Merit Sensor AP Series in Pharmaceutical and Medical Applications

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In the field of medical science, pressure is an indispensable physiological parameter. In a range of environments and applications involving both liquids and gases, precise measurement is essential for diagnostic accuracy and therapeutic efficacy.1 Merit Sensor Systems, a leader in MEMS piezoresistive pressure sensing, provides high-performing solutions for a range of industries.2 Among their innovative products, the AP Series pressure sensors are specially designed for pharmaceutical and medical applications.

In this article, we examine two configurations of the AP Series pressure sensor:

  1. AP-Series with polycarb port, or ferrule port for direct backside media contact
  2. AP-Series with gel-port plus dielectric gel for enhanced media biocompatibility

This is followed by an exploration into their application in various medical and pharmaceutical processes, including the integration of these sensors in Merit Medical’s Blue Diamond™ Digital Inflation Device.

The AP-Series: Examining the Sensor’s Dual Configurations

Utilizing a piezoresistive Wheatstone bridge with a chemically etched silicon diaphragm, both configurations of the AP-Series pressure sensor are engineered to provide precise pressure measurements in both static and dynamic environments.3 Each sensor, capable of measuring both liquids and gases, ensures cost-effectiveness without compromising on functionality.

 

Key Features

  • Wide Pressure Range: The AP-Series sensors cover several apressure ranges from 0 to 1000 psi (0 to 70 bar) accommodating a variety of medical and pharmaceutical applications, from vacuum aspiration applications, to low pressure blood pressure, up to high pressure injection and pump control applications. 4
  • High Accuracy: The sensors offer a trimmed output signal with minimal offset for easy amplification with an operational amplifier. This is achieved by calibrating the sensors using laser-trimmed resistors.4
  • Robustness: Designed to withstand high burst pressures, these sensors are reliable even in challenging environments. Their compact geometry and durability make them suitable for integration into a multitude of medical devices. The design is suitable for single-use disposable applications, as well as long term applications.
  • Sterilization Compatibility: These sensors are compatible with sterilization processes, including ETO, Gamma-ray, and autoclave, ensuring they meet the rigorous standards required in medical applications.
  • Easy Integration: With options for flexible or cable interfaces, the AP-Series sensors can be seamlessly integrated into existing systems.
  • High Resolution and Frequency: These sensors deliver a pure analog signal to allow exceptional performance in high-resolution and high-frequency applications.3
  • Reliable Through Backside: Both configurations ensure that the active side of the sensing element (wirebonds and conductor traces) remains protected from direct contact with the media, enhancing the sensor’s longevity and reliability.

Applications

The AP-Series sensors, which have a polycarb and ferrule port as well as direct media contact on the backside, are suited for measuring liquid and gas pressure and flow in medical and pharmaceutical equipment. Typical applications include:

  • Mixing Machines: Guaranteeing accurate pressure control during the mixing of pharmaceuticals.
  • Analysis Machines: Precise pressure monitoring in laboratory equipment for fluid analysis.
  • Fluid Treatment and Processing: This is used in systems that require precise pressure regulation to ensure the integrity of the fluid being processed.
  • Aseptic Liquid Processing: Key when it comes to maintaining sterility and preventing contamination during the production of pharmaceuticals.

The AP-Series pressure sensors feature enhanced media compatibility with gel-port and dielectric gel, reducing wetted materials and making them ideal for challenging environments in pharmaceutical and medical applications, including:

  • Bio-Decontamination Equipment: Monitoring pressure in systems that are created to sterilize equipment and facilities.
  • Bioreactor Monitoring, Chromatography, and Flow Filtration: Ensuring reliable pressure measurements in critical biocompatibility processes.
  • Laboratory Equipment: Providing precise pressure data in equipment used for sophisticated chemical analyses and experiments.

Integration in the Blue Diamond™ Digital Inflation Device

A notable application of the AP-Series pressure sensors is in Merit Medical’s Blue Diamond™ Digital Inflation Device and Fluid Dispensing Syringe. This device is designed to inflate and deflate balloon angioplasty catheters and other interventional devices. It can also be used to accurately measure the pressure and duration of inflation while simultaneously dispensing fluids into the body and monitoring pressure levels.5

