Comparison of mechanical and electronic differential pressure gauges

1. Should you choose a mechanical or electronic differential pressure gauge? A quick comparison to help you decide

In cleanroom systems, controlling pressure differentials between zones is critical to ensure that airflow moves in the right direction - preventing cross-contamination and maintaining cleanliness levels. But should you choose a mechanical or an electronic differential pressure gauge for each specific area?

This article helps you quickly understand the differences and choose the right type for each application - from changing rooms to main production areas, weighing rooms, and microbiology zones.

Comparison mechanical vs electronic differential pressure gauges

2. When should you choose a mechanical differential pressure gauge?

While it lacks advanced monitoring features like electronic models, the mechanical differential pressure gauge remains a cost-effective and efficient choice for many standard cleanroom zones. Consider using a mechanical gauge in the following situations:

• No need for signal output
  If your facility does not use a BMS or SCADA system to monitor pressure centrally, a mechanical gauge helps simplify the setup and reduce initial investment costs.
• Support zones with low cross-contamination risk
  Areas like gowning rooms, buffer corridors, and secondary airlocks typically only require visual pressure checks - automatic alarms are not necessary.
• Projects requiring budget optimization
  With low cost, easy installation, and minimal maintenance, mechanical gauges are ideal for small facilities, pilot stages, or quick multi-point installations.
• Stable environments without continuous monitoring needs
  If pressure remains steady, doesn’t fluctuate during shifts, or there’s no need to store data, investing in an electronic device may not be justified.

See more: Digital Differential Pressure Gauges: The New Trend of 2025

3. When should you use an electronic differential pressure gauge?

When pressure control requirements become stricter - not just visual checks, but precise measurements, timely alerts, and system integration - electronic gauges become nearly mandatory.

Situations where electronic gauges are highly recommended:

• Critical zones: weighing rooms, microbiology labs, primary airlocks
  These areas require stringent contamination control (GMP Class A/B, ISO 5-6), accurate pressure readings, and immediate alerts if balance is lost.
• Facilities with central monitoring systems (BMS/SCADA)
  Electronic gauges can output 4-20mA analog signals for real-time system integration, data logging, and automatic alarms in case of failure.
• Areas needing instant alerts when pressure thresholds are breached
  These gauges can connect to warning lights, buzzers, or HVAC shutoff signals to prevent cross-contamination before it becomes serious.
• Where data tracking and documentation are required
  Some models come with data loggers, helping retrieve audit trails during GMP or ISO validations.

4. Factors influencing your choice

There’s no one-size-fits-all solution - only what suits your specific context best. Before investing, engineers or facility owners should consider:

• Cleanroom classification (ISO/GMP)
  ISO 5-6 or GMP Class A/B areas require stringent pressure control, typically demanding electronic gauges. ISO 8-9 zones or support rooms may only need mechanical types.
• Monitoring and reporting frequency
  If you need continuous monitoring, periodic reporting, or data archiving, electronic gauges offer better integration and accuracy.
• System integration (BMS/SCADA)
  Modern factories often centralize equipment control. In these setups, signal-capable devices like electronic gauges are essential.
• Initial investment and maintenance cost
  For large-scale deployment or limited budgets, combining both types - mechanical for support zones, electronic for critical areas - can balance cost and performance.

5. Recommendations by industry

Depending on environmental control requirements, selecting the right differential pressure gauge helps optimize costs while meeting compliance needs. Here's a breakdown by sector:

• Pharmaceuticals (GMP)
  Weighing, filling, and sterile packaging zones require high cleanliness and pressure control. Electronic gauges are mandatory, especially if alerts or data validation are needed.

• Food industry
  Airlocks, corridors, and raw material storage often use mechanical gauges. However, for sealed packaging or fresh product handling, electronic gauges are preferred for precision.
• Cosmetics
  Use both:
  → Mechanical gauges in support zones like changing or waiting rooms
  → Electronic gauges in packing/filling zones - typically ISO 7-8, or with contamination risks
• Electronics
  Extremely sensitive to dust, pressure, and static. Even small errors can affect circuit boards or components. Electronic gauges are nearly mandatory in main production, SMT rooms, or clean benches.

See more: How to Regularly Calibrate Differential Pressure Gauges

6. Frequently Asked Questions

1. Can mechanical differential pressure gauges be used in pharmaceutical weighing rooms?

→ Not recommended. Weighing rooms require strict pressure control, high accuracy, and timely alerts - features lacking in mechanical gauges, making them non-compliant with GMP standards.

2. Do electronic pressure gauges need regular calibration?

→ Yes. Like any measurement device, electronic pressure gauges must be calibrated every 6-12 months to maintain acceptable accuracy and meet GMP/ISO audit requirements.

3. Can electronic differential pressure gauges be used outdoors?

→ Yes, provided the unit has at least IP65 protection and is installed in a protective enclosure to shield it from rain, dust, humidity, or direct sunlight.

7. Need help choosing the right differential pressure gauge?

Are you building a factory that complies with GMP or ISO standards?
Not sure whether to use a mechanical or electronic differential pressure gauge for each area?

Contact VCR engineers for fast, industry-specific consultation.

Hotline: 090.123.9008

Email: [email protected]

Website: https://donghochenhap.com/

Diep VCR