Dielectric Grease & Sensor Reliability in Washdown Environments
A simple maintenance step to protect sensors, reduce downtime, and improve reliability in washdown food production environments.
At Blentech, we engineer our systems to perform in the most demanding food production environments, including areas with high-pressure washdowns. Even though our sensor cabling is wash-down rated, one simple practice can go a long way in protecting critical components: applying dielectric grease to sensor plugs and connectors.
Why Dielectric Grease?
Dielectric grease is a non-conductive, moisture-blocking compound used to seal electrical connectors and protect against water, chemical exposure, and corrosion. For food manufacturers, that protection is essential, especially on equipment that undergoes regular sanitation with pressure sprayers and caustic chemicals.
Where to Apply It
- Sensor Plugs and Connectors – particularly those located on column dumpers, cover interlocks, flowmeters, and other exposed areas.
- Proximity Switches (e.g., ZSS06–ZSS08) – as documented during real-world troubleshooting, loose alignment or moisture can cause erratic behavior and trip safety relays.
- Any Washdown-Exposed Connector – regardless of application, if it’s getting sprayed, it should be greased.
A food-grade product like CRC Food Grade Dielectric Grease Select-A-Bead or similar is typically available in most plants. If not, our team can recommend a compatible alternative.
Installation Tips
- Apply a thin layer of dielectric grease to the threads before connection.
- Do not put grease inside the plug, only the threads.
- Hand-tighten only—do not overtighten M12 connectors, as this can damage the pins and rubber O-ring.
- Reapply grease periodically or after maintenance, especially if plugs are disconnected and reconnected.
During an equipment startup, Blentech engineers noted intermittent safety relay trips traced back to moisture or misalignment at connector points. Applying dielectric grease to plugs—as well as confirming sensor alignment—resolved the issue and restored stable operation.
Don’t Overlook the Simple Fix
Protecting your sensors with dielectric grease is a quick, low-cost step that can prevent unexpected downtime, sensor errors, and frustrating electrical noise issues in high-moisture environments.
Need support identifying which connectors on your system could benefit from added protection? Our Parts & Service team can help.
