Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Steam Temperature Control (Process Heating, Food & Beverage Safety)
Food safety & efficiency
Temperature
Quick Overview
| Problem | Steam temperature is a critical parameter for heating, sterilisation, pasteurisation, and energy efficiency in food & beverage and process industries. Temperature drift, heat losses, or control valve malfunction can compromise product safety, increase energy costs, and cause regulatory non-compliance—often without continuous visibility. |
| Solution | Sensa.io’s wireless temperature sensors provide continuous monitoring of steam lines, heat exchangers, and process heating circuits, ensuring stable thermal control and traceable compliance. |
| Value | Improved food safety • Reduced energy waste • Stable process quality • Lower operational risk |
| ATEX | Typically non-ATEX; ATEX-certified temperature sensor variants available for classified steam or solvent-adjacent areas |
The Operational Challenge
Steam is widely used in process industries for:
- Pasteurisation and sterilisation
- Process heating and cleaning-in-place (CIP)
- Heat exchangers and jacketed vessels
- Drying and thermal treatment
Key challenges include:
- Temperature loss due to insulation degradation
- Control valve malfunction or fouling
- Inconsistent steam quality or pressure
- Limited instrumentation on secondary steam lines
Traditional monitoring methods rely on:
- Local gauges and manual checks
- Inferred control via pressure measurements
- Reactive troubleshooting after deviations
These methods provide limited assurance for continuous compliance and energy efficiency.
Why Continuous Steam Temperature Monitoring Matters
Temperature—not pressure—is the true indicator of thermal performance at the point of use.
Continuous monitoring enables operators to:
- Verify effective pasteurisation and sterilisation
- Detect heat losses and insulation failures
- Identify control valve or trap malfunction
- Optimise steam distribution efficiency
Stable steam temperature directly impacts product safety, quality, and energy consumption.
Sensa.io Solution
Sensa.io delivers a wireless temperature monitoring solution for steam and process heating systems.
Core Components
Temperature Sensor
High-accuracy sensor (±0.2 °C) suitable for steam pipes, heat exchangers, and vessel jackets.
Wireless Communication
Supports LoRaWAN, Modbus, and MQTT, enabling integration with BMS, SCADA, and quality systems.
Installation & Power
Battery-powered clamp-on installation — no wiring, no steam shutdown.
Operational Benefits
- Continuous verification of heating processes
- Reduced energy losses
- Improved regulatory compliance
- Faster detection of thermal deviations
Results and ROI
ATEX Compliance and Safety
When required, Sensa.io temperature sensors support:
- ATEX Directive 2014/34/EU
- Ex II 2 G Ex ia IIC T4 Gb (Zones 0–2)
- IECEx certification
This allows safe deployment near flammable vapours or classified process areas.
Integration and compatibility
| Protocols | LoRaWAN, Modbus RTU/TCP, MQTT, REST API |
| Systems | SCADA, BMS, food safety and quality platforms |
| Vendors | Siemens, Schneider Electric, ABB, Honeywell |
| Cybersecurity | AES-128 encrypted communication |
FAQ - Common Questions
Are Sensa.io sensors compatible with any gateway or network?
What ATEX certifications apply to Sensa.io devices?
All hazardous-area models are certified Ex II 2 G Ex ia IIC T4 Gb and IECEx approved for Zones 0–2.
What is the typical battery life?
Up to 10 years at 15-minute intervals, depending on signal strength and environment.
How are the sensors integrated into existing systems?
Through standard protocols — LoRaWAN, Modbus, MQTT, REST API — no proprietary middleware needed.
How does predictive maintenance reduce OPEX?
Early anomaly detection reduces emergency interventions by 30–40 %, extends equipment life and lowers energy costs.
What does the Sensa.io Valve Position Sensor actually measure?
The device detects real-time valve position states—open, closed, or intermediate—with high accuracy. It continuously sends this information wirelessly to your monitoring dashboard.
Can this sensor detect partial valve movement or stuck valves?
Yes. The sensor identifies irregular patterns such as partial movement, delayed response, or stuck valves, enabling early maintenance before failure occurs.
Is this sensor suitable for manual, motorized, and actuated valves?
Yes. It supports a wide range of valve types including ball, gate, butterfly, actuator-driven, and manual valves.
How fast does it update the valve position?
You can configure the reporting interval—from seconds to minutes—depending on your operational and battery needs.
How long does installation take?
Most installations take under 10 minutes. The sensor mounts using brackets or clamps without modifying existing valves.
Explore Our Sensors
Valve position
The Sensa iO Valve Position Sensor provides real-time open/close feedback for manual and automated valves in oil & gas, chemical, and hydrogen operations.
Pressure
A rugged, industrial-grade pressure sensor designed for high-demand oil & gas applications. Provides continuous gas and liquid pressure monitoring, with ATEX intrinsic safety, IP67 housing, and LoRaWAN® connectivity.
Temperature
Sensa iO’s temperature sensor delivers precise temperature data for process lines, steam systems, heat exchangers, and storage assets.
Differential Pressure (ΔP)
A compact DP solution using dual synchronized pressure inputs to deliver accurate differential pressure data for filters, heat exchangers, separators, and manifolds.
Vibration
A high-resolution vibration sensor built for predictive maintenance of pumps, motors, compressors, and rotating equipment.
Acoustic
The Sensa iO acoustic sensor identifies ultrasonic leak signatures, gas escape, steam trap failures, and flare noise anomalies.
Trusted by a Worldwide Network
With partners in over 20 countries, Sensa IO delivers rugged sensor solutions to the toughest environments — everywhere.
