both bag manufacturer and end-user sites, compared to sensors with shorter shelf lives.
• Robust Design Protection: The glass electrodes of the sensor are shielded against damage during transport and bag preparation by round-edged protective guards. To maintain bag purity, a protective coating on the reference electrode prevents the release of electrolytes into the bag during storage and transport.
• Proven Measurement Technology: The measurement principle of the InSUS 310 single-use pH sensor is based on proven pH glass technology, offering identical reliability and accuracy as reusable pH sensors.

The InSUS H30i: Reusable Intelligence for Single-Use Applications

The InSUS H30i reusable sensor head works in conjunction with the InSUS 310i to deliver unprecedented capabilities. The reusable sensor head is operated in conjunction with the InSUS 310i and is ISM (Intelligent Sensor Management) ready. ISM is Mettler Toledo's digital sensor platform, enabling advanced diagnostics, predictive maintenance, and seamless integration with asset management systems, as well as single-use pH sensors. The sensor head has no product contact surfaces and does not require heat sterilization before being combined with an InSUS 310i sensor.

This innovative design separates the intelligent electronics from the single-use measuring element, providing:

• Seamless Integration: For standardized integration into process control equipment, the InSUS H30i offers identical connectivity options as a reusable InPro pH ISM sensor.
• Automatic Configuration: With ISM's Plug and Measure feature, the sensor head is automatically recognized for fast and trouble-free transmitter self-configuration.
• Electronic Documentation: The InSUS H30i is compatible with our ISM Core software for generating electronic documentation for InSUS 310i sensors used in your processes.

Why Operators and Quality Managers Prefer Mettler Toledo's Solution

Enhanced Signal Reliability

This digital sensor's signal is resistant to interference and noise, providing highly reliable measurements for sustaining process consistency. This combination yields a digital measurement solution that is resistant to electronic interference and noise, resulting in more accurate and reliable pH measurements.

Traditional analog sensors are susceptible to signal degradation over long cable runs and electromagnetic interference from surrounding equipment. Mettler Toledo's digital solution eliminates these concerns through robust digital signal transmission.

Intelligent Sensor Management (ISM) Technology

The true game-changer lies in Mettler Toledo's ISM technology. The solution features METTLER TOLEDO's Intelligent Sensor Management (ISM™) technology, which enables efficient sensor management and generation of electronic documentation, abilities that operators and quality managers will appreciate in the biopharmaceutical industry.

ISM provides operators with unprecedented insight into sensor performance:

• Predictive Diagnostics: ISM sensors are digital analytical sensors from METTLER TOLEDO that utilize Intelligent Sensor Management technology to provide predictive diagnostics, enhancing maintenance operations. This technology delivers a strong and reliable measurement signal to prevent interference, as well as rapid commissioning and startup, thereby reducing downtime.
• Proper Predictive Maintenance: While most digital sensors offer some diagnostics, often, these are based on counters and are not truly predictive diagnostics. ISM sensors provide diagnostic information on the remaining days, enabling maintenance teams to assess sensor health easily.
• Regulatory Compliance: ISM sensors, when used with ISM Core CFR, are fully technically compliant with 21 CFR Part 11 and EudraLex Volume 4 Annex 11.

Operational Excellence Benefits

Quality managers particularly value several key aspects:

• Inventory Management: For single-use bag manufacturers, the InSUS 310i pH sensor can be safely and easily integrated into bioreactor bags. Long sensor shelf life facilitates enhanced bag inventory control at bag manufacturer and end-user sites.
• Process Consistency: Digital sensors with ISM continuously monitor their condition and, using advanced algorithms, predict when calibration, maintenance, or replacement will be required. These diagnostic tools significantly reduce calibration and maintenance time and effort.
• Risk Mitigation: Uncertainty about whether a sensor is measuring accurately. Not knowing if a sensor is suddenly going to fail during the process. Sensor measurements that fluctuate due to electromagnetic interference from surrounding equipment. ISM technology addresses all these critical concerns.

Economic Advantages

ISM technology can have various benefits to production, including increased process reliability, reduced risks to operators, and lower overall annual costs. The combination of extended sensor life, predictive maintenance capabilities, and elimination of unplanned downtime creates substantial cost savings.

Backward Compatibility: The digital InSUS 310i is backward compatible with its analog, industry-proven version, InSUS 310. This enables an easy retrofit of your existing hardware to benefit from ISM technology.

The Future of Bioprocess Analytics

Many customers have requested a technology transfer of our digital ISM concept for reusable sensors to sensors in a single-use format. Mettler Toledo's response demonstrates their commitment to innovation in bioprocess analytics.

The InSUS 310i and H30i combination represents more than just technological advancement—it embodies a paradigm shift toward intelligent, connected bioprocessing. ISM sensors provide valuable input into Industry 4.0 and IIoT schemes and systems. Sensor diagnostic data can be sent directly to your higher-level asset management systems, driving the management of maintenance programs and the ordering of replacement equipment.

Mettler Toledo's InSUS 310i single-use pH sensor and InSUS H30i reusable sensor head combination deliver unparalleled advantages in biopharmaceutical manufacturing. From the 30-month shelf life and gamma-sterilization compatibility to the advanced ISM technology, which provides predictive diagnostics and electronic documentation, this solution addresses every primary concern of operators and quality managers.

The transition from analog to digital single-use pH measurement represents a fundamental improvement in bioprocess control, offering enhanced reliability, simplified operations, and comprehensive regulatory compliance support. For biopharmaceutical manufacturers seeking to optimize their single-use processes while maintaining the highest quality standards, Mettler Toledo's solution sets the industry benchmark.

Real-Time TOC Analysis: Safeguarding Power Generation Equipment from Organic Water Contamination

Organic contamination in pure power plant waters poses significant operational and economic challenges, particularly in cogeneration systems where steam is utilized for both power generation and industrial heating. In such systems, the steam that condenses and returns to the boiler may become contaminated by organic compounds during industrial processes. This contamination is not always detectable through traditional conductivity measurements, as many organic compounds are non-conductive. Nonetheless, their presence can significantly compromise the efficiency and safety of power generation infrastructure.

The consequences of organic contamination are multifaceted. Organic substances can clog ion exchange resins, resulting in increased maintenance and replacement costs. More critically, they can degrade into acids under high temperatures, which lowers the pH of the water and accelerates corrosion in boilers and turbines. Organic residues may also deposit onto heat exchange surfaces, reducing thermal efficiency and causing foaming in boilers, which leads to the undesirable carryover of contaminants into the steam phase. Each of these issues can threaten the reliability and longevity of expensive equipment.

Sources of organic contamination in cogeneration plants vary widely. The most direct source is the return of condensate from production processes, where it may pick up organic matter through leaks or exposure to plant materials. Additional sources include makeup water, which is mainly derived from surface water, or reclaimed sources that vary seasonally in their organic content. Even ion exchange resins, while essential to purification, can degrade and release organic compounds. Other contributors include lubricants, leaking condensers, and certain chemical additives.

Given that traditional monitoring methods, such as conductivity or resistivity, are insufficient for detecting non-ionic organics, power plants are increasingly relying on Total Organic Carbon (TOC) measurements. TOC sensors work by oxidizing organic compounds into carbon dioxide using ultraviolet light and then measuring the conductivity of the resulting carbonic acid. This technique enables accurate detection and quantification of organic contamination, even at trace levels, allowing for real-time monitoring and rapid response.

Steam used in evaporation can pick up organics that, if returned to the boiler untreated, may damage the system. Early detection through TOC measurement enables corrective actions to be taken before significant damage occurs. Devices like METTLER TOLEDO Thornton's 450TOC and 4000TOCe analyzers provide fast, continuous monitoring and are designed to integrate into process systems with minimal disruption.

