Literature Review · Peer-Reviewed Sources Only

PendoTECH Single-Use Pressure Sensor: Performance Review from Four Peer-Reviewed Studies

Published 5 August 2026 · 14 min read · 4 citations
PendoTECH single-use pressure sensor pair across a TFF hollow-fibre module — schematic Hollow-fibre TFF module P₁ P₂ P₃ permeate Feed from bioreactor Retentate return TMP calculation TMP = (P₁ + P₂)/2 − P₃ Cross-membrane driving force for permeate flux control Mettler-Toledo Pendotech PREPS-N series
Figure 1: canonical peer-reviewed deployment of the PendoTECH single-use pressure sensor family — two upstream sensors on the feed and retentate legs of a hollow-fibre TFF module and a third on the permeate side, all reading through moulded polycarbonate housings without dead legs in the flexible-tubing fluid path. Transmembrane pressure is derived from the three readings and drives permeate-flux and crossflow control.
Literature Verdict

Across four peer-reviewed deployments in tangential flow filtration and alternating tangential flow perfusion, the PendoTECH single-use pressure sensor family is a credible primary pressure element for single-use bioprocessing under 25 psi. The MEMS-based chip resolves TMP-drop of ~1.2 psi per centimetre along a UF cassette [1] and tracks fouling-driven TMP escalation to 0.9–0.95 bar in ATF perfusion [3]. Its main limitations are the 75 psi ceiling (which excludes high-pressure chromatography), the looser accuracy in the vacuum regime, and the operational overhead of tracking single-use consumables.

PendoTECH single-use pressure sensor at a glance

The PendoTECH single-use pressure sensor is an in-line, disposable pressure element designed for flexible-tubing single-use bioprocess assemblies. A MEMS-based piezoresistive chip (the vendor's proprietary MEMS-HAP high-accuracy pressure chip) is bonded into a moulded polycarbonate or polysulfone housing that connects directly to the fluid path via hose-barb, luer, or sanitary fitting, so there is no separate diaphragm or fill fluid. PendoTECH was acquired by Mettler-Toledo in 2020 and the sensors are now sold under the Mettler-Toledo Pendotech brand. Product details below are sourced from the vendor specification sheet and the accuracy and implementation technical note; field performance data comes from independent studies cited throughout this review.

SpecificationValue
Measurement principleMEMS-based piezoresistive pressure chip (MEMS-HAP), in-line contact with fluid
Operating pressure range−7 to 75 psi (~−0.5 to 5.2 bar)
Accuracy (vendor-claimed)±2% of reading (0 to 6 psi), ±3% of reading (−7 to 0 and 6 to 30 psi), ±5% of reading (30 to 75 psi)
Response timeEffectively instantaneous at typical bioprocess flow rates (millisecond-scale MEMS response)
Operating temperatureRated for typical bioprocess ambient use; not autoclavable
SterilisationGamma and x-ray irradiation compatible up to 50 kGy; supplied non-sterile or pre-sterilised in single-use assemblies
Process connectionHose barb 1/8" to 1.5" ID, luer, sanitary flange, molded connector; integral 12" cable
Fluid-contact materialsPolycarbonate or caustic-resistant polysulfone; USP Class VI compliant, EMEA 410 Rev 2 compliant
Continuous use lifeValidated for up to 90 days of continuous fluid contact (93-day 10 psi durability study)
Typical use envelopeTangential flow filtration TMP monitoring, ATF perfusion cell retention, single-use bioreactor headspace pressure, chromatography column inlet/outlet

What the peer-reviewed literature says

Four peer-reviewed studies published between 2023 and 2025 deployed the PendoTECH single-use pressure sensor as the primary pressure element in bioprocess research. All four papers use two or more sensors flanking a filter to derive transmembrane pressure directly from measured upstream and downstream values, which is the canonical control-loop configuration the vendor documents. None of the papers reports a sensor-hardware failure over the observation windows tested; the reported failures are process failures (membrane fouling, protein deposition, extractable-vesicle accumulation) that the pressure sensor faithfully detected.

