Study on low-cost calibration-free pH sensing with disposable optical sensors

Highlights: ► Development of disposable calibration-free optical pH sensor. ► Derivation of theoretical calibration model. ► Strategy to eliminate inter-coaster inconsistency. - Abstract: As labor costs become more expensive, less labor-intensive disposable devices have become more ubiquitous. Similarly, the disposable optical pH sensor developed in our lab could provide a convenient yet cost-effective way for pH sensing in processes that require stringent pH control. This optical pH sensor is prepared in uniform individual lots of 100–200 sensors per lot. Calibration is accomplished on a few randomly selected sensors out of each lot. We show that all others in the same lot can then be used directly without requiring individual calibration. In this paper, a calibration model is derived to include all the factors that affect the signal of the disposable sensor. Experimental results show that the derived calibration model fits the experimental data. The readings of 28 randomly selected disposable sensors with 4 sensors from each of the 7 lots show an error less than 0.1 pH units in the useful sensing range of the sensor. The calibration model indicates that if further improvement on precision is desired, more uniform porous material and more advanced coating techniques will be required. When it comes to the effects of the varying coasters, house-made low-cost fluorometers, the variability in the brightness ratio of the blue-to-violet LEDs is the primary reason for the lack of precision. Other factors like LED light intensity distribution, optical properties of the filters and electronics also contribute to the coaster-to-coaster difference, but to a lesser extent. Two different methods for correcting the instrument variations were introduced. After correction, the collective reading errors for all the tested instruments were reduced to less than 0.2 pH units within the sensor's useful sensing range. Based on this result, our lab is currently implementing further improvements in modifying the coasters to equalize the ratios of blue-to-violet LED brightness.