Recommended TOC Monitoring Approach:

For comprehensive organic contamination monitoring in cogeneration systems, consider implementing a dual-strategy approach using METTLER TOLEDO Thornton's proven UV oxidation technology. 

Deploy the 4000TOCe online analyzer at critical fixed monitoring points such as condensate return lines and makeup water inlets for continuous, real-time surveillance. This provides operators with immediate alerts when contamination levels exceed safe thresholds, enabling them to take rapid corrective action.

Complement this fixed monitoring with the portable 450TOC analyzer for diagnostic troubleshooting and multi-point system profiling. Utilize the portable unit to identify contamination sources, verify treatment effectiveness, and conduct regular water quality audits throughout the plant. Both analyzers deliver results in approximately 60 seconds from sample inlet to final measurement, ensuring operators can respond quickly to contamination events before significant equipment damage occurs.

This combined approach provides both the continuous protection required for critical process streams and the flexibility to investigate emerging issues throughout the water/steam cycle, offering comprehensive coverage against organic contamination risks.

Ultimately, the ability to detect and respond to organic contamination in pure water systems is essential to maintaining the performance, efficiency, and safety of cogeneration and power generation facilities. Investing in TOC monitoring safeguards equipment and helps avoid costly downtime while ensuring compliance with increasingly stringent water quality standards.

Alliance Technical Sales, Inc.
312 Park Avenue Unit 145
Clarendon Hills, IL 60514-0145
Phone: 630-321-9646
https://alliancets.com

Guided Wave Radar: The Modern Solution for Tough Tank-Level Challenges

Guided Wave Radar (GWR) level transmitters entered the process-control toolbox a little more than two decades ago and quickly earned the confidence of plant engineers because they answer an old dilemma: how to read an accurate level when vapors swirl above a boiling solvent when foam rides a fermenter, or when a mud-like slurry drags on every mechanical part it touches. GWR solves those headaches by steering short microwave pulses down a metal probe that acts as a waveguide. The pulse travels at the speed of light until it meets a change in dielectric constant at the product surface, and then it bounces back to the transmitter electronics. Because the probe confines the energy, ambient conditions—agitation, vapor, dust, even vacuum—cannot deflect the signal as they sometimes distort a conventional “through-air” radar reading. Engineers, therefore, gain repeatability better than ±3 mm without elaborate software filtering, and they keep that accuracy across the full measurement span, whether the tank stands five feet tall or 125 feet high. 

Unlike ultrasonic sensors, GWR ignores temperature gradients, condensation, and pressure swings. The probe physically shields the pulse from turbulence, so the device delivers stable output while a feed pump hammers the vessel or a mixer whips the surface. Operators can push the process to 400 °C and 4,000 psi if metallurgy allows, yet the electronic head remains at a comfortable ambient temperature because the probe alone penetrates the hot zone. High-pressure gaskets, steam jackets, or low-temperature insulation never disturb the reading; the microwave reflects when it sees the interface.  

GWR also thrives in low-dielectric applications that challenge float switches and capacitance probes. Light hydrocarbons often register below εr = 2, too weak for older technologies, but a guided pulse still returns with a readable amplitude. When an emulsion blankets the boundary between oil and water, the transmitter resolves the first echo and continues down the probe until it meets the second interface. Hence, operators track both layers simultaneously and confidently automate their draw-off valves.  

Maintenance crews appreciate the simplicity. A GWR instrument contains no moving parts, so it never sticks or drifts as a displacer can. Calibration involves entering the probe length and telling the device where the vessel zero lies—usually the bottom nozzle. After that initial setup, the transmitter self-monitors. Modern models supply Power-over-Ethernet so technicians can pull diagnostic waveforms, check echo curves, or update firmware from any browser without opening the enclosure.  

