Scalable pH Sensors: Manufacturing, Performance, and Real-Time Calibration

Introduction
pH monitoring is critical in industries ranging from biotechnology to environmental science. At Zimmer & People (ZP), we’ve developed a highly scalable, cost-effective pH sensor technology that balances precision with manufacturability. In this post, I’ll walk you through our sensor design, share performance data over 16 hours, and explain how real-time calibration optimizes accuracy.

A Sheet of Sensors: Scalable Manufacturing

One of our key innovations is mass-producing pH sensors on sheets—like the one I’m holding here. This approach allows us to manufacture sensors at scale while maintaining consistency. Each sensor can be individually removed and deployed, making it ideal for both small-scale prototyping and large-volume applications.

Why This Matters:

• Cost-Effective: Eliminates complex assembly processes.

• Flexible: Cut or deploy sensors as needed.

• Proven: Already tested in multi-hour continuous monitoring scenarios.

Performance Over Time: 16 Hours of Data

We tested our pH sensors over 62,000 seconds (~16 hours), tracking voltage (mV) and converting it to pH values. Here’s what we observed:

Key Findings:

1. Initial Drift:

   • Without calibration, the sensor drifted from pH 7.0 to ~7.8 over 16 hours.

   • Most drift occurred in the first 3,000 seconds (~50 minutes), followed by stabilization.

2. Calibration Resets Accuracy:

   • By introducing calibration points at 1,000s, 8,000s, and later intervals, we reset the drift each time, bringing readings back to pH 7.0.

   • After ~8,000 seconds, the sensor reached equilibrium, requiring no further calibration for the remaining 8 hours.

3. Final Stability:

   • Post-equilibrium, the pH varied only between 6.97 and 7.11—a tight range for most applications.

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Example: Calibration resets (red arrows) counteract drift, stabilizing readings.

Remote Calibration with Julie Real-Time

For advanced users, our Julie Real-Time system enables:

• Remote data analysis and calibration adjustments.

• Dynamic recalibration without physical intervention.

• Custom TRL Support: We can guide your project from proof-of-concept (TRL 3) to full deployment (TRL 9).

How to Access ZP pH Sensors

1. For Independent Use:

   • Purchase ready-made sensors from our web store.

   • Includes datasheets with performance specs (e.g., testing at pH 2–10).

2. For Custom Development:

   • Engage our contract R&D team to tailor sensors for your application (e.g., tighter drift control, longer durations).

Conclusion: Precision at Scale

Our pH sensor technology offers a rare combination of affordability, scalability, and adaptability. Whether you need off-the-shelf sensors or a fully customized solution, ZP’s stack—from manufacturing to real-time calibration—can meet your needs.