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Choose the Best Ozone Sensors for WFI

Understanding Ozone Sensor Technology for Water for Injection

Home Online bibliotheek Ozone Selection Guide

Understanding Ozone Sensor Technology for Water for Injection

Ozone sanitization is becoming an increasingly popular alternative to traditional heat sanitization, driven by evolving regulations and a greater emphasis on sustainability. While heat sanitization can be costly—especially with Water for Injection (WFI) produced by distillation—high-quality ozone sensors for WFI provide an efficient monitoring solution. Accurate ozone measurement in WFI loops is critical to ensuring product quality and compliance, making sensor technology a key consideration.


Ozone sanitization has been gaining popularity in recent years due to regulation changes and a stronger focus on sustainability. Heat sanitization can be costly to operate, with WFI produced by distillation about 150%-350% more expensive than ambient WFI.

Ozone analytics play a massive role in WFI loops, ensuring that no ozone gets through UV destruction to the final product and that ozone levels are correct for sanitization. Proper analytics can be the difference between compliance and a high-quality product, and non-compliance and a damaged product. Knowing the different types of sensors can help with making an educated decision on which type of sensor to choose.

Two Main Types of Ozone Sensors for WFI: Galvanic vs Polarographic

Both types of sensors have similar measurement principles but offer key differences that can distinguish themselves.

• Galvanic

• Polarographic

Galvanic Ozone Sensors

Galvanic sensors are electrochemical sensors, that utilize an anode/cathode, electrolyte, and gas-permeable membrane to generate an ozone measurement. The anode and cathode are dissimilar metals, which allows them to create and hold an internal electrical potential between them.

This means the sensor utilizes less external power and allows the sensor to quickly measure without a distinct polarization period.

Ozone Sensors for WFI

The Maintenance Cycle

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Longevity and Wear

Due to the mechanics of this type of sensor, the galvanic sensor consumes the anode, resulting in a shorter lifetime of the sensor.

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Physical Servicing

Semi-frequently, these electrodes need to be serviced for polishing and cleaning to ensure they remain at peak efficiency. This polishing often requires an external electro polisher piece of equipment, and/or harsh chemicals in high concentration.

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The Stabilization Requirement

A post calibration stabilization period of about 24 hours is required in order to get accurate measurements.

This is particularly important for low concentrations of ozone, which are vital in pharmaceutical waters.

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Polarographic Ozone Sensors

Polarographic sensors are similar to galvanic sensors in the way that they measure. Polarographic sensors also use an anode/cathode, electrolyte, and gas-permeable membrane to generate an ozone measurement.


The sensor technology has been used widely for a long time, so is robust, reliable, and well studied. Polarographic sensors produce a reliable and accurate measurement of ozone.

Maintenance and Durability

Consumption of the anode/cathode is not an issue for this sensor technology, since the reaction happens between the electrolyte and the ozone. No electropolishing is required during maintenance either.

Understanding the Drawback: Polarization

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The Polarization Requirement

Since the polarographic sensor doesn’t use different types of metals, the sensor does not carry an internal electrical potential, requiring external voltage for the sensor to polarize. This also requires more electricity draw from a polarographic sensor.

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The Timeline

Polarization can last hours, but once the sensor is polarized, it can measure for long periods of time with high accuracy and sensitivity.

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The Benefit

After this polarization time, no additional time is required for the sensor to stabilize in order to read low concentrations of ozone.

METTLER TOLEDO’s Solution

image - Ozone Selection Guide

The pureO3 ozone sensor offered by METTLER TOLEDO is a polarographic sensor that is designed to last long periods in ozonated water systems. Features like the Adaptive Calibration Timer and Dynamic Lifetime Indicator take historical ozone and sensor data and can indicate when calibration or maintenance is required to ensure an optimal service frequency. With a 2-hour polarization time, the pureO3 offers a rapid time to first measurement after maintenance and calibration, helping increase system uptime for maximum productivity. The pureO3 reduces the time to measurement by 80% compared to some galvanic sensors in the industry.

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Jared Culbertson

Global Product Manager - Conductivity

Jared Culbertson is a dedicated engineer with a deep technical foundation in the biotechnology and pharmaceutical water industries. Over his tenure at METTLER TOLEDO Thornton, he has become a go-to resource for navigating the technical nuances of pure water measurement. By bridging the gap between innovative sensor hardware and regulatory governance, Jared ensures that manufacturers have the tools and the knowledge necessary to maintain precise process control.

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