Cunha et al. 2023 in Biotechnology Progress [1] is the sharpest test of the sensor's pressure-resolution because the study measures the axial pressure gradient along a modified flat-sheet 30 kDa regenerated cellulose UF cassette during bovine IgG concentration to more than 200 mg/mL. The authors used PendoTECH pressure transmitters (PMAT4A monitor family) to record local pressure at multiple axial positions and derived that the transmembrane pressure drop remained approximately constant at 1.2 psi per centimetre along the membrane while axial pressure fell by roughly 58 psi across the cassette. Resolving a 1.2 psi/cm gradient over the full 75 psi operating envelope is the practical benchmark: the sensor cleared it with the resolution needed for confocal correlation of protein-deposition thickness to local TMP.

Veje et al. 2024 in the Journal of Membrane Science [3] uses PREPS-N-038 sensors on the permeate side and PREPS-N-5-5 sensors on the feed side of two polysulfone hollow-fibre modules attached to a CHO recombinant-protein perfusion bioreactor. Short flux-step experiments identified critical flux up to 69 LMH without exceeding the critical fouling boundary. Prolonged operation at 8.3 LMH produced TMP escalation from baseline to 0.9–0.95 bar (~13 psi) accompanied by measurable membrane pore-size change; protein transmission through the fibre stayed above 88% throughout. The pressure sensors resolved TMP with enough fidelity to draw the flux-vs-fouling operating curve that separates safe-perfusion flux from the fouling regime.

Madabhushi et al. 2025 in Biotechnology and Bioengineering [2] used PendoTECH pressure sensors at the inlet and outlet ports of small-scale offline hollow-fibre model filters to isolate the contribution of individual perfusion-culture components to fouling. Working with recombinant GS-knockout CHO K1 cells expressing a monoclonal antibody at target 85–100 million cells/mL in 3 L glass and 50 L Xcellerex XDR single-use bioreactors, the study established that simethicone-based antifoam accumulates over a 28-day perfusion campaign and, at 500 ppm, is by itself sufficient to cause complete filter blockage. The pressure sensors were the primary readout for both the offline model and the perfusion bioreactor cell-retention loop. Vu et al. 2024 in Biotechnology Progress [4] extends the same approach to a stacked-filter geometry, using PendoTECH transmitters in the retentate loop and near the inlet and outlet of 20 cm hollow-fibre segments to quantify hydraulic-resistance reduction and confirm Starling-flow suppression at 3 L and 50 L perfusion scales.

Performance data from cited studies

Study Conditions Pressure metric Reported value / drift Conclusion
[1] Cunha 2023 Flat-sheet 30 kDa RC UF cassette, 150 kDa bovine IgG concentration to >200 mg/mL, PMAT4A monitors Axial P and derived TMP-drop along cassette Axial P fell ~58 psi across module; TMP drop constant at ~1.2 psi/cm along membrane length Sensor resolved a per-cm pressure gradient over the full 75 psi envelope with confocal-correlatable fidelity
[2] Madabhushi 2025 Perfusion CHO K1 mAb, 3 L glass and 50 L Xcellerex XDR SUB, 85–100 M cells/mL, 28-day runs Filter inlet/outlet P, TMP profile Complete filter blockage at 500 ppm simethicone antifoam; significant fouling 75–250 ppm Sensor pair reliably detected antifoam-driven TMP escalation and complete blockage endpoints
[3] Veje 2024 ATF perfusion, polysulfone hollow-fibre, CHO recombinant protein, PREPS-N-038 (permeate) + PREPS-N-5-5 (feed) Critical flux, TMP escalation at fixed flux Critical flux up to 69 LMH; TMP rose to 0.9–0.95 bar at 8.3 LMH prolonged operation Resolved the flux-vs-fouling operating boundary directly from measured TMP
[4] Vu 2024 Stacked 20 cm TFF filters, 3 L and 50 L perfusion, retentate-loop and inlet/outlet P Hydraulic resistance, retentate-loop P profile Lower hydraulic resistance confirmed for segmented permeate; improved sieving at both scales Pressure sensors verified the Starling-flow suppression hypothesis quantitatively at scale

Every row is a separate peer-reviewed publication; see References section for full citations. Conditions and metrics are paraphrased from the authors' text and tables, not from vendor literature.

