In contemporary manufacturing, accurate level measurement is paramount for operational efficiency, cost management, and process integrity. Consequently, robust measurement techniques are indispensable within the beverage sector, where substantial volumes of liquid raw materials are processed.
Adopting outdated, manual methods carries the risk of not only material shortages and overfilling but also significant inefficiency.
Döhler, a global producer of intermediate products for the beverage industry, successfully transitioned to advanced level measurement systems. The implementation of radar level transmitters from VEGA's BASIC series enabled the company to optimize its production processes for the long term, serving as a compelling example of digitalization and automation in industrial settings.
The Challenge: 105 Tanks Lacking Real-Time Oversight
At its Oosterhout facility in the Netherlands, Döhler manages a substantial raw material storage area comprising 105 tanks for liquids integral to recipes used by numerous well-known beverage brands.
These tanks, with capacities ranging from 50 to 1000 cubic meters, hold ingredients such as fruit concentrates, ‘Not from Concentrate’ (NFC) products, and other liquid components.
Previously, tank levels were determined manually. Employees used a single portable VEGA radar transmitter, placing it on each tank's filling port. The resulting measurements were then manually transferred to spreadsheets and converted into volume figures. This approach presented several drawbacks:
- Time-intensive: The measurement process consumed valuable working hours.
- Imprecise: Tanks lacking elevated platforms could not be measured accurately, necessitating estimations of their levels.
- Operational risks: Errors in measurement data frequently led to overfilling, production bottlenecks, and unnecessary tanker dispatches.
Project engineer Niels van den Hooven aptly summarized the situation:
Sometimes we thought there were 25 tons in the tank, but in reality there were only 20. Then we had to react quickly. Conversely, it has also happened that tanks were overfilled because there was already more material in them than estimated. That’s what happens when you don’t have an exact overview of your stocks.
The Solution: Permanently Installed Radar Level Transmitters from VEGA
In pursuit of dependable and efficient level monitoring technology, Döhler engaged with measurement specialists at VEGA. Building upon prior positive experiences with a portable VEGA transmitter, the decision was made to permanently install fixed radar level transmitters.
VEGA customer advisor, Lode Simons, collaborated closely with Döhler to identify the most suitable transmitters for a customized solution:
First, we make clear exactly what the customer needs. What liquids are involved? Are there agitators or other interfering factors? How high is the viscosity? Is foam generated? Then we make sure that the radar instrument measures the level precisely and that the data can be reliably converted into volume.
Two models from the VEGAPULS BASIC series were employed:
While the high-end VEGAPULS 6X transmitter offers advanced features, these two transmitters from the VEGA BASIC series are engineered for less complex applications, while still delivering comparable accuracy and reliability.
Given that Döhler's tanks do not experience foam generation and their liquid surfaces remain stable, with agitators positioned on the tank sides, the conditions are ideal for the VEGAPULS BASIC series.
The wired-connected radar transmitter VEGAPULS C 23 reliably measures in real time levels in tanks over 15 meters high. Image Credit: VEGA Controls Ltd.
VEGA BASIC Series: Radar Technology for Standardized Applications
The VEGA BASIC series has been specifically developed for applications under moderate process conditions, such as those encountered at Döhler.
VEGAPULS radar transmitters provide highly accurate measurements, combining the advantages of advanced radar technology with a cost-effective, durable construction, rendering them virtually maintenance-free.
They are thus particularly well-suited for routine processes within the food and beverage industry where reliable level transmitters are essential without escalating investment costs.
Key features of this series include:
- Advanced 80-GHz radar technology.
- Availability in standardized configurations.
- Flexible integration into process control systems via interfaces such as 4...20 mA, Modbus, or HART.
- Bluetooth interface for simplified configuration and diagnostics.
- An optional integrated display.
- The ability to be augmented with pressure transmitters and level switches for comprehensive process monitoring.
The compact VEGAPULS 31 radar transmitter ensures efficient and reliable level measurement in tanks up to 20 meters high. Image Credit: VEGA Controls Ltd.
Installation and Integration: Swift, Secure, and Future-Oriented
The installation of the initial 15 transmitters proceeded smoothly, with systems operational within three days. The primary challenge involved cabling, as many control panels are situated near ground level, requiring long cables to be routed to the tank summits.
However, with the assistance of VEGA experts for transmitter calibration and external contractors for welding and cabling, Döhler successfully integrated the measurement systems quickly and reliably.
Particularly beneficial aspects included:
- Simplified calibration by VEGA
- The Trendwatch tool for precise volume calculation and real-time level visualization
- Training for personnel to empower them to resolve issues independently, identify urgent requirements, and optimize transmitter utilization
As a result, Döhler now benefits from a comprehensive monitoring system that significantly streamlines both production planning and logistics.
Advantages of Radar Level Transmitters at a Glance
The transition to VEGAPULS BASIC transmitters provided Döhler with numerous advantages in adhering to current production standards:
- Real-time transparency: All tanks can be digitally inspected at any moment.
- Time savings: Employees are no longer required to conduct manual measurements.
- Error prevention: Accurate measurements preclude overfilling and planning errors.
- Cost efficiency: Reduced labor time, minimized material loss, and optimized tanker utilization
- Maintenance-free: The transmitters are robust and require minimal maintenance.
- Future-proof: Seamless integration into digital systems and Industry 4.0 strategies
Level Measurement as a Key to Enhanced Efficiency
The implementation of fixed radar level transmitters at Döhler illustrates how modern level instrumentation can positively impact production processes, especially when fully digitalized.
With the VEGAPULS BASIC series, the company has eliminated manual measurements, reduced operational expenses, and elevated process reliability, resource planning, efficiency, and transparency to new heights.
In an era where digitalization and automation are critical determinants of competitiveness, Döhler's example demonstrates that radar transmitter-based level measurement is not an optional addition but a fundamental component of today's process industry.
This is particularly relevant for companies in the beverage sector, characterized by fluctuating raw material availability, stringent quality demands, and tight deadlines, as well as for other industries. Investing in intelligent level-sensing technology today lays the groundwork for enduring success in future production environments.
This information has been sourced, reviewed and adapted from materials provided by VEGA Grieshaber KG
For more information on this source, please visit VEGA Grieshaber KG