echo dyn

Dynisco Echo™
Melt Pressure Sensor

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For many extrusion processes in the plastics and polymer industries, solid measurement accuracy is more than sufficient. The Echo™ Sensor by Dynisco is designed exactly for this purpose: It offers precise, reliable melt pressure measurement – while delivering excellent value for money.

✅ High repeatability of ± 0.2 %
✅ Overall accuracy better than ± 0.5 %
✅ Wide output options: 3.33 mV/V, 4–20 mA, 0–5 VDC or 0–10 VDC
✅ Titanium-Aluminum-Nitride (TiAlN) membrane coating for long-term durability
✅ Optional integrated temperature measurement (Thermocouple Type J/K or RTD)
✅ Pressure ranges from 100 to 1,000 Bar (1.5M–15M psi)
✅ Two-year warranty, a traditional hallmark of performance and value

 

echo echo

The Dynisco Echo™ melt pressure sensor was specifically developed for applications where robust reliability, solid measurement performance, and strong cost-effectiveness are key. This makes the sensor particularly suitable for manufacturers and processors in the plastics industry who want to control their processes efficiently and economically – without compromising on quality.

Typical application areas:

  • Production of plastic profiles, pipes, and films
    In these sectors, consistent melt pressure monitoring is essential for dimensional accuracy and surface quality. The Echo™ provides reliable real-time data to quickly detect any process deviations.

  • Plastic compounding
    When blending, coloring, or modifying base polymers, melt pressure is a sensitive indicator of material changes. The Echo™ enables stable process control and early detection of deviations in material quality.

  • Recycling extrusion
    Recyclates often bring variable material properties. The Echo™ helps identify these fluctuations and allows for immediate process adjustments – without the need for time-consuming lab analysis.

Feature Benefit
TiAlN-coated diaphragm High wear and corrosion resistance
± 0.2 % Repeatability Stable and reproducible measurements
± 0.5 % Total accuracy Precision measurement for process control
Output options Flexible integration into industrial control systems
Temperature option Combines pressure and temperature sensing in one device
Pressure ranges 100–1,000 Bar Suitable for a wide range of applications
2-year warranty Extra assurance for production systems

The Dynisco Echo™ sensor is designed for fast, safe commissioning without requiring special expertise. Both the mechanical and electrical integration are user-friendly and flexible – especially in production environments where time and accessibility are critical factors.

 

Mechanical Connection – Flexible and Compatible

The Echo™ can be easily integrated into existing machine setups thanks to its standardized threaded connections. Depending on your system design, the following options are available:

      • 1/2‑20 UNF thread – widely used in the industry and ideal for replacements

      • M18 × 1.5 or M22 × 1.5 – commonly used in European extrusion lines

      • Flexible or rigid stem length – selectable based on installation position and heat input

The sensors feature a welded design, making them particularly robust and durable. An optional flexible capillary protects the sensitive area between the process connection and electronics from vibrations and thermal stress – ideal for applications requiring frequent cleaning or in confined spaces.

 

Electrical Connection – Versatile & Industrial-Grade

The Echo™ supports various signal outputs, making it compatible with almost all common displays, controllers, and process control systems:

      • mV/V output – supply voltage 10 V DC (max. 12 V)

      • 4–20 mA & VDC versions (0–5 V, 0–10 V etc.) – supply voltage 14–36 V DC

This range of output signals enables flexible integration, whether you're using an analog PLC, a basic pressure display, or a complex control system. Even when retrofitting older machines, Echo™ sensors can be integrated into existing infrastructure with ease.

 

The maximum permissible ambient temperature of the electronics unit is:

      • up to 85 °C for 4–20 mA or VDC outputs

      • up to 120 °C for mV/V versions

This makes the devices well-suited for typical conditions in plastics processing environments.

 

R-Cal™ Calibration Function – Practical and Time-Saving

A highlight of the Echo™ series is the optional R-Cal™ calibration function, which allows the user to easily verify and adjust the sensor – without the need for external reference devices or removal from the system.

How it works:

      • The sensor sends a defined calibration signal of 80% of full scale at the push of a button

      • This enables the connected display or PLC to be checked for deviation and adjusted if necessary

      • Particularly useful for regular maintenance intervals or verification after cleaning

This feature not only saves time but also improves measurement reliability – especially in quality management systems with calibration requirements or ISO-certified processes.

 

 

To ensure that the Dynisco Echo™ melt pressure sensor performs at its best, proper installation and regular monitoring of specific operating parameters are essential. The following recommendations will help you maintain measurement accuracy, service life, and operational safety at a high level – with minimal effort.

 

Preparing the Bore Hole

      • Ensure that the threaded hole is clean, deburred, and free of plastic residue.

      • For thorough cleaning, Dynisco recommends the specially designed Tool P/N 200100, which can also remove stubborn residues effectively.

Optimal Installation Position

      • The sensor should not be mounted directly above a vertical hot channel, as this increases thermal load unnecessarily.