Engineers sometimes ask where a GWR truly shines because the technology tolerates such a wide envelope of process conditions. Separators in the upstream oil and gas sector illustrate the ideal fit. A wellhead separator must measure the height of crude-produced water and the frothy hydrocarbon vapor that hovers above them. Pressure fluctuates with every surge from the formation; temperatures shift as the heater treater cycles; paraffin and scale can coat anything that intrudes into the vessel. A guided wave radar slips through a small coupling, rides inside a stainless or Hastelloy probe, and delivers a clean echo from each fluid layer. The refinery no longer relies on floating skimmers or rinser sprays to keep sight glasses clear; instead, control logic receives real-time level data even while the brine level rises, the oil contracts with temperature, or the gas cap foams. Well-test operators, therefore, send the proper fractions to storage, reinjection, or sales without pausing to recalibrate. The result: tighter material balance, less flaring, and fewer unscheduled call-outs.

Closer to home, chemical formulators, power-plant boiler operators, and food processors borrow the same advantages. They install GWR on sulfuric-acid day tanks, black-liquor dissolvers, milk-powder silos, or de-min water drums, confident that CIP detergents, vacuum swings, or blanket nitrogen will never trip the reading. The probe adapts to slender stilling wells, bridle pipes, and long-stroke retractable assemblies, so designers rarely reposition nozzles when they retrofit older equipment.

Alliance Technical Sales of Clarendon Hills, Illinois, supplies a standout example: the Hawk Measurement Centurion Guided Radar Level Transmitter. This model adds Power-over-Ethernet, built-in display, SIL-2 safety approval, and a 38-meter measuring range, so it covers everything from small skid tanks to towering asphalt silos. Plants across Indiana, Illinois, and Wisconsin rely on Alliance’s application expertise and local inventory to shorten lead times and keep projects on schedule. Contact their team to see how the Hawk Centurion can deliver rock-solid level measurement in your toughest vessel.

Alliance Technical Sales, Inc.
312 Park Avenue Unit 145
Clarendon Hills, IL 60514-0145
Phone: 630-321-9646
https://alliancets.com

Shattering Traditional Limits: How the InPro X1™ Revolutionizes Dairy pH Measurement

The Mettler-Toledo InPro X1™ pH sensor sets a new standard for in-line pH measurement in the food and beverage industry by combining unbreakable X-Chip™ technology with a robust, user-friendly design. Operators eliminate the worry of glass contamination because the InPro X1 does not contain a fragile glass bulb. This feature proves especially critical in dairy processing, where product purity and safety remain top priorities, and even the smallest glass fragment can cause expensive rework or scrapped products.

X-Chip technology relies on a fully solid composite pH-sensing element that replaces traditional glass with layers bonded through advanced diffusion processes. This composite material forms a stable gel layer, which responds to hydrogen ion activity just like conventional glass electrodes but without the mechanical weakness of a thin glass bulb. As a result, operators no longer need costly retractable housings or protective hardware to guard against accidental breakage. The InPro X1 has undergone rigorous testing and demonstrates remarkable resistance to impact and thermal shock, making it an ideal candidate for the stringent cycles of cleaning-in-place (CIP) and sterilization-in-place (SIP) that dairy production demands.

The sensor’s pre-pressurized liquid electrolyte maintains stable measurement conditions during high-temperature processes, reducing drift and extending intervals between calibrations. Conventional glass pH probes often exhibit increasing drift as temperatures rise, mainly because an internal buffer changes over time. The InPro X1’s solid-state design eliminates that buffer and ensures consistent measurement, even in repeated CIP or SIP procedures that subject sensors to drastic temperature fluctuations. Dairy operations benefit from greater accuracy during critical steps like fermentation and pasteurization, where slight pH variations can significantly impact product consistency and flavor.

The InPro X1’s innovative form also simplifies installation and servicing. Its 12 mm diameter matches standard sensor housings, so operators can swap it in quickly without modifying existing hardware. The sensor works seamlessly with Mettler-Toledo’s Intelligent Sensor Management (ISM™) platform, which allows convenient, off-line calibrations and advanced diagnostics. Plant managers gain real-time insight into sensor status and can schedule proactive maintenance based on actual operating data rather than following arbitrary timetables.

