High humidity and condensation in molding facilities pose significant risks to thermocouple reliability. Moisture can penetrate imperfect seals and reach the internal magnesium oxide insulation, reducing its effectiveness and causing signal noise, drift, or short circuits. Once insulation absorbs moisture, it cannot be easily dried, leading to permanent sensor degradation.
Condensation forms when cool airflow contacts hot thermocouple cables, especially during startup or shutdown cycles. This moisture accelerates corrosion of the sheath and internal components. In outdoor or poorly ventilated facilities, humidity-related failures become more common.
Sealed mineral-insulated thermocouples with robust fittings provide the best protection against humidity. Keeping connectors dry and avoiding rapid temperature swings that cause condensation also helps extend service life. In humid environments, regular inspection and maintenance of thermocouple seals prevent moisture-related failures.