      • A horizontal or diagonal alignment is ideal to minimize thermal influence and potential material buildup.

Thread Mounting with Care

      • Use a maximum tightening torque of 500 in·lb (≈ 56 Nm) – this ensures a secure, stress-free seal without overloading the housing.

Mind the Temperature

      • Keep the ambient temperature around the electronics housing as low as possible, especially with flexible stems.

      • A maximum temperature of 85 °C should not be exceeded – this protects internal components and extends the sensor's service life.

Calibration at Operating Temperature

      • Perform calibration after the thermal warm-up phase.

      • The so-called “warm zero” ensures that the sensor is adjusted under real operating conditions – for maximum accuracy and minimal drift.

 

With just a few targeted measures during installation and maintenance, you can get the most out of your Echo™ sensor. Investing in clean installation and precise calibration quickly pays off in the form of reliable readings, stable processes, and reduced downtime.

 

cleaning tool kit

Mounting Hole Cleaning Tool Kit

The cleaning tool kit from DYNISCO has been specifically developed for cleaning contaminated mounting holes of pressure and temperature sensors.

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borhung

Mounting Hole Tool Kit

The tool kit includes all drills and tools required to create the mounting bore for pressure sensors.

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The Dynisco Echo™ melt pressure sensor stands out for its robust construction, reliable measurement performance, and easy integration. It is suitable for a wide range of applications in plastics processing – from standard extruders to specialized setups in sensitive industries such as medical technology and food production.

Film & Pipe Extrusion

In film and pipe production, a stable melt pressure is crucial for consistent wall thicknesses, smooth surfaces, and uniform material flow. The Echo™ sensor provides reliable real-time data to immediately detect even the slightest pressure variations.
This enables precise control of the extrusion process – regardless of material viscosity, environmental factors, or production speed.

Blow Molding and Profile Extrusion

Especially in blow molding – whether for hollow bodies, tanks, or technical components – quick responsiveness to changing materials and processing conditions is essential.
Thanks to its compact design and optimized signal processing, the Echo™ reacts particularly quickly to pressure changes, issuing early warning signals before deviations result in defects.
This is a key advantage when frequent material changes or varying flow characteristics are involved.

Recycling & Compounding

When using recycled materials or compounding with additives, fillers, or color masterbatches, consistency control is essential.
Variations in material properties directly affect melt pressure – accurate measurement helps detect quality fluctuations early and automatically compensate.
The Echo™ thus ensures greater process stability and reduces waste – a clear advantage for companies increasingly focused on sustainable materials.

Medical & Food Processing

Industries like medical technology and food production demand the highest standards of material purity and hygiene.
The Echo™ is available with TiAlN-coated diaphragms that are not only technically robust but also chemically resistant and hygienically safe.
This makes the sensor ideal for use in contamination-sensitive environments while ensuring consistent product quality.

 

In industrial applications, it's not just technical precision that matters – reliability, cost-efficiency, and ease of use are also key. The Dynisco Echo™ melt pressure sensor combines all these requirements in a compact device, offering a smart alternative to expensive high-end sensors – especially when "simply good" is the best solution.

Top performance at a low price

The Echo™ was developed for users who need high functionality without overloaded extra features. Instead of relying on complex communication protocols or special software, the sensor focuses on precise pressure measurement, stable signals, and high repeatability – exactly the parameters that matter in day-to-day production.

With an accuracy of up to ± 0.5% Full Scale and various signal options, the Echo™ meets the performance requirements of many medium- to high-volume extrusion applications – at significantly lower investment costs.

Reliability for Daily Industrial Use

In harsh industrial environments, a sensor must do more than just measure: it must withstand impacts, temperature fluctuations, cleaning cycles, and vibrations — often for years. The Echo™ is equipped with a TiAlN-coated diaphragm that provides excellent protection against corrosion, abrasion, and chemical stress.

Additionally, the fully welded design of the sensor housing ensures long-term sealing and stability — even under the toughest conditions. This means: less downtime, less maintenance, and greater process reliability.

Seamless System Integration

Not every production line is equipped with modern fieldbus or HART technology. Many facilities still rely on proven analog signals for control and monitoring. The Echo™ adapts flexibly to these requirements:

      • mV/V output for simple display or control devices

      • 0–5 V, 0–10 V or 4–20 mA for compatibility with standard PLCs, controllers, or data loggers

This allows the sensor to be seamlessly integrated into existing control system architectures without the need for costly retrofits.

Easy Maintenance & Calibration with R-Cal™

A common issue in industrial environments: sensor calibration is often time-consuming, costly, and requires specialized equipment. Not so with the Echo™: Thanks to the integrated R-Cal™ function, the sensor can provide a defined reference signal (80% full scale) at any time.

This allows the connected control loop to be quickly tested or recalibrated — without removal or external testing equipment.

This not only saves time and maintenance costs, but also increases operational reliability.