Features of the Blue Diamond™ Digital Inflation Device

  • Integral Pressure Transducer: The AP-Series sensors integrated into this device provide exact pressure measurements essential for the safe and effective performance of angioplasty procedures.5
  • Microcomputer and Back-Lit LCD: These features facilitate precise control and easy monitoring of the inflation process in low and no-light situations.5,6
  • Threaded Plunger Assembly and High-Pressure Extension Tube: Combined with Merit Sensor’s robust pressure sensors, these components ensure the device can generate and monitor positive and negative pressures over a range of -0.4 to +30 ATM/BAR (-6 to 441 psi).5
  • Data Recording and Recall: This feature of the syringe electronics allows users to record and recall prior inflation information, making it ideal for procedure data tracking.7

Merit Sensor Systems: Pharmaceutical and Medical Solutions You Can Trust

Merit Sensor Systems’ AP Series pressure sensors are a top-tier option for a diverse suite of pharmaceutical and medical applications. The two configurations—gel-port with direct backside media contact and gel-port with dielectric gel—offer versatility and enhanced media compatibility while guaranteeing precision, robustness, and cost-effectiveness. Moreover, their compliance with stringent medical standards and integration into critical devices, such as Merit Medical’s Blue Diamond™ Digital Inflation Device, highlight their reliability and adaptability in demanding medical environments. To find out more about how these devices can be integrated into your workflow, contact a member of the Merit Sensor System’s team today.

References and Further Reading

    1. Casey, V., et al. (2011). Pressure Measurement at Biomedical Interfaces. Applied Biomedical Engineering. doi.org/10.5772/21855
    2. Merit Sensors. [Online] Applications. Available at: https://meritsensor.com/ (Accessed on 26 May 2024).
    3. Merit Sensor. Data Sheet: AP Series. Available at: https://meritsensor.com/assets/documents/pdf/AP-series.pdf (Accessed on 26 May 2024).
    4. Merit Sensor. [Online] AP Series. Available at: https://meritsensor.com/products/AP-Series/ (Accessed on 26 May 2024).
    5. Merit Medical. Blue Diamond™ Digital Inflation Device. Available at: https://cloud.merit.com/catalog/IFUs/407737001.pdf (Accessed on 02 July 2024).
    6. Merit Medical. [Online] Blue Diamond™ Digital Inflation Device. Available at: https://www.merit.com/product/blue-diamond-inflation-device/#documents_education (Accessed on 2 July 2024).
    7. Merit Medical. A Global Leader in Inflation. Available at: https://cloud.merit.com/catalog/Brochures/400899001.pdf (Accessed on 2 July 2024).

The Instrumental Role of MEMS Pressure Sensors in Water Conservation

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In this interview, AZoSensors speaks to Merit Sensor’s Rick E. Russell about the critical role MEMS pressure sensors will play in water conservation efforts.

Could you describe the role of water in the MEMS pressure sensor manufacturing process and the key reasons behind implementing a water-conservation initiative?

Deionized water is the main ingredient for wafer fabrication processing and is similarly the largest waste product that we have to deal with. We have been prioritizing the sustainability of our operations for a number of years, and both reducing water usage and minimizing water waste have been central to this initiative.

This work also links into our wider organizational goals around sustainability. We believe that as a global leader in healthcare technology, Merit Medical has a major role to play in contributing to a sustainable future. Improving our organization’s sustainability is also key to the success of our overall business strategy.

In what ways does the water-recycling program address the challenges associated with wastewater treatment and disposal during the sensor fabrication process?

Many of our sites are based in desert environments where available water is at a premium, so we strive to conserve as much water as possible.

Our waste naturalization system already balances the wastewater’s pH before we send it down the drain, so we thought it would be worth the investment to see if we could recycle this water instead.

Can you walk us through the steps involved in recycling and reusing wastewater to produce MEMS pressure sensors?

We utilized the Water Risk Filter tool provided in collaboration between the World Wildlife Fund for Nature (WWF) and KFW DEG, and this helped us to understand basin water risk at our operating locations.

Since then, we have identified three manufacturing locations (Tijuana, Mexico; Salt Lake City, Utah; and Pearland, Texas) as water-stressed sites and invested capital over the past three years at these drought-vulnerable operations to allow us to better conserve and store water.

To recycle and reuse wastewater, we essentially pass it through additional filtration cycles and add chemicals to strip away any unnecessary contaminants.

In 2022, we implemented two successful projects of this nature at our Salt Lake City site: a cooling-water recirculation project and a process-water recirculation project within our sensor operations. We are also working on a similar project at our facility in Tijuana, Mexico, which is our second largest site for water consumption and another where a risk of water scarcity has been identified.

Considering the involvement of acids and bases in manufacturing, what measures have been implemented to treat and neutralize wastewater before discharge?