Limitations and failure modes reported

Across the reviewed studies and the vendor validation record, the following limitations recur. Each bullet is tagged with the specific citation or vendor document that describes it.

When the literature recommends PendoTECH single-use pressure sensors

Recommended for

  • Ultrafiltration TMP monitoring under 25 psi, where per-cm axial gradients need to be resolved [1]
  • ATF and TFF perfusion cell-retention loops with hollow-fibre modules, feed and permeate side [3]
  • 28-day-plus intensified perfusion campaigns where antifoam-driven fouling must be detected early [2]
  • Multi-scale (3 L to 50 L) perfusion process development where sensor cross-manifold consistency matters [4]

Caveats / not recommended for

  • Pressure above 75 psi — excludes high-pressure chromatography and high-pressure homogenisation (vendor specification sheet)
  • Fine vacuum monitoring — looser accuracy in the −7 to 0 psi range constrains permeate-side low-TMP resolution [3]
  • Continuous campaigns beyond 90 days without scheduled sensor replacement — outside the vendor validation envelope (vendor validation guide)
  • As the only line of defence — a pressure-triggered abort strategy is still required because the sensor detects but cannot prevent runaway fouling [2]

Use cases documented in the literature

Specific deployments reported in the cited studies. Each card corresponds to a real published bioprocess use case.

TFF ultrafiltration
150 kDa bovine IgG to >200 mg/mL retentate

Modified flat-sheet 30 kDa RC UF cassette with PendoTECH PMAT4A monitors resolving axial pressure profile and TMP drop of ~1.2 psi/cm along the membrane, later correlated to confocal-imaged protein deposition.

[1]
Perfusion CHO mAb
28-day intensified perfusion, 3 L glass + 50 L XDR

PendoTECH pressure sensors at the inlet/outlet of small-scale offline hollow-fibre models and the perfusion bioreactor cell-retention loop identified simethicone-antifoam accumulation as the dominant fouling driver.

[2]
ATF perfusion
Polysulfone hollow-fibre CHO recombinant protein

PREPS-N-038 (permeate) and PREPS-N-5-5 (feed) sensors quantified critical flux up to 69 LMH and TMP escalation to 0.9–0.95 bar at prolonged 8.3 LMH operation with >88% protein transmission.

[3]
Stacked TFF perfusion
3 L and 50 L stacked hollow-fibre segments

Retentate-loop and inlet/outlet PendoTECH transmitters confirmed lower hydraulic resistance in segmented-permeate stacked TFF, quantifying the Starling-flow suppression that drove the improved sieving coefficient.

[4]

Sizing the TFF or ATF membrane behind the pressure sensors?

The TFF membrane sizing and diafiltration calculator returns membrane area, diavolume schedule, and TMP-flux envelope from your feed volume, target concentration, and flux target — a natural downstream companion to reading TMP off a PendoTECH pair.

Open the TFF sizing guide

User reviews from bioprocess engineers

Real-world experience from engineers who deployed PendoTECH single-use pressure sensors. All reviews are moderated before publishing. Share your own below — 2 minutes, anonymous option available.

