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Low Cost Temperature Sensor Design

Low Cost Temperature Sensor Design

Sensor buyers always need great value for money. This can mean high specification units built to last, or simply low cost temperature sensor assemblies.

Simple Thermal Probe
Low Cost Temperature Sensor Design from Peak Sensors

The simplest probe arrangement comprises a sensing element, such as a Pt 100 or thermistor. This is extended with cable to a termination requirement. The sensor as well as the cable to sensor connection are within a metal (usually stainless steel) closed one end tube. The probe is complete.

The cost components can be broken down to:

Sensing element

Thin film Pt 100 elements are cheaper than wire wound sensors. Wire wound will always be slightly more accurate over a wider thermal span but for most applications this is trivial.

Nominal accuracy costs. Pt 100’s are available as a standard F0.3 in BS EN 60751:2008 (which approximates to the old but familiar Class B) F0.15 or F0.1 increase the cost. The new standard has an even wider F0.6 definition which will be cheaper still

Thermistors are similarly price banded by tolerance. The tolerances are significantly wider than for resistance thermometers. Thermistors are cheaper than Pt 100’s but the lack of standardisation can be an asset (to deter copies) or a problem if the sensor element becomes obsolete.


The extension cable can often be the dominant cost element in higher temperature assemblies. Cables made from PVC are very inexpensive, but have a temperature range limited to 70 or 105 °C depending on the PVC specification. Above that PTFE, FEP, PFA are available but may cost 5 times more than PVC. Adding shielding or braid increases cost further.


Thermistors, resistance thermometers and cables must fit into the closed one end protection tube. Around Ø 6.0mm is often practical. This tube is inexpensive, even in 316SS. Brass is occasionally used if the housing needs to be a specific machined shape. The housing is usually filled with a suitable filler like epoxy. Occasionally we sell even cheaper units without hot end enclosures.


The cheapest assemblies come in volume. Peak Sensors can utilise numerous automatic processes to reduce labour time. We have auto cable dereelers, cutters, strippers and welders.

Extra Processes

Subsequent operations can include calibration, physical integrity tests, cold end plugs, serial marking or a range of other actions. If they are needed for the application then there is no choice. To maintain a low cost temperature sensor, specifiers must understand the cost components.

Whatever your requirement, Peak Sensors would like the opportunity to quote to supply your sensors. Please contact us and we will be pleased to be of service

Custom Built Temperature Sensor

Custom Built Temperature Sensor

The vast majority of contact temperature sensors have to be fully immersed in the specific process to be monitored. Careful consideration should always be given to factors which can effect the sensors performance including:

  • Application temperatures
  • Pressure constraint
  • Process medium
  • Signal connection

This creates a high demand for custom built temperature sensor designs, we have been proud producers of custom temperature sensors since 1997.


Our temperature sensor designs are “custom made” to your requirements

We Have The Experience

The team of engineering experts here at Peak Sensors have built up an extensive knowledge of temperature solutions through experience over the years. Although there are a number of common design themes,  most of the products we supply are custom built temperature sensors, unique to each and every customer.

Our core focus on custom built temperature sensors allows us flexibility to respond to new requirements. It also allows us to offer quick delivery as standard.

The potential range of sensor designs is huge. Peak Sensors therefore welcomes new customers from any industry to talk to us and together identify optimal solutions.

We Have The Quality

By using the experience we have gained over our many years in manufacturing, our team is able to produce high quality produced to your exact requirements. If you need a bespoke temperature sensor, then we are the trusted team of professionals to call. Our product quality is proven through our level of customer retention and positive customer feedback which we receive a lot of over the course of a year.

Call Us Today

For your custom built temperature sensor requirement, please contact the sales team at Peak Sensors Limited on 01246 261999.

Industries that we often work with include:

  • Glass
  • Chemical and Petrochemical
  • Automotive
  • Steel
  • Foundry
  • Heat Treatment
  • Aerospace
  • Cement
  • Metal Processing
  • Mineral Processing
  • Solar Energy
  • Laboratory equipment manufacturing
  • Water treatment
  • Aluminium processing
  • Furnace manufacturers
  • Marine
  • Compost

Actually the list is virtually endless as temperature sensors can be used across a wide range of industries.