Finding the right temperature sensor at a price that fits your budget can be a challenge. During an industrial project for a critical application that required both RTDs and thermocouples (two common types of temperature sensors), the buyer's main concern was cost. He had assumed these instruments were priced similarly.
The reality is not all applications are the same and not all temperature sensors are created equal. A sensor designed to measure air temperature in a room is vastly different from one built to withstand 1,400 °C in a heat-treating furnace. The type of sensor, the environment it's used in and the level of accuracy or durability required can all influence the price.
As a trusted leader in temperature and pressure measurement, we created this article to help you understand what really goes into the cost of a temperature sensor. Read this article to learn the top five cost drivers for temperature sensors so you can make a confident, cost-effective decision. By identifying what matters most to your application, you can avoid overpaying for unnecessary features—and feel confident that you’re selecting the right tool for the job.
When you are done reading you will have a better idea of how much you can expect to pay for these instruments. Plus, you will see additional resources that can address other questions you may have about temperature sensors.
How Much Do Temperature Sensors Cost by Industry Application?
The cost of a temperature sensor is closely tied to how it's used. Some applications require basic sensing, while others must withstand extreme environments or meet strict industry standards.
Here’s a general breakdown of typical costs by application:
OEM/HVAC Systems ($10–$200): OEM systems may require temperature measurement for hydraulic power units, air compressors and more. For heating, ventilation and air conditioning, temperature sensors are typically used to monitor ambient or duct air temperature in controlled environments.
Industrial Equipment ($25–$500): Machinery monitoring often requires more rugged sensors that can handle vibration, moisture, or elevated temperatures.
Food & Beverage and Pharma/BioTech Processing ($50–$1,500): Sanitary sensors with hygienic fittings are needed for food safety compliance, pushing costs higher. These applications demand high-accuracy sensors with FDA-compliant materials and validation documentation, contributing to a higher price.
High Accuracy Applications ($1,000–$2,000+): Sensors in industries like oil and gas where accuracy and hazardous approvals are important often require explosion-proof housings, extreme temperature resistance and regulatory certifications like ATEX or CSA, all of which will add to the cost.
Top 5 Temperature Sensor Cost Drivers
As you can see, when it comes to temperature sensors like RTDs and thermocouples, price can vary dramatically. But what drives these differences? Below are the five most important factors that influence the cost of a temperature sensor.
1. Market Applications
- OEM / HVAC applications use custom deigned sensors, which include RTDs, NTCs, and KTY thermistors. These are often small, cost-effective probes made from plastic or metal, and can come with or without electrical connectors.
These sensors are compact and economical, offering sufficient accuracy for monitoring lower temperature ranges typically found in compressors, pumps, underfloor heating systems, and HVAC units. Their simple construction makes them easy to install and integrate into OEM systems. - Industrial applications frequently use S80/S81 or S50-type sensors, which include RTDs and K-type thermocouples designed with rugged construction and robust mechanical features.
These sensors are built for durability and reliable performance in environments with vibration, moisture, or moderate temperature extremes. RTDs in this category often feature 316 stainless steel sheaths, while thermocouples use materials like Inconel for high-temperature resistance. Many models come with extension leads, making them easy to install in machinery like turbines, motors, and industrial equipment without requiring thermowells. - Process applications depend on S50 or S70-type RTDs and thermocouples, typically used with thermowells and designed for harsh environments or continuous operation.
These instruments are available with head-mount transmitters, hazardous location approvals (FM, IECEx, ATEX) and wide temperature ranges—with RTDs operating up to 600 °C and thermocouples up to 2,000 °C. Commonly used in oil & gas, chemical processing, power generation, and petrochemical sectors, these designs offer exceptional accuracy and are built for long-term stability. Materials like sapphire insets and precious metals support extreme conditions and aggressive media exposure. - High Accuracy applications require precision-type RTDs or thermocouples, typically custom-built to meet strict performance standards for calibration or metrology-level accuracy.
These sensors offer ultra-low drift, excellent repeatability, and an accuracy of ≤0.1% of the measuring span. They are built with high-grade resistance elements and specialized insulation to ensure high stability over time. Used in applications where exact measurement is non-negotiable, they help average temperature over long zones, serve as alternatives to multiple sensors, and support critical control systems in advanced manufacturing or research environments.
Figure 1: Market Applications for Temperature Sensors
2. Temperature Measurement Range
The temperature range of a sensor can be a major factor in the price:
- Room temperature sensors (e.g., in HVAC) have very simple designs and less expensive components, resulting in a lower cost.
- RTDs operate from -200 °C to 600 °C and offer good accuracy at a moderate price.
- K-type thermocouples can measure from -200 °C to 1,100 °C.
- Precious metal thermocouples with sapphire insets, which are used in extreme applications (up to 2,000 °C), significantly increase the cost.
3. Hazardous Location Approvals
If a temperature sensor is used in a hazardous environment, it must meet regulatory standards from agencies like FM, IECEx or ATEX. These approvals can add significantly to the price.
There are two main types of approved designs:
- Intrinsic Safety: Limits electrical energy to prevent an explosion.
- Explosion-Proof: Contains a limited explosion to prevent a larger explosion.
Both types require additional costs; the intrinsic safety has extra electrical testing and the explosion-proof design must use an explosion-proof head.
4. Sensor Construction
The materials, size and mechanical design of a sensor all impact price:
- Probe Length & Diameter: Longer or thinner probes are more expensive due to complexity and material use.
- Materials: Common materials like aluminum or brass are cheaper. 316 stainless steel and Inconel are more durable but increase cost.
- Sensor Head & Cable Gland: Aluminum heads are standard, while stainless steel or explosion-proof heads increase costs. Cable gland material and certification (e.g., XP-rated) also add to the final price depending on the material used and whether it is explosion proof or not.
- Lag Extensions: Longer lags or special mounting configurations add material and labor costs.
5. Options and Accessories
There are several common options or accessories that will add to the cost. Common examples include:
- Transmitters: For 4–20 mA output, HART, PROFIBUS or FOUNDATION Fieldbus compatibility.
- Documentation: Calibration certificates, material traceability and compliance testing.
- Thermowells: Often required in industrial and process applications. In some cases, the thermowell can cost as much—or more—than the sensor itself.
Ready to learn more?
You now know there’s no one-size-fits-all answer when it comes to temperature sensor pricing. From low-cost HVAC probes to high-accuracy sensors used in critical applications, the right choice depends entirely on your performance requirements, environment, and regulatory needs.
Using the appropriate sensor configuration will help extend product life, ensure accurate measurement, and protect both equipment and operators. When you understand what drives cost, you’re better equipped to choose a sensor that balances price and performance—without compromising safety or reliability.
To learn more about temperature instruments, here are a few related articles that may interest you:
- What is a Temperature Sensor?
- Which RTD or Thermocouple Lag Extension is Right for Me?
- What are Safe Temperature Sensors for Hydrogen Applications?
- When to Use an RTD vs. a Thermocouple Temperature Sensor
- Fitting a Thermowell to Bimetal Thermometers or RTDs/Thermocouples
- How Much Do Thermowells Cost? 5 Factors that Influence Price
Feel free to contact us and speak to one of our product specialists who can answer all of your temperature measurement questions. In the meantime, download our temperature sensor product guide to learn more about our RTD and Thermocouple products.
