Food Processing Gas Detection Solutions: Nexisense SGA Series Application Practices

The food processing chain, from raw material washing and sterilization to refrigeration, storage, packaging, and bleaching, relies on specific gas media to maintain quality and efficiency. Chlorine dioxide (ClO₂) and ozone (O₃) are used for surface sterilization, liquid nitrogen (LN₂) and liquid ammonia (NH₃) support cold chain logistics, while hydrogen peroxide (H₂O₂) and sulfur dioxide (SO₂) assist in preservation and bleaching. While these gases enhance processing efficiency, they also pose risks: NH₃ leaks can cause respiratory burns, SO₂ overexposure can trigger allergic reactions, and abnormal ClO₂/O₃ concentrations can be explosive or corrosive to equipment. GB 14881 and GB 2760 standards require strict residual control, and GBZ 2.1 sets occupational exposure limits. Recent poisoning incidents highlight monitoring gaps, making 24-hour online detection and inspections a safety cornerstone.

The Nexisense SGA-500 series online gas detectors use imported electrochemical/infrared sensors with secondary calibration, achieving ±5%FS accuracy and T90 response<15 1="" seconds.="" full-range="" temperature="" and="" humidity="" compensation="" ensures="" stable="" operation="" in="" humid="" processing="" ip65="" suitable="" for="" zone="" hazardous="" areas.="" they="" power="" on="" automatically="" alarm="" when="" thresholds="" are="" support="" relay="" linkage="" with="" valves.="" the="" sga-600="" portable="" series="" features="" industrial-grade="" compact="" size="" one-hand="" sampling="" probe="">10-hour battery life, real-time display with audible/visual alarms. Combined with the SGA-800 alarm controller, multi-point centralized management, data storage/printing, and area linkage are possible. 

As a full-chain gas detection supplier, Nexisense offers 1000+ custom options, covering modules to complete systems. This article analyzes processing risks, selection, integration, and case studies for practical reference for food companies and engineering integrators.

Food Processing Gas Risks and Monitoring Scenarios

Food processing gas risks mainly arise from sterilization and refrigeration steps. NH₃ refrigerant system leaks (0-100ppm threshold) can cause poisoning; SO₂ overuse in bleaching (0-5ppm) contaminates products; ClO₂/O₃ sterilization (0-0.1ppm) fluctuations can be explosive or leave residues; LN₂ liquefaction risks O₂ enrichment and hypoxia in cold zones. Humid and dusty environments exacerbate diffusion, and traditional manual detection is slow.

The SGA-500 series is deployed at exhaust outlets of cold rooms or sterilization tunnels to track NH₃/SO₂/ClO₂ in real time, supporting 0-100ppm ranges. The SGA-600 portable units are used for inspecting tanks/pipelines, with pump mode quickly pinpointing leak sources.

Example: A South China meat plant integrated SGA-500 NH₃ monitoring into the refrigeration room connected to PLC; excess triggered ventilation, reducing incidents by 70%, complying with GB 5009.60 ammonia residue standards. A beverage company used SGA-600 O₃ inspections; sterilization line peak values stayed within thresholds, increasing product pass rate by 15%.

Gas Detection Product Selection Guide

Selection must balance gas type, sampling method, and environment. SGA-500 fixed online detectors are preferred for sterilization/refrigeration areas: diffusion mode for open spaces, pump mode for enclosed tanks; NH₃/SO₂ use electrochemical sensors (0-100ppm, OSHA PEL 10ppm threshold), ClO₂/O₃ use specialized electrochemical sensors (0-0.1ppm). SGA-600 portable is suitable for inspection; probe mode reaches 2m pipelines, with built-in data storage and CSV export.

Environmental matching: corrosion-resistant probes for humid workshops; heating compensation for low-temperature zones. Nexisense sensors are NIST-traceable, zero drift <±1%FS/month, lifespan 2-5 years. Cost: online $800-1200/unit, portable $400-600/unit. ROI: safety loss reduction + compliance fine avoidance, payback 12-18 months.

System Integration Considerations

Integration emphasizes compatibility and response. SGA-500 supports Modbus RTU (9600bps), 4-20mA (<500Ω), RS-485 bus, connecting to Omron PLC or MES. SGA-600 supports USB export and LabVIEW analysis.

Linkage: dry contact relays (30VDC/2A) drive valves/sprays, dual-threshold +5%FS hysteresis. Power 24VDC (ripple<100mV), SGA-800 controller centralizes multi-point supply. Wiring: AWG 22 shielded <1200m, with isolation for loop protection.

Software tools support batch parameter deployment, OPC UA trend export. FAT/SAT include EMC and stability testing, uptime >99%. These measures enable closed-loop control in 10-15 days.

OEM Customization and Bulk Supply Advantages

Nexisense specializes in B2B OEM full chain. SGA-500/SGA-600 can customize range/sampling/protocol, MOQ 50 units, delivery 4 weeks. Gas combinations and thresholds are parameterized. Bulk >500 units get tiered discounts, annual production ample, FOB Shenzhen, with ATEX/IECEx certification.

