A simple, rapid, reliable, and reproducible method for mass production of disposable sensors using screen-printing technology is described. Homemade printing has been characterized and optimized on the basis of effects of the modifier and plasticizers. The fabricated bi-electrode potentiometric strip containing both working and reference electrode was used as dextromethorphan (DXM) sensor. The proposed sensors worked satisfactorily in the concentration range from 10−5 to 10−2 mol L−1 with detection limit reaching 6 × 10−6 mol L−1 and adequate shelf life of 8 months. DXM was determined in pharmaceutical formulations under batch and flow injection analysis (FIA) conditions with sampling output 120 h−1. Copyright © 2010 John Wiley & Sons, Ltd.