Temperature Sensors

Temperature is one of the most measured variables in manufacturing. Temperature plays a vital role in efficiency, energy consumption, product quality and safety.

Just some of the places that EAS has installed temperature sensors include:

  • Coolstores to monitor product & room temperatures.
  • Process lines.
  • Clean In Place (CIP) lines to make sure CIP is at the desired temperature, ensuring proper cleaning.
  • Milk Lines to ensure the milk is <4 Degrees Celcius.
  • Boilers to monitor temperatures, maintaining boiler efficiency.
  • Throughout Milk Driers, providing overtemperature deluge alarm status.


There are various types of temperature sensors that can provide you with effective monitoring of temperature in your plant or process and EAS can assist you with selecting the right sensor for your needs.

The most commonly used sensors are Resistance Temperature Detectors (RTDs) and Thermocouples (T/Cs).

Thermocouples (T/Cs) are probably the most used method of temperature measurement. Thermocouples are contact sensors that are basically made up of two wires of different metals and joined at one end. Changes in the temperature at the junction of the dissimilar metals create a change in electromotive force (emf) between the other end and allow temperature to be measured.

There are many different types of thermocouples to fit a wide range of applications suitable for all industries, their appearances can be quite different.


But, as can be seen in the thermocouple diagram below, they all rely on the same basic principles and systems.


Image source: www.nz.rs-online.com/

Two or more dissimilar thermocouple wires form at least two junctions within a circuit. One of these is always kept at a steady and stable temperature – usually lower, but sometimes higher, than the temperature at the measuring (‘hot’) junction.

A voltmeter connected to the circuit reads the current created by electromotive forces because of the temperature differential. This can then be used to give a precise temperature reading.


Resistance Temperature Detectors (RTDs) are also contact sensors. They work on the principle that the electrical resistance of a metal increases as temperature increases – this is known as thermal resistivity. RTDs are made of resistive material such as platinum, copper or nickel depending on the requirements of the process.

The resistance of Resistance Temperature Detector (RTD) changes constantly with the applied temperature so the temperature is quite predictable by measurement of its resistance. It is this property which allows Resistance Temperature Detector (RTD) to measure temperature accurately and consistently.



Image source: www.instrumentationtoday.com

Each type of temperature sensor will work best in a particular set of conditions.  The table below provides an indication of some of the conditions where thermocouples or RTDs are best used as well as the advantages and disadvantages each offers.


As you can see there are many factors that can affect the selection of the best temperature device for your application. EAS can help guide you in selecting the best sensor for your plant or process. Just get in touch with the team on 07 834 0505 or [email protected]

Puzzle – February 2021 Newsletter

Was your answer 19?

Check out the picture below for any you missed.


For more great riddles check out www.briddles.com

Terms & Conditions – $20,000 Referral Bonus

To be eligible for the $20,000 referral bonus the following conditions must be met:

  • EAS must employ the person you recommend.
  • The referrer must be identified in the covering email sent with the job application.
  • Job applications must be received by the close off date.
  • The bonus will paid out in increments. $4,000 on the completion of 3 months employment, a further $4,000 after 12 months employment and then $4,000 every 12 months for the next 3 years of employment.
  • If the staff member leaves during the payment period, the bonus will be forfeited.


To apply, refer to our job ad on Seek

Christmas Puzzle – December Newsletter

Well, Santa could just get rid of Rudolph but…

It sounds like Santa’s having a bad day with Rudolph. The Elf is afraid that that the reindeer will bite him, and without Santa around, Rudolph just can’t keep himself from eating the Snowman’s carrot nose.

What is Santa to do? He and his crew need to cross a bridge, but Santa has to act as a guide and cross with each one. This bridge is sure making his travels complicated! Darn that global warming!

Well, let’s think about it. On his first trip across, he has to take Rudolph with him, because he can’t leave the reindeer with either of the other two. Who knows what would happen to them?

So, you get the Snowman and the Elf on one side and Rudolph on the other. Santa comes back to the original side and now has a problem, because neither the Elf nor the Snowman wants to travel across to be alone with Rudolph. Santa, being the persuasive guy that he is, convinces one of them (let’s say the Elf) to cross with him. He has a solution, you see.

When he and the Elf get to Rudolph’s side of the bridge, the Elf is looking particularly worried. Santa tells him not to fret — he’s going to take Rudolph back with him.

He and Rudolph travel back together towards the Snowman — Rudolph has lots of energy from resting all year long, so he doesn’t get tired. This time, Santa travels across the bridge with the Snowman, leaving Rudolph behind on the first side and pairing the Elf and the Snowman together on the second side.

Santa has just two trips left to make. He travels back alone along the bridge, collects Rudolph and then everyone joins up together at the far side of the bridge.


Source: http://thescienceexplorer.com/universe/can-you-solve-christmas-puzzle

Puzzle – November Newsletter

Answer: 8 Animals. Elephant, Dolphin (trunk), Ant (Trunk), Horse, Dog, Cat, Mouse, Seahorse (tail).

