Gas Detection in the Food and Beverage Business
Many gases are used for different reasons in food and beverage production. Water is the primary raw material at the beginning and the end of the process, which has to be treated regarding odor and sterility. The vessels and pipes need to be cleaned regularly with sterilizing fluids, which can generate toxic gases that become a threat to workers. For carbonation and during fermentation, CO2 is used in high concentrations. The refrigerating and cooling system can contain pressurized ammonia, which needs to be monitored to protect people and property. Under certain circumstances, the gases from the chemicals in use can become a threat to human health, because they are either toxic or flammable. Monitoring gases in the workplace is necessary.
The production process and the storage of goods require controlled temperature and environmental conditions. Therefore, refrigeration and cooling systems are widely used. Cooling fluids like Ammonia, Hydrocarbons or Halogenated Hydrocarbons circulate in the cooling systems under pressure, and any leaks can pose a danger to workers. Monitored areas that should be considered are heat exchanger, joints, the compressor, and valves.
Carbon Dioxide will naturally generate during wine and beer fermentation or added later to carbonize the beverages. This gas can accumulate on low levels from leaks and lead to asphyxia if undetected. To prevent leaks and system brake-downs, the gas detection system monitors the workplace, ensuring concentrations are below TLV.
​Chlorine Cl2 is a very toxic and corrosive gas used for disinfecting. It is stored in cylinders at high concentrations and blended down to the concentration used in the process or dissolved in water.
2ClO2 --> Cl2 + 2 O2 + heat.
ClO2 vapors are reactive with most organic compounds.
If pressurized cooling fluids are being used in refrigeration and air conditioning systems, leak monitoring is essential. A small leak at a pipe joint can have a great impact and cause a lot of damage if not detected early. Cases are known where personnel has been intoxicated, and stored goods have been destroyed by exposure to leaking Ammonia. Please refer to RC Systems APN-1042 for more information.
In breweries and wineries, odorless carbon Dioxide CO2 naturally occurs in the malting, fermentation, and storage process. Because it is heavier than air, low-level clouds of CO2 may collect in poorly ventilated areas or confined spaces, replacing the oxygen. The same can happen in the beverage industry where CO2 is used for carbonation of soft drinks and mineral water. CO2 detectors are always used to monitor the concentrations and alert personnel and control fans. Selected thresholds for pre-alarms are 1000 ppm to 3000 ppm, and the main alarm is 5000 ppm for CO2. Transmitters should be mounted at low levels since CO2 is much heavier than air. They should be protected from mechanical damage and against water ingress if washed down occasionally.

Application Fields:
- Food Processing
- Brewery
- Milk
- Bottled Water
- Soft-Drink Manufacturing
The production process and the storage of goods require controlled temperature and environmental conditions. Therefore, refrigeration and cooling systems are widely used. Cooling fluids like Ammonia, Hydrocarbons or Halogenated Hydrocarbons circulate in the cooling systems under pressure, and any leaks can pose a danger to workers. Monitored areas that should be considered are heat exchanger, joints, the compressor, and valves.
Carbon Dioxide will naturally generate during wine and beer fermentation or added later to carbonize the beverages. This gas can accumulate on low levels from leaks and lead to asphyxia if undetected. To prevent leaks and system brake-downs, the gas detection system monitors the workplace, ensuring concentrations are below TLV.
​Chlorine Cl2 is a very toxic and corrosive gas used for disinfecting. It is stored in cylinders at high concentrations and blended down to the concentration used in the process or dissolved in water.

- TLV/TWA: 1 ppm
- TLV/STE: 3 ppm
- TLV/IDLH: 25 ppm
- NIOSH/ceiling: 0,5 ppm 15 min
2ClO2 --> Cl2 + 2 O2 + heat.
ClO2 vapors are reactive with most organic compounds.
- TWA: 0.1ppm
- STEL: 0.3 ppm
- TWA: 0.1ppm
- STEL: 0.3 ppm
If pressurized cooling fluids are being used in refrigeration and air conditioning systems, leak monitoring is essential. A small leak at a pipe joint can have a great impact and cause a lot of damage if not detected early. Cases are known where personnel has been intoxicated, and stored goods have been destroyed by exposure to leaking Ammonia. Please refer to RC Systems APN-1042 for more information.
In breweries and wineries, odorless carbon Dioxide CO2 naturally occurs in the malting, fermentation, and storage process. Because it is heavier than air, low-level clouds of CO2 may collect in poorly ventilated areas or confined spaces, replacing the oxygen. The same can happen in the beverage industry where CO2 is used for carbonation of soft drinks and mineral water. CO2 detectors are always used to monitor the concentrations and alert personnel and control fans. Selected thresholds for pre-alarms are 1000 ppm to 3000 ppm, and the main alarm is 5000 ppm for CO2. Transmitters should be mounted at low levels since CO2 is much heavier than air. They should be protected from mechanical damage and against water ingress if washed down occasionally.
- TLV: 5000 ppm
- STEL: 15000 ppm
- MAK: 5000 ppm
Gas Detection in the Food and Beverage Business (PDF version)
RC Systems’ Recommendation:
Wired Gas Detection System |
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Gases | Detectors | Controller |
Cl2, NH3, O3, ClO2 | SenSmart 5100/6100 EC | ViewSmart 400 (Up to 4 points) ViewSmart 1600 (Up to 16 Points) ViewSmart 6400 (Up to 64 Points) |
CO2 | SenSmart 5400/6400 IR | |
Wireless Gas Detection System |
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Gases | Detectors | Controller |
Cl2, NH3, O3, ClO2 | SenSmart 7100 EC | WNR WaveNet Receiver |
CO2 | SenSmart 7400 IR | (Up to 32 Points) |