Frequently asked questions

What does the PendoTECH single-use pressure sensor actually measure?
The PendoTECH single-use pressure sensor is an in-line pressure transducer that sits directly in the fluid path of a flexible-tubing bioprocess assembly. A MEMS-based piezoresistive chip (the vendor's MEMS-HAP high-accuracy pressure chip) is bonded into a moulded polycarbonate or polysulfone housing with hose-barb, sanitary, or luer connections and no dead legs. The chip reports absolute static and dynamic pressure of the flowing liquid at that point in the manifold; two sensors mounted upstream and downstream of a filter membrane are the standard configuration for calculating transmembrane pressure (TMP) and delta-P in tangential flow filtration and alternating tangential flow perfusion, which is precisely how Cunha 2023 (DOI 10.1002/btpr.3389), Veje 2024 (DOI 10.1016/j.memsci.2024.122764), Madabhushi 2025 (DOI 10.1002/bit.28987), and Vu 2024 (DOI 10.1002/btpr.3472) deployed them.
How accurate is the PendoTECH single-use pressure sensor in real bioprocess use?
The vendor reports accuracy of ±2% of reading from 0 to 6 psi, ±3% of reading from −7 to 0 psi and from 6 to 30 psi, and ±5% of reading above 30 psi, with MEMS-HAP chips 100% tested against a NIST-traceable reference. Peer-reviewed use validates this operating envelope directly: Cunha 2023 (DOI 10.1002/btpr.3389) used PendoTECH transmitters to resolve TMP-drop profiles of about 1.2 psi per centimetre along a 30 kDa flat-sheet ultrafiltration cassette while retentate mAb concentration rose above 200 mg/mL, and Veje 2024 (DOI 10.1016/j.memsci.2024.122764) tracked ATF-perfusion TMP rising to 0.9–0.95 bar (about 13 psi) at prolonged 8.3 LMH flux with PREPS-N-038 (permeate) and PREPS-N-5-5 (feed) sensors. In both studies the reported TMP resolution was sufficient to detect fouling onset within a single crossflow pass, which is the practical benchmark for a process-control-grade single-use pressure sensor.
Can PendoTECH single-use pressure sensors be gamma-sterilised?
Yes. All fluid-path materials are USP Class VI compliant and gamma / x-ray irradiation compatible up to 50 kGy per the vendor validation guide. The vendor's own long-term validation subjected 30 sensors from three lots to gamma doses of 27.5–33 kGy and 40–45 kGy without loss of accuracy, and a separate durability study exposed sensors to a constant 10 psi for 93 consecutive days with sensors remaining within specification. The peer-reviewed deployments cited here typically integrate PendoTECH sensors into pre-sterilised single-use manifolds that are gamma-irradiated as a unit prior to installation on the bioreactor or filtration skid, and none of the four studies reported an irradiation-related accuracy or hydration excursion.
What is the operating pressure range and where does it saturate?
The rated operating range is −7 to 75 psi (approximately −0.5 to 5.2 bar), which covers the entire useful envelope for flexible-tubing bioprocessing. Below 6 psi (±2% of reading) is the tight-accuracy regime that Annarelli et al. characterised specifically for low-pressure single-use bag-inlet or sterilising-filter integrity applications. Above 30 psi accuracy loosens to ±5% of reading, and above 75 psi the sensor is out of specification — the failure mode is not a fluid path burst but loss of chip linearity, so a hardline overpressure trip in the control system is still required. In practice this means the sensor is well matched to TFF and perfusion (where working TMP rarely exceeds 25 psi), and less well matched to high-pressure chromatography or high-pressure homogenisation.
How does PendoTECH compare to a reusable stainless-steel pressure transducer?
The trade-off is set-up cost against per-run cost, not measurement quality. A reusable stainless-steel diaphragm transducer is dimensionally more rugged (rated to hundreds of bar, cleanable, sterilisable in place) and carries no per-run consumable cost, but adds a dead-leg fluid contact that must be cleaned and validated between products in a multi-product facility. The PendoTECH single-use sensor removes the cleaning validation burden entirely — each sensor is dedicated to a single manifold, gamma-sterilised with it, and discarded — at the cost of a modest per-run consumable spend and a lower absolute pressure ceiling (75 psi vs. typically several hundred). For high-value biologics facilities running multi-product single-use trains the PendoTECH design has become the default; for reusable stainless-steel skids the traditional diaphragm transducer remains the incumbent.
Which PendoTECH model should I use for what tubing size?
PendoTECH publishes single-use pressure sensors for hose-barb tubing IDs from 1/8 inch to 1.5 inch, plus luer, sanitary-flange, and molded-connector variants. The PREPS-N-038 (3/8 inch hose barb, non-sterile) is the sensor Veje 2024 (DOI 10.1016/j.memsci.2024.122764) used on the permeate side of an ATF hollow-fiber module. The PREPS-N-5-5 (1/2 inch on both ends) is what the same study used on the higher-flow feed side. For higher-flow bioreactor-recycle or larger TFF skids the 3/4 inch and 1 inch variants and the sanitary-flange versions replace hose-barb entirely. Choose the smallest tubing that keeps process linear velocity above the vendor-recommended minimum (roughly 0.5 m/s to avoid stagnation in the sensor housing) and matches the connector geometry of the rest of your single-use manifold.
How long can a PendoTECH single-use pressure sensor stay in continuous service?
The vendor validation guide qualifies the sensor for up to 90 days of continuous fluid contact, backed by a 93-day continuous-pressure exposure study at 10 psi in which sensors remained within accuracy specification. That envelope covers a full mAb perfusion campaign and most intensified-perfusion N-1 seed-train use cases; the Madabhushi 2025 (DOI 10.1002/bit.28987) 28-day perfusion runs and the Veje 2024 (DOI 10.1016/j.memsci.2024.122764) prolonged critical-flux experiments both fall comfortably inside it. For campaigns longer than 90 days the intended design pattern is scheduled sensor replacement at a planned manifold change, not extending the same sensor beyond its validated life.
What are the reported limitations of PendoTECH single-use pressure sensors?
Four practical limitations recur. First, the 75 psi ceiling excludes high-pressure chromatography, high-pressure homogenisation, and depth-filter tail-end use above the sensor limit. Second, accuracy in the −7 to 0 psi vacuum regime is looser (±3% of reading) than in the 0 to 6 psi positive regime (±2%), which matters for permeate-side monitoring where TMP can transiently go negative. Third, the sensors are dedicated single-use consumables: a control loop that assumes a re-usable stainless transducer will need to be re-costed, and the operational overhead of tracking sensor lots and expiry dates is added. Fourth, per Madabhushi 2025 (DOI 10.1002/bit.28987), extreme antifoam accumulation in extended perfusion (500 ppm simethicone) can cause complete filter blockage — a failure mode the pressure sensor faithfully detects as a runaway TMP spike but obviously cannot prevent.

