Fox Thermal Blog

Industries Relying on Flow Monitoring: Finding New Efficiencies

Across a spectrum of sectors, precise flow monitoring has become essential for uncovering new efficiencies and optimizing complex operations. From advanced manufacturing environments to research laboratories, industries depend on accurate flow measurement to maintain product quality, streamline processes, and ensure safety. Modern flow technologies empower businesses to achieve greater reliability and innovation in applications where precision truly matters. Here are a few examples of industrial applications of flow monitoring for efficiency improvements.

Cleanrooms & Semiconductor Manufacturing

Thermal mass flow meters are well-suited for applications like bulk air flow monitoring and fuel gas measurement, delivering accurate readings for gases supplied to industrial equipment. Their ability to handle variable gas compositions and provide reliable performance with no moving parts makes them ideal for monitoring compressed air and process gases that power manufacturing tools and equipment.

Vortex shedding flow meters excel in monitoring steam and water used for process heating, cooling, and cleaning operations. Their robust design enables stable performance even with fluctuating flow rates, making them a dependable choice for applications like boiler feedwater, steam distribution, or other liquid handling tasks central to facility operations.

Fox Thermal flow meters, known for their digital outputs and NIST-traceable calibration, help facilities achieve greater efficiency and control in a range of industrial processes, from managing energy use to optimizing equipment performance.

Challenges include:

• Wafer defects from gas fluctuations
• Inconsistent layer deposition
• Contamination control
• Etching from non-uniform flow

Biogas & Waste-to-Energy Facilities

Monitoring flow rate in biogas reclamation facilities is essential because it ensures optimal energy recovery, helps maintain system efficiency, and enables accurate measurement for regulatory compliance and process control. By tracking the flow of biogas, operators can maximize resource utilization, prevent potential losses, and enhance both environmental and operational performance.

Thermal mass flow meters handle air flow, pure gases, mixed gases, and variable compositions well, making them the go-to for aeration and biogas at these facilities.
Vortex meters can be used in steam recovery systems or liquid waste processing, where flow stability and robustness are key.

Challenges include:

• Variable gas mixtures
• Moisture and particulate content
• Compliance with environmental regulations

Thermal mass and vortex shedding flow meters offer reliable readings when it matters most.

Pharmaceutical & Chemical Processing

In the pharmaceutical industry, accurate flow monitoring directly impacts the quality and safety of high-value products. Precise control over gas and liquid flows ensures that critical processes—such as mixing, pill coating, and sterilization—meet stringent regulatory standards while maintaining sterile environments. By implementing advanced flow measurement technologies, companies not only safeguard product integrity but also optimize operational efficiency and demonstrate their commitment to delivering consistent, top-quality pharmaceuticals to the market.

Consequently, chemical processing also necessitates accuracy. Accurate flow measurement enables efficient use of raw materials and energy. By monitoring and adjusting flows in real-time, plants can reduce excess consumption, optimize resource use, and avoid unnecessary spending on utilities and inputs. Additionally, flow meters can detect leaks in piping and systems, which helps prevent costly losses and energy waste.

Thermal mass flow meters help to monitor combustion fuel gas flow in burners and furnaces.
Vortex shedding meters are excellent for liquid chemical flows and steam sterilization systems, offering durability and consistent performance under high pressure and temperature.

In pharma and chemical plants, flow monitoring is critical for:

• Gas blanketing
• Sterilizing
• Purging and inerting

Flow meters provide the repeatability and reliability needed for efficient systems and product quality.

Food & Beverage Industry

From carbonation in soft drinks to modified atmosphere packaging (MAP) for perishables, gas flow plays a key role in food production. Carbon dioxide (CO₂), nitrogen (N₂), and oxygen (O₂) must be delivered in exact quantities.

Thermal mass flow meters are used for CO₂ injection, nitrogen flushing, and other gas-based processes.
Vortex meters are commonly applied in steam cooking, pasteurization, and liquid ingredient batching, where their ability to handle varying flow rates and temperatures is beneficial.

Benefits of flow meters here include:

• Compact design for tight spaces
• Easy integration with SCADA and PLCs
• Low maintenance in hygienic environments

Aerospace & Research Labs

In aerospace testing and scientific research, gas flow monitoring supports everything from propulsion experiments to climate simulations.

Thermal mass flow meters are preferred for precise gas flow measurement in propulsion and simulation experiments.
Vortex shedding meters may be used in cooling systems, fuel flow monitoring, or steam-based testing environments, where ruggedness and versatility are required.

These applications demand:

• Extreme precision
• Wide flow range
• Data logging and remote monitoring

Fox Thermal’s advanced diagnostics and Modbus capabilities make them a trusted choice in these cutting-edge fields.

Recommended Fox Thermal Products by Industry

To help you match the right technology to your application, here’s a quick guide to Fox Thermal’s most suitable products for each industry:

Ready to find the perfect flow meter solution for your application? Connect with a Fox Thermal expert today!

Frequently Asked Questions (FAQ)

Q: What are the main benefits of thermal mass flow meters in low-flow applications?

A: Thermal mass flow meters are highly sensitive to low flow rates, making them ideal for semiconductor manufacturing and other lab environments. They provide direct mass flow measurement without needing pressure or temperature compensation.

Q: Are vortex meters suitable for food and beverage applications?

A: Vortex meters can be used in steam and water flow applications within food processing.  For gas flow (e.g., CO₂ in carbonation), thermal mass flow meters are preferred.

Q: Can vortex shedding meters be used in aerospace testing?

A: Vortex meters are robust and can handle high-pressure environments, but for precise gas flow measurement and data logging in aerospace labs, thermal mass flow meters like the FT4X provide low-flow accuracy and flexibility in features.

Q: How do vortex shedding flow meters perform in steam applications?

A: Vortex meters are highly effective in steam flow measurement due to their ability to withstand high temperatures and pressures, making them ideal for sterilization and cooking processes.

Q: Can vortex meters measure gas flow?

A: Yes, but they are typically used for higher pressures, higher velocities, and clean gas flows. They are less suitable for low-pressure, low-flow, or mixed-gas applications, where thermal mass flow meters perform better.

Q: What makes vortex meters ideal for liquid flow?

A: Vortex shedding meters are robust, require minimal maintenance, and provide accurate flow readings for clean liquids in industrial processes.