Example: Central China dairy plant OEM SGA-500 SO₂+NH₃ combo integrated into refrigeration line for efficient food safety traceability.

Project Application Cases

Guangdong seafood processing plant SGA-500 ClO₂/O₃ monitoring + ventilation linkage, sterilization residues<0.02mg/kg, export compliant.

Jiangsu canned food company SGA-600 SO₂ inspections + data export, bleaching process peaks controlled, quality complaints zero.

Zhejiang cold chain logistics center multi-zone SGA-500 NH₃ network, MES predicts leaks, operating costs reduced 18%.

These cases demonstrate fast integration and stable precision, verifying Nexisense applicability for food processing.

Frequently Asked Questions

1. Which gases does Nexisense SGA series monitor in food processing?
Key gases include sterilization gases (ClO₂ 0-0.1ppm, O₃ 0-0.1ppm), refrigerants (NH₃ 0-100ppm, LN₂ related O₂ 0-25%VOL), bleaching/preservation gases (SO₂ 0-5ppm, H₂O₂ 0-10ppm), and potential flammable gases (ethanol vapor 0-100%LEL). Single or multi-channel configurations are available depending on process: meat/seafood prioritize NH₃+ClO₂, beverages/vegetables SO₂+O₃, dairy O₂/NH₃. Cross-interference assessment ensures accuracy in humid, dusty, oily environments, complying with GB 2760 and GBZ 2.1.

2. How to choose diffusion vs pump sampling in cold rooms or sterilization tunnels?
Diffusion for open cold rooms or tunnels, real-time response, easy maintenance, suitable for wide-area NH₃/O₃ monitoring. Pump recommended for closed tanks/pipes, actively draws gas, avoiding blind spots and adsorption loss. Nexisense CFD modeling based on 3D layout and airflow recommends sampling points, tube length<5m to control response delay. Pump mode reduces NH₃ leak response to <10s.

3. How is sensor accuracy and stability ensured in humid, dusty, oily workshops?
Built-in temperature/humidity compensation (polynomial + real-time adjustment), 0-95%RH, -10°C to 40°C, zero drift <±1%FS/month, full-scale drift <±2%FS/year. Probe with 316L stainless + PTFE filter, resistant to acid, alkali, oil. Replaceable prefilters recommended. Quarterly calibration with nitrogen zero + standard gas ensures compliance with GB 5009. Sensor life: electrochemical 2-3y, IR/catalytic 3-5y. Health diagnostics monitor baseline, sensitivity, noise; alerts below 80% via Modbus for proactive replacement.

4. SGA-600 portable output options & SGA-500 integration?
SGA-600: USB TTL/RS485 Modbus RTU, 4-20mA, CSV export. SGA-500: 4-20mA (<500Ω), RS485 Modbus RTU, relay contacts. RS485 use AWG22 shielded twisted, max 1200m, terminal resistors; 4-20mA isolate loops. Standard Modbus mapping, batch deployment, firmware upgrade. OPC UA/RESTful API for trend analysis and batch correlation; integration 1-2 weeks.

5. How to reduce cross-interference and false alarms?
Electrochemical sensors with filter layers and compensation: NH₃ module vs SO₂<5%, ClO₂ vs O₃ <3%; PID for VOCs, non-target interference <8%. Cross-testing with reports. Threshold programming: high-low dual alarm +5%FS hysteresis, SGA-800 area management reduces false alarms. Food processing false alarms <1/month.

6. How to integrate with MES/ERP for data traceability?
RS485 Modbus RTU or 4-20mA to PLC/gateway; Modbus TCP/OPC UA server for real-time collection, trends, alarms, batch correlation. Tools for threshold modification, SMS/WeChat push, CSV/Excel export. Integration: protocol mapping → communication test → linkage → SAT. Isolation for RS485; repeaters for long lines. Cloud/local visualization enables batch-level gas residue traceability, audits.

7. Bulk procurement: certifications, lead time, logistics?
Each device includes ATEX/IECEx, CNEx, CE/RoHS, NIST-traceable calibration. MOQ flexible (SGA-600 50 units), standard customization 4 weeks; deep firmware/hardware dev 6-8 weeks. Bulk >500 tiered pricing. FOB Shenzhen, also EXW/DDP, global shipping, batch serials and packing lists provided. Local supply >80%.

8. Maintenance cycle, sensor lifespan, predictive maintenance?
First month: monthly zero/range calibration; quarterly after stable. Sensor life: electrochemical 2-3y, IR/catalytic 3-5y. Health diagnostics monitor baseline, sensitivity, noise; alerts<80% via Modbus/SGA-800. Proactive replacement reduces unplanned maintenance ~40%, provides full audit logs.

Conclusion

Nexisense SGA series, with accuracy, stability, and flexible linkage, offers full-chain gas safety solutions from online to inspection for food processing. It protects personnel, ensures product compliance, and maintains operational continuity, meeting GB 14881 standards. IoT enhancements will further improve predictive capability. Food companies and engineering teams are invited to contact Nexisense for POC and custom support.