Guide for your compressed air flow meter price

In the manufacturing industry, compressed air flow meters play a crucial role in monitoring air and gas consumption. These instruments provide valuable insights that help optimize energy usage and improve production efficiency. However, with a variety of options on the market, understanding flow meter cost can be challenging. This article explores for mass flow meters the factors influencing these costs, typical price ranges, and tips on selecting the best solution for your compressed air and gas system. As mass flow meters are typical to use for compressed air and gas, we focus on this type of flow meter.

Table of contents

• Generic mass flow meter cost
• Key factors affecting your flow meter price
  • Application and flow meter working principle
  • Pipe sizes
  • More measurands for complete picture in one flow meter
  • Accuracy requirements for a maximized ROI on your flow meter cost
  • Installation Conditions
  • Installation costs and servicing
  • Integration and Communication Options
• The cost of not investing in a flow meter?
• The value of investing in a quality compressed air flow meter
• How to choose the best compressed air flow meter

Generic mass flow meter cost

The compressed air flow meter price can vary widely depending on its type, functionality, and application. On average, prices range from 500 to over 15,000 USD. Basic models, such as those used for simple indications in non-critical applications, tend to fall at the lower end of this range.

In contrast. higher-end models designed for industrial use, featuring advanced diagnostics, enhanced accuracy, or integration with digital systems, are higher priced. For instance, specialized flow meters for high-pressure or corrosive environments may come with a price tag exceeding 10,000 USD.

For compressed air and gas monitoring, the most commonly used mass flow meters typically fall within the range of 1000 to 5000 USD.

Key factors affecting your flow meter price

Application and flow meter working principle

There are several of technologies offering mass flow readings, like the following.

• A thermal mass flow meter is typically used in dry air applications. Condensing liquids in the gas or air can affect the reading and can cause erratic flow indications. It is therefore better to use these flow sensors after compressed air or gas treatment system, such as a dryer. Thermal mass flow meters offer a wide flow measurement range (typically 1:100) making them ideal for monitoring both maximum system flow and low flow ranges, such as those needed for leakage management.
• A DP mass flow meter can be used in saturated air conditions or condensing applications, where no air treatment is needed. Their limited flow range (1:10) makes them less effective for detecting low flows, such as those associated with leakages or other deviations. However, they often offer higher velocity and temperature ranges compared to thermal mass flow sensors
• The Coriolis flow meter is known for its exceptionally high accuracy, making it a common choice when a certified mass flow meter is required. The benefit of Coriolis is that it offers long term stability with minimal maintenance. On the downside, Coriolis flow meters have a high initial investment, are typically bulky and heavy, and installation is quite sensitive and complex.

Where possible, we recommend using a thermal mass flow meter due to their turndown ratio, versatility and great ROI. DP flow meters are about 25% more expensive and Coriolis flow meters another 25%, making thermal mass flow meters a more cost-effective option.

Pipe sizes

There are two main types of flow meters: in-line and insertion. In-line flow meters are more affordable for pipe sizes up to 2 inches but become less cost-effective for larger pipes. They offer high accuracy due to controlled installation and are less sensitive to human error. However, they are fixed to specific pipe sizes and require stopping the air/gas supply or adding a costly bypass for servicing.

Insertion flow meters are versatile and can be installed in pipe sizes from 1” to 20”. A key advantage of insertion meters is that they can be installed under pressurized conditions by using ball valves, avoiding supply interruptions. This feature reduces overall installation and servicing costs.

Where in-line flow meter price varies between 500 USD to 1500 USD pending on size and the other factors discussed in this article. Insertion flow meter price varies from 2000 to 4000 USD.

More measurands for complete picture in one flow meter

While additional measurands increase the compressed air flow meter price, they provide a more comprehensive data analysis. Mass flow alone offers valuable insights, but integrating pressure and temperature in one sensor gives a complete picture. For example, such a sensor can reveal if filter failure is due to high flow rates or if low pressure is linked to insufficient flow.

A flow meter with bi-directional flow measurement adds even more value, allowing you to monitor ring networks or detect backflow. Although the initial cost is higher, it eliminates the need for additional sensors and reduces installation costs, ultimately making it a more cost-effective solution.

Accuracy requirements for a maximized ROI on your flow meter cost

High-precision flow meters often come at a premium. If your manufacturing process requires ISO-certified air consumption measurement, such as for metering purposes, investing in a certified high-accuracy mass flow meter may be essential, adding to the flow sensor cost but providing critical data for cost savings. The mass air flow sensor price for these types is easily above 10,000 USD. In contrast, for applications where only general trend monitoring is needed, an accuracy level of around 5% may suffice.

For energy savings purposes or improving your efficiency, a flow meter with an accuracy of 1–2% is typically recommended. This level of precision ensures a strong return on investment (ROI) by balancing cost and performance, making it a cost-effective choice for optimizing compressed air and gas systems.

Installation Conditions

Compressed air flow meters can be installed in various environments, from clean indoor factory settings to harsh industrial locations. Installation in challenging conditions, such as outdoor exposed to rain and sunlight, may require additional protective features, raising costs by 10-20%.

Installation costs and servicing

One often only looks at the compressed air flow meter cost. While mechanical and electrical installation costs, and thus also costs for servicing your flow meter, often doubles the initial price. Regular calibration is essential for maintaining accuracy, which typically involves sending the flow meter to a certified lab or getting an exchangeable sensor. In your search to the right flow meter, it is important to account for installation and servicing expenses to get a comprehensive understanding of the total cost.

Integration and Communication Options

Your usage and need for communication options, adds also to the compressed air flow meter price. Advanced models with digital outputs (e.g., Modbus, Ethernet, or 4-20mA) for real-time monitoring and data integration with plant management systems are often more expensive. Similarly, features like a built-in display or data logger add to the cost. Enhanced connectivity typically adds 15-25% to the flow meter cost but can greatly enhance efficiency and tracking capabilities.

The cost of not investing in a flow meter?

We often hear that a flow meter is expensive and there is no budget or approval for their purchase. However, many factories continue to make significant investment decisions based on no data or inaccurate data. The price of the flow sensors needs to be seen in the light of your costs for compressed air and compressed air investments. Air is not free; it is 8-10 times more expensive than electricity. We have seen numerous cases where just one flow meter saved customers tens of thousands of dollars.  The real question is not why to invest in a flow meter, it is why not to invest in one.

The value of investing in a quality compressed air flow meter

Though upfront flow meter cost is an important consideration, investing in a quality compressed air flow meter will result in significant long-term benefits:

• Energy efficiency: By accurately monitoring compressed air usage, flow meters help identify and reduce wasted air, often resulting in energy savings of 10-30%.
• Operational optimization: Reliable data on compressed air flow allows for more effective system management, which can minimize downtime and enhance production efficiency.
• Maintenance reduction: Quality flow meters tend to be more durable, reducing the need for frequent maintenance and replacement, which lowers costs over time.

How to choose the best compressed air flow meter

Selecting the right flow meter involves balancing budget with your operational needs. For many manufacturing applications, a mass flow meter offers a great combination of accuracy and value.

At VPInstruments, we specialize in a wide range of compressed air flow meters suited to various industrial needs. Our team of experts can help you find the ideal air flow sensor solution tailored to your requirements and budget. Reach out to us today for a customized quote or additional information on how a compressed air flow meter can improve efficiency and reduce costs for your facility.