Overcoming sensor drift in extreme temperature measurement conditions

In industrial environments where precision is non-negotiable, the effects of extreme temperatures on sensor performance can be a critical risk. Sensor drift, particularly under extreme thermal conditions, poses a significant threat to measurement accuracy, potentially undermining product quality and compliance.

Fortunately, this challenge can be met head-on through rigorous and consistent calibration practices. Businesses need to be aware of how they can maintain measurement reliability in harsh environments by mitigating the impact of sensor drift.

What is sensor drift?

Sensor drift refers to the gradual change in a sensor’s output signal without a corresponding change in the input. In simpler terms, the sensor starts reporting inaccurate readings even though the measured condition hasn't changed.

Temperature sensors like thermocouples, RTDs and thermistors are particularly susceptible. In environments where instruments are exposed to extremes, such as cryogenic cold or high heat, thermal stress can cause physical and electrical changes in the sensor components. These changes may be subtle at first but can compound over time, resulting in measurement inaccuracies that compromise entire processes.

Why extreme temperatures can accelerate drift

Extreme temperature conditions can impact sensors in several ways.

Material degradation: Metals and alloys in sensor elements may expand, contract, or oxidise, affecting signal transmission.
Thermal cycling: Repeated exposure to fluctuating high and low temperatures causes microstructural changes in materials.
Insulation breakdown: Electrical insulation can degrade in high-heat environments, leading to increased noise and reduced accuracy.
Mechanical stress: Prolonged thermal exposure can deform sensor housing or displace components, altering calibration settings.

In applications such as food processing, pharmaceuticals, aerospace and high-heat industrial manufacturing, these effects can quickly lead to non-compliance and/or safety risks.

Regular on-site temperature calibration as a solution

The most effective countermeasure to sensor drift is a structured calibration programme, ideally one that includes on-site calibration. On-site calibration ensures regular verification of accuracy and also validates sensor performance within the actual environmental context in which it operates.

On top of this, UKAS-accredited mobile calibration services bring laboratory-grade precision directly to your facility. Whether you're dealing with cryogenic freezers or high-temperature furnaces, expert technicians calibrate your sensors in-situ using traceable standards, ensuring accuracy where it matters most. This also provides additional benefits.

Minimal downtime: Calibration is performed without removing sensors from their installed position, keeping your operations running smoothly.
Environmental fidelity: Calibration occurs under real operating conditions, accounting for the exact thermal stresses and environmental variables that affect your measurements.
Compliance assurance: Temperature calibration services are performed to ISO and UKAS-accredited standards, giving you confidence in compliance and audit-readiness.

Additional tips to combat sensor drift

Increase calibration frequency in extreme environments, quarterly or even monthly checks may be warranted depending on usage and criticality.
Log historical calibration data to identify drift trends and proactively replace sensors before they compromise process outcomes.
Utilise high-stability reference instruments that are themselves regularly calibrated to UKAS standards.
Train maintenance teams to spot early signs of drift and carry out basic in-field verification.

Keep accuracy on track in harsh conditions

Sensor drift is an unavoidable reality in extreme temperature environments but it doesn't have to disrupt your operations. With consistent, high-quality calibration, especially through on-site services, you can ensure your temperature measurement systems remain precise, compliant and reliable.

At DM Systems & Test, we’re committed to helping businesses overcome the environmental challenges that affect measurement accuracy. Our mobile calibration service offers a responsive, tailored solution for organisations operating at the edge of what’s possible where measurement accuracy is essential.

Download our guide below to learn more about the value of our UKAS accredited and traceable calibration services.