THE CHALLENGE
A leading pharmaceutical manufacturer operating under Schedule M (GMP) guidelines was struggling with inexplicable spikes in compressor run-hours. Existing differential-pressure-based flow indicators were installed only at the main header, leaving individual production zones — tablet compression, coating, and granulation — completely unmonitored. Compressed air was being consumed well above engineering estimates, yet the source of the excess draw could not be pinpointed.
THE SOLUTION
Zone-Level Monitoring with Insertion Thermal Mass Flow Meters LEOMI-586 Insertion Thermal Mass Flow Meters were installed at seven sub-branch points across the distribution network without shutting down the facility, owing to the hot-tap insertion capability. Each meter measured actual mass flow directly — no temperature or pressure compensation required. A digital output (Modbus RS-485) fed directly into the plant's existing SCADA system, enabling zone-by- zone reconciliation of consumed versus supplied air.
Within 72 hours of commissioning, two zones showed persistent night-shift consumption despite no scheduled production — confirming leakage in the distribution piping behind a false ceiling. Leak repairs were prioritised and completed within the next planned maintenance window.
◆ Product Used: LEOMI-586 Insertion Thermal Mass Flow Meter
