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Food Industry
The production of dairy cultures is a process characterised by heat treatment, cooling, inoculation, incubation and storage. Exact timing and temperatures must be maintained throughout all phases of production. In addition, contamination from outside must be avoided. Reliable level measurement and point level detection are important for maintaining an optimal process.
Food Industry
The milk is mixed with the cultures and the rennet and fed into the cheese vat. The milk is then coagulated at a constant temperature of +35 °C. After it has solidified, the curd is cut. The whey is then pumped out through a pipeline. The curd is removed for further processing. Reliable point level detection prevents dry run.
Food Industry
In a plate heat exchanger, the milk is heated up to +85 °C, depending on the process, so that all germs are killed. The milk is heated in multiple sections, kept hot and cooled down again by cold, inflowing milk. This in turn warms up the inflowing milk. Reliable pressure measurement is required to maintain an optimal process in the heat exchanger.
Food Industry
In order to prevent the milk fat from settling on top of the milk, either just the cream or the whole milk is homogenised in the next step. This is where the cream or milk is pushed through micro-sized nozzles, which reduces the size of the fat globules and distributes them evenly in the liquid. The homogenised cream is then returned to the skimmed milk. Pressure in the feed line is monitored to control the homogenisation process. At the same time, pressure monitoring of the hydraulic oil ensures optimal control of the pistons.
Food Industry
Deseeded fruits and other ingredients for the production of jam are weighed and placed in a cooking vessel and gently heated. The cooking process takes place in a closed vacuum boiler at a temperature of 65 °C to 85 °C, in order to maintain the product quality and preserve the fruits’ flavours and colours. Pressure transmitters are deployed to closely monitor the vessel pressure and jam cooking process to ensure the setting point for the conserve is reached. One transmitter measures the head pressure, the other at the bottom of the tank measures the total pressure. The difference between the two is used to calculate the level with great precision.
Food Industry
In the production of soft cheeses, various types of cheese are mixed and melted in a mixing tank. The cheese collects on the walls of the tank and is scraped off again by large spatulas. To ensure efficient production of the soft cheese, reliable level measurement is required.
Food Industry
After the raw milk has been delivered and stored, it is first preheated to approx. +55 °C in the preheater before being passed on for separation. To ensure an optimal heating process, both the cool and hot water need to be monitored by a reliable pressure measuring system.
Food Industry
The incoming raw milk is stored at a temperature of about 4 °C and stirred gently at all times to ensure it is kept until it is forwarded for further processing. As well as measuring the level in the vessel, the milk is protected against contamination with an overpressure. Point level detection prevents any overfilling of the raw milk tank.
Food Industry
After the raw milk has been heat treated, it is cleaned in the separator and separated into the components cream and skimmed milk. The raw milk and cream are brought back together again in mixtures that depend on the desired fat content. To ensure a continuous supply of raw milk to the separator, the pressure in the raw milk supply line is monitored. The pressure in the skimmed milk and cream outlets is also regulated to ensure uniformity and standardisation. A point level detection system monitors the separated solid particles, such as the dirt or bacteria that settle to the bottom of the separator, and controls the cleaning processes.
Food Industry
The milk lactose is converted to lactic acid under controlled heating in stirring and batching tanks. This process thickens the milk to yoghurt and gives it its sourish taste. The resulting product is then cooled down. In further processing into a fruit based yoghurt, berries, nuts or grains are added and stirred in. The level and point level detection must be reliably detected to enable optimal filling of the vessel.
Food Industry
The rennet is needed to coagulate the milk when making cheese. It is stored in a storage container and metered out into the cheese vat as needed. Reliable level and point Level detection are essential to ensure that sufficient rennet is on hand for continuous cheese production.
Food Industry
Milk and milk-based products such as cream, standard and pasteurized milk have to be stored in the correct quantities depending on production requirements. Since whole milk tends to separate into milk and cream even at low temperatures, it has to be circulated during storage. The quality of the milk must not be affected by stirring. To ensure that the circulation does not begin until the agitator is completely covered with product, a reliable measurement is required.
Food Industry
Yoghurt is stored in the supply tank of the filling machine. Reliable level measurement and point level detection are important for maintaining the filling process. A point level sensor is also used to prevent dry running of the supply to the machine.
Food Industry
During the brewing process, a thick layer of foam is always present in the beer tanks. Therefore usually two pressure transmitters are used for level measurement. One transmitter measures the head pressure, while the other at the bottom measures the total pressure. The level is precisely calculated from the differential between these two pressures. Hygienic process fittings are absolutely necessary for these sensors.
Food Industry
Before they are filled with beer, the bottles are thoroughly cleaned. The bottles are fed into the system and filled with caustic water in the basin of the washing facility, which removes all coarse dirt and contamination. Water at different temperatures is then sprayed into the bottles via high-pressure nozzles in order to remove any remaining dirt and the caustic solution. To ensure optimal system operation, the level in the basin is hydrostatically monitored. In addition, the pressure in the supply line to the basin and in the water pipeline to the rinsing nozzles is measured.
Food Industry
CO2 is produced during the fermentation process in the fermentation tank. It is captured to increase efficiency and used later in the filling process. To this end, CO2 recirculation systems are integrated in the brewing process. In whats known as a foam trap, the CO2 is fed into a small container and passed through a tank filled with water, in order to filter out any residues in the gas generated in fermentation. Foam is produced during this process. If too much foam accumulates, it has to be flushed out at an early stage. For this purpose, a fine spray of water is introduced via a spray ball to 'kill the foam'. A point level detection system ensures a reliable and efficient flushing process and reduces water consumption.
Food Industry
The cleaning of process equipment in the food industry takes place within the framework of validated "Cleaning in Place (CIP)" processes that ensure aseptic conditions in production tanks. Sodium hydroxide or concentrated acid are frequently used as cleaning agents, which are stored in the storage tank of the CIP system and diluted in the production vessel. Level measurement enables optimal storage of these cleaning agents. Point level detection serves as overfill and dry run protection.
Food Industry
In the condenser, potable water evaporated as steam and condensed to form pure, clean water . Inside the condenser there is a cooling system that cools the steam to make it condense. The feed of cooling liquid is monitored in the pipeline. Point level detection ensures that sufficient condensate is present to prevent steam from directly entering the circulation reservoir.
Food Industry
After a large part of the yeast has already been filtered out in the separator, the brew leaves the green beer storage tank and is pumped into the diatomaceous earth filter for filtration. Here, the remaining yeast cells and other substances causing turbidity are removed with the help of diatomaceous earth, which clