In the world of industrial sensors—whether for pressure, level, or flow—the performance of your system doesn’t depend solely on the sensor’s core technology. Often, what protects that technology and maintains signal integrity in harsh environments is the cable—and more specifically, its outer jacket material.
Choosing the wrong cable jacket can lead to signal interference, chemical degradation, cracking, or even total system failure. So how do you choose the right one for your application?
This article compares the four most common cable jacket materials—PUR, PE, PVC, and FEP—to help you make the right decision when integrating sensors into your HVAC, water treatment, industrial automation, or process control systems.
Why Jacket Material Matters for Sensor Applications
Sensor cables are not just electrical conductors; they are lifelines connecting delicate sensor elements (e.g., pressure transducers, ultrasonic level sensors, electromagnetic or vortex flow meters) to control systems.
They often operate in:
Wet or submerged environments (e.g., level sensors in tanks)
Mechanically demanding setups (e.g., flow sensors with moving arms)
Chemical processing plants (e.g., pressure sensors in corrosive media)
Outdoor installations exposed to UV, temperature shifts, or rodents
Each of these conditions stresses the cable jacket differently. That’s why material selection must align with the environment and motion profile.
Comparing the Cable Jacket Materials: PUR, PE, PVC, FEP
Let’s break down each material by how well it handles the real-world challenges in sensor deployment:
1. PUR (Polyurethane) – For Tough, Dynamic Environments
Best for: Pressure or flow sensors in moving, flexing, or oily environments (e.g., drag chain systems, packaging lines, compressors)
Highly flexible and abrasion-resistant
Resists oil, grease, and mechanical wear
Moderate chemical resistance
Flame retardant and halogen-free (in most variants)
Sensor-specific use cases:
Pressure sensors in hydraulic systems
Flow meters on mobile machine parts
Level sensors in washdown zones
⚠ Avoid if exposed to strong acids or high continuous temperatures above 90°C.
2. PE (Polyethylene) – For Wet, Buried, or Outdoor Installations
Best for: Level sensors in tanks or wells, or sensors installed outdoors (especially in water/wastewater or environmental monitoring)
Excellent moisture and chemical resistance
UV stable (especially black PE)
Very low dielectric loss—ideal for signal integrity
Stiff at low temperatures, poor flame resistance
Sensor-specific use cases:
Submersible pressure/level sensors
Flow sensors in open channels or irrigation
Long-distance pressure signal cables in outdoor installations
⚠ Avoid if frequent flexing or dynamic movement is involved.
3. PVC (Polyvinyl Chloride) – For General Indoor Sensor Wiring
Best for: Economical pressure or level sensor cabling in control panels, indoor systems, or protected conduit installations
Easy to install, flexible, flame-retardant
Moderate oil and chemical resistance (formulation-dependent)
Limited UV resistance
Contains halogens (can release toxic fumes in fire)
Sensor-specific use cases:
Pressure transmitters in HVAC control cabinets
Flow meters in laboratory or office environments
Level sensors in clean water applications
⚠ Avoid for outdoor, high-flex, or chemically aggressive environments.
4. FEP (Fluorinated Ethylene Propylene) – For Extreme Conditions
Best for: Sensors in cleanrooms, chemical processing plants, or high-temp environments
Chemically inert—resists nearly all solvents and acids
Withstands -200°C to +200°C
Low outgassing, flame resistant, UV resistant
High dielectric strength
Sensor-specific use cases:
Pressure sensors in semiconductor or pharma applications
Level sensors in CIP/SIP systems
Flow meters in aggressive chemical dosing lines
⚠ Avoid if budget is a key concern or flexibility is essential.
Summary Table: Best Fit by Environment
| Environment | Best Jacket | Sensors Commonly Used |
|---|---|---|
| Dynamic/flexing machinery | PUR | Flow sensors, pressure sensors in motion |
| Wet/submersed/outdoor | PE | Level sensors, long-range pressure sensors |
| Cost-effective indoor | PVC | Basic pressure/flow sensors in panels |
| Chemically aggressive/high-temp | FEP | Process pressure sensors, pharma-level probes |
How to Choose
Ask yourself:
Where will the sensor operate? (indoor, outdoor, submerged, mobile)
What environmental threats are present? (chemicals, UV, heat, rodents)
How important is flexibility or drag chain capability?
What regulations must be met? (halogen-free, cleanroom, fire safety)
General tip:
If you’re selling pressure, level, or flow sensors into industrial automation, HVAC, or water systems, recommend:
PUR for dynamic or mobile applications
PE for outdoor or buried sensors
FEP for chemical or thermal extremes
PVC when price matters more than ruggedness
Conclusion
The right cable jacket ensures that your sensors perform reliably and safely throughout their service life. By understanding the strengths and weaknesses of PUR, PE, PVC, and FEP, you’ll not only reduce maintenance and failure risks—you’ll offer your customers a smarter, longer-lasting sensor solution.
👉 Learn more about our Level Sensors and find the right solution for your application.