Our waste neutralization system continuously monitors the pH of the contaminated water and balances the pH with the necessary acid or base before discharging the water down the drain.

How does Merit Sensor’s water-saving initiative align with the broader regional efforts to mitigate water usage?

As reported by our CEO in our 2023 Sustainability Report, Merit completed its third year of progress toward our 2030 Operational Sustainability Goals, and we are seeing more evidence of momentum as we consistently reach and surpass each of our targets for energy, water, and greenhouse gas emissions.

Efforts to mitigate water use vary between regions. Water is one of our main environmental challenges and opportunities, so we have worked to better understand the impact of water use at each of our operating facilities and to implement water efficiency programs on a regional level.

These goals and initiatives are addressed at the individual site level, and we can do this by understanding the local and regional water basin activity and stress.

Achieving a ninety percent water recycling efficiency is an ambitious goal. What innovative approaches or technologies are Merit Sensors exploring to reach this objective?

As pointed out in our 2023 Sustainability report, we have other ongoing projects, such as closed-loop water cooling and xeriscaping, that will help us reach our goal. The water recirculation project will also be instrumental in our success in this area.

We have already seen a 17 % decrease in water withdrawal per dollar of revenue earned since 2020, already surpassing our global 2030 targets. This water intensity improvement was primarily driven by water-reduction and efficiency projects, including the use of xeriscaping and installing water-recirculation systems at our largest site in Salt Lake City, Utah.

Can you share some of the critical lessons your team learned throughout the process and how these experiences have influenced your approach to sustainability in other aspects of the company’s operations?

Merit was initially focused on xeriscaping because it was the most straightforward. We knew that fabrication was the biggest culprit for water consumption, but the cost of water does not provide any payback. We learned very quickly that you must spend money to save water. If water costs more than gasoline, then everyone would be focused on saving water.

Does the water-recycling program offer any other potential environmental benefits besides conserving water?

We at Merit believe that spending money to save water would, in turn, save lives. Water is essential for drinking, farming, firefighting, reservoirs and dams, wildlife, and much more. This is also important because several of our sites are located in regions prone to droughts, and any water saved can potentially be used by local communities or amenities.

How do you envision the long-term impact of this initiative on the company’s operations and its contribution to sustainable manufacturing?

Merit is committed to our long-term goals of maintaining our ISO14001 and ISO50001 certifications. This includes not only water but also energy consumption and emissions.

For example, 50 % of our manufacturing sites (Salt Lake City, Utah; Galway, Ireland; Venlo, the Netherlands; and Paris, France) are certified to ISO 50001, and we continually seek to improve our energy management systems.

By implementing this system in our sensor operations and fine-tuning its performance, we are paving the way for similar solutions at other Merit sites to continue reaping the benefits of using water efficiently.

MEMS pressure sensors find applications in various industries. can you elaborate on the quality control measures to ensure recycled water meets the required standards for diverse applications?

Further testing has proven that recycled water does not affect the quality of our MEMS pressure sensors or the operation of our fab. We currently deliver pressure sensors to monitor the pressure in various water applications, such as water meters and tank levels.

Apart from the current water-recycling project, has Merit Sensor integrated other sustainable practices into its manufacturing process?

Merit is focused on three major sustainability goals: decreasing water intensity by 10 %, decreasing energy intensity by 10 %, and decreasing GHG emissions by 15 % by 2030. We are also working towards increasing the proportion of Merit’s energy from renewable sources to 50 % of total usage.

Increasing our use of renewable and carbon-free energy is a key part of our long-term strategy. We have already committed to purchasing 50 % of our total energy from renewable and carbon-free sources by 2030, and given the large amount of energy required by our operations, we also plan to explore opportunities around installing solar panels and the potential of carbon offset credits.

Wider goals include reducing product packaging, transitioning to paper-free systems where possible, and increasing the percentage of waste at our facilities that is recycled.

About the Speaker

Rick joined Merit Sensor in October of 2009 where he managed worldwide sales and business development until he became President of the group in 2013.  He brings many years of organizational management and technical expertise in the area of MEMS silicon fabrication. With more than 25 years of experience managing sales to product development across multiple industries, his knowledge has enabled him to expand the operations to accommodate a number of new customers in their state-of-the-art wafer fab located in Salt Lake City.

Rick studied mathematics and computer science at Eastern Michigan University and received a Bachelor of Science in Electrical-Engineering from Lawrence Technological University.

This article was published by AZo Network.