References

  1. Cunha, F., Zuponcic, J., Rossi, F., Springer, G., Ximenes, E., Bruns, N., Moomaw, J.F., Bowes, B.D., Qian, K.K., Yu, Z., Yang, D., Corvari, V.J., Ardekani, A., Reklaitis, G., Ladisch, M. (2023). Intramodule pressure profiles and protein accumulation during tangential flow filtration. Biotechnology Progress. DOI: 10.1002/btpr.3389.
  2. Madabhushi, S.R., Zuo, Q., Zhou, C., Phuangthong, C., Ruppert, N., Tang, T., Pelaez, F. (2025). Systematic Investigation of Impact of Antifoam and Extracellular Vesicles on Fouling of Hollow Fiber Filters in Intensified Perfusion Processes Highlights the Key Impact of Antifoam. Biotechnology and Bioengineering. DOI: 10.1002/bit.28987.
  3. Veje, M.H., Quirós, M., Kristensen, P., Jørgensen, M.K. (2024). Investigation of fouling in perfusion cell culture processes using alternating tangential flow filtration. Journal of Membrane Science, 701, 122764. DOI: 10.1016/j.memsci.2024.122764.
  4. Vu, J., Gadberry, J.A., Coffman, J., Lee, K. (2024). Improved sieving coefficient in perfusion cell culture with reduced effective filtration length of hollow fibers. Biotechnology Progress. DOI: 10.1002/btpr.3472.