Personally I don’t see an ant, I see a fish – but still got the same total!

Power Factor Correction

Power factor is the ratio of active power (the power flowing to a system/appliance) vs the amount it uses to perform its function. A device’s power factor represents how effectively that device is using the power supplied to it – essentially its electrical efficiency.

Devices with high power factors make better use of the power being supplied to them than devices with low power factors.  Power factors range from 0 to 1 where 1 represents 100% efficiency. A device that has a power factor of 1 is using all the power supplied to it.

Generally, a power factor of 0.8 or above is considered good.  Lower than 0.8 and it should be corrected to save on consumption and comply with the requirements of the electricity network operator.

Other key reasons for improving power factor:

  • Increases the efficiency of your power use
  • Reduces your power bills
  • Filters unwanted frequency harmonics
  • Reduces stress on your electrical equipment
  • Extra kVA available from your existing supply.
  • Extends equipment life as there is reduced electrical burden on cables and electrical components.


How do we measure Power Factor?

Power factor isn’t static – it fluctuates and can be influenced by changes in processes such as motor loading.

The power factor in a single-phase circuit (or balanced three-phase circuit) can be measured with the wattmeter-ammeter-voltmeter method, where the power in watts is divided by the product of measured voltage and current. The power factor of a balanced polyphase circuit is the same as that of any phase.


What causes poor power factory?

The main cause of low Power factor is Inductive Loads such as:

  • Electric motors
  • Transformers
  • Arc welders
  • HVAC systems
  • Molding equipment
  • Presses
  • High-intensity discharge lighting

Unlike resistive loads (i.e., incandescent lights, electric heaters, cooking ovens), which involve a more direct conversion to useful work in the form of heat energy, inductive loads operate off of the magnetic field that is created by reactive power.


How can you improve your power factor?

While low power factor can cause a significant increase in your plant expenses and a decrease in your system’s efficiency, you can take several steps to help correct your power factor, including:

  • Minimizing the operation of idling or lightly loaded inductive equipment, particularly motors
  • Replacing defunct motors with energy-efficient ones, and operating these near their rated capacity
  • Avoiding operating your equipment above its rated voltage
  • Installing capacitors to decrease the amount of reactive power used
  • Upgrading or replacing inductive loads that don’t operate close to their design capacity
  • Local power factor correction at the load
  • Centralised capacitive correction with a power factor correction unit.


The simplest way to improve power factor is to add power factor correction capacitors to the electrical system. Power factor correction capacitors act as reactive current generators. They help offset the non-working power used by inductive loads, thereby improving the power factor.

If you want advice on improving the energy efficiency of your plant get in touch with the EAS team today on 834 0505.




Do you know if your lighting levels are up to standard?

Lighting in your workplace is critically important to your staff’s ability to accomplish tasks efficiently and safely. In addition, proper light levels prevent eye strain, which allow us to work comfortably for longer periods of time.

Light is measured using lumens and lux. Lumens are used to measure the amount of light being given out by a bulb.  For example, a High Bay 200 watt LED light gives off 25,000 lumens.

Lux measures the amount of light reaching a surface.  One Lux is equal to one Lumen per square meter.

While some lights may have a high lumen output when first installed, the level of lighting can depreciate quickly, this is another reason why LED lights provide a good replacement option.

The table below highlights the lux levels required to ensure efficient operation of your workplace.


Area/Activity Recommended Lux
Computer workstations 300 – 500
Large item processing or assembly 300
Small item processing or assembly 500 – 1000
Inspection and testing 500 – 2000
Loading bays 150
Packing & Dispatch 300

Source of figures: https://www.rexellighting.co.nz/uploads/attachments/Light-Level-Recommendations.pdf


If you are concerned that your lighting is not at the required level EAS can conduct lux measurements to assess your current level of lighting and where improvements may be required.


This can also provide a good opportunity to consider upgrading to LED lights which also offer the benefits of:

  • Increased lifespan
    LED lights have a lifespan of 50,000 hours and include a 5 year warranty compared to Metal Halide’s which carry no warranty and have a lifespan of just 5 years. Most Metal Halide light fittings in use today will be past their 5-year lifespan and their lumen output would be well below their maximum output of 32,000 lumens; while still using full power input of 400 watts. The lumen output of a metal halide lamp depreciates much faster than an LED. In fact, they depreciate about 20% each 1,000 hours.
  • Reduced Power Consumption
    High bay LED lights have a lumens/watt ratio of 125 vs Metal Halide Light with 80 lumens/watt.

    This means the LED light is 56% more efficient than its Metal Halide counterpart and this efficiency only improves over the lifetime of the fitting as the lumens in a metal halide light depreciate quite rapidly while the LED lumen output hold steady.

  • Better Lighting
    LED lights emit light over 180° vs the standard metal halide light which emits light in a 360° range. With the LED light, lighting is being directed where you need it, so your energy consumption is reduced – saving you more money.
  • Reduced Maintenance
    With a lifespan of 50,000 hours the LED lamp will require less changes which means less maintenance work for your team and less interruption to your business.