Dairy processors rely on precise pH monitoring to ensure product safety and quality, and the InPro X1 rises to that challenge by combining high accuracy with unmatched durability. Glass-bulb sensors present contamination risks and demand frequent recalibrations, but X-Chip technology lifts these limitations. Instead of worrying about fragile probes, operators focus on improving efficiency and consistency, confident that the InPro X1’s measurement signal remains stable throughout demanding processes. By enabling safer operations and delivering accurate results under challenging dairy conditions, the InPro X1 pH sensor ushers in a new era of reliable in-line pH measurement for the food and beverage industry.

Alliance Technical Sales, Inc.
312 Park Avenue Unit 145
Clarendon Hills, IL 60514-0145
Phone: 630-321-9646
https://alliancets.com

Top-Tier Process Control: Alliance Technical Sales Delivers Reliable Analytics and Instrumentation

Alliance Technical Sales, based in Clarendon Hills, IL, partners with industrial and municipal facilities throughout the Midwest to deliver outstanding process control solutions. Their product specialties include process analyzers, process instrumentation, and electric process heating. Alliance Technical Sales helps clients optimize their operations and maintain consistent quality by combining technical expertise with top-tier brands like Mettler-Toledo, Jogler, Micronics, and BriskHeat.

Alliance Technical Sales proudly offer its robust process analytics solutions for facilities that monitor chemical composition, environmental parameters, or other critical factors in real-time. These include:

• pH/ORP Sensors: Reliable inline probes ensure precise control of acidity or alkalinity across applications such as water treatment, chemical processing, and food and beverage production.
• Dissolved Oxygen Sensors: Advanced optical measurement technology reduces maintenance requirements and delivers fast, accurate readings for various process conditions.
• Conductivity and Resistivity Sensors: Continuously measuring the ionic content in liquids helps identify contamination, verify purity, and maintain compliance with strict process specifications.
• Turbidity and Suspended Solids Analyzers: Inline solutions provide real-time insights into particle concentration, helping operators preserve product quality and meet regulatory standards.
• Gas Analyzers: Certain production lines must track oxygen, carbon dioxide, and other gases, and Mettler-Toledo's analyzers deliver dependable results to protect personnel and products.

Alliance Technical Sales works closely with customers to match Mettler-Toledo's process analytics devices to specific applications. This personalized approach ensures that each instrument addresses site-specific challenges and compliance requirements. These high-performance systems also include built-in diagnostic tools that alert operators to sensor drift, fouling, or other issues before they impact production.

Process Instrumentation and Electric Process Heating

In addition to Mettler-Toledo analyzers, Alliance Technical Sales supplies process instrumentation, and electric process heating solutions. Their selection spans sensors, transmitters, controllers, and other devices that govern critical variables such as flow, level, temperature, and pressure. Operators rely on these measurements to maintain operational efficiency, reduce downtime, and enforce product consistency.

On the heating side, Alliance Technical Sales collaborates with customers to specify electric heating solutions that tackle challenging environmental and process conditions. Their portfolio includes heat tracing and container heating for freeze protection and viscosity maintenance,  and more specialized products that keep materials at the right temperature without excessive energy use.

Territory and Service

Alliance Technical Sales covers Illinois, Indiana, Iowa, and Wisconsin. They emphasize local, hands-on support to address immediate concerns and offer on-site consultation. Their experienced engineers are ready to assist with product selection, system design, and ongoing troubleshooting.

Clients rely on Alliance Technical Sales for more than just the products themselves. Their commitment to customer success includes streamlined project management, training, and responsive customer service. This dedication, combined with top-quality brands such as Mettler-Toledo, BriskHeat, and Micronics, places Alliance Technical Sales at the forefront of the Midwest's process analytics, instrumentation, and electric heating solutions.

Alliance Technical Sales, Inc.
312 Park Avenue Unit 145
Clarendon Hills, IL 60514-0145
Phone: 630-321-9646
https://alliancets.com