    With LEDs there is also less chance of glass breakage over essential product areas such as bulk stores and process areas in your plant.


If you’d like a lighting assessment conducted at your workplace, get in touch with the EAS team today on 07 834 0505.

Using Regenerative VSD Braking to improve your energy efficiency

When an electric car brakes, its kinetic energy is converted into electricity and returned to the car’s batteries to extend the driving distance. This same principle, Regenerative Braking, can also be applied to electric motors used in a wide variety of industrial applications where frequent braking is required or when stopping high inertia loads. Examples where Regenerative Braking can be applied include centrifuges and separators used in the dairy industry, shredders and chippers/debarkers for the milling industry, and grinders and presses at ore refineries.

A regenerative Variable Speed Drive (VSD) captures wasted energy and returns it to the network so it can be used by other equipment, offering substantial improvements in energy efficiency, and reducing overall energy costs.

For example, the annual savings of a waste handling crane powered with a 55kW hoisting motor, 9 kW long travel motor and a 4.5kW trolley motor was 15.6 megawatt/hour (MWh) and $2,750 based on the measurements at a customer site. This equates to a 32% energy saving compared to the previously used technology of resistor braking.

With a traditional resistor and mechanical braking methods, excess energy is dissipated as heat, which often requires additional cooling in an electrical room to cope with it. When regenerative braking is used, the braking energy is not wasted as heat and further cost savings can be achieved with reduced cabinet building costs as the installation footprint is smaller due to the lack of need for external braking components.


Ongoing maintenance

All VSDs require regular maintenance and with temperatures increasing, putting more load on the drive’s cooling system, now is a good time to make sure your Variable Speed Drives are in top condition for the summer period to ensure there is no disruption to production.

Key checks include:

  • Visual check:
    To make sure the drive is clean; the cooling fan and cooling system are all in good condition. Dust on VSD hardware can cause a lack of airflow, diminishing performance. Dust also absorbs moisture which can contribute to failure. Connections should also be checked as heat cycles and mechanical vibration can lead to sub-standard connection and cause erratic operation resulting in damage to machinery.
  • Settings:
    Parameter settings should be checked and recoded so that if there is a failure, the drive can be easily replaced. EAS utilise Drive Software to enable us to upload the correct settings straight back into your drive to get it up and running as quickly as possible.
  • Stocktake of spare parts:
    By performing a stock take of the spare parts available we can ensure that any breakdowns can be handled quickly and efficiently. It also gives the opportunity to identify drives where spare parts are no longer available so that a planned upgrade of the drive can be scheduled where it will be least disruptive to production.


EAS are experts in installing and maintaining Variable Speed Drives. We can assist you with your regular preventative maintenance checks, servicing and can provide advice and installation for regenerative braking systems on new and existing VSDs, depending on age and condition.

If you want to know whether a regenerative braking system may be a good option for your plant, or need to schedule in your VSD preventative maintenance checks; get in touch with the EAS team today on 834 0505.


Gas monitoring – keeping your site & staff safe


picture2Manufacturing industries use chemicals and machinery that can produce dangerous levels of poisonous gases. The presence of these gases can be apparent through their pungent smell, but others are odourless and tasteless making them particularly hazardous. The most common types of toxic gasses found in industrial workplaces include ammonia, hydrogen sulphide, chlorine, carbon monoxide and carbon dioxde.

Gas detectors are essential to protecting your staff and your site from the dangers of noxious gasses. Gas detectors can be used to detect combustible gasses, flammable gases, gases that pose inhalation hazards and gases that can asphyxiate by preventing the intake of oxygen. The early warning system that gas detectors provide can ensure staff are able to evacuate an area before toxic gas levels reach a level where they cause harm. This is especially important for staff who are working in confined spaces.


How are gas levels monitored?

There are several methods used to detect the presence of different gases:

  • Electrochemical detectors are most commonly used for the detection of toxic gases such as carbon monoxide, chlorine, and nitrogen oxide.
  • Metal Oxide semiconductors are also used for detecting toxic gases (commonly carbon monoxide).
  • Catalytic sensors are used to detect combustible gases such as hydrocarbon.
  • Infrared sensors detect combustible gases, specifically hydrocarbon vapours.

EAS will provide advice on the right sensor for your company’s needs and provide a certified design and installation service. All gas monitors installed by EAS are tested and calibrated using current standards and testing equipment to ensure they operate when you need them.


Ongoing maintenance

EAS will work with you to design an inspection, testing and calibration schedule suited to your company’s specific Gas Detection requirements, whether it be monthly, six monthly or annually. We can also programme a friendly reminder into our job management software to remind you when your next calibration/maintenance is due.

We will also provide you with an asset register and documentation to back up our testing to ensure your company remains compliant with health and safety standards.

EAS are experienced in the installation, inspection, maintenance, testing and calibration of gas monitoring devices. We ensure we keep up-to-date with the latest standards and equipment available to meet your needs.

If you would like advice or servicing for your gas monitoring solutions, get in touch with the EAS team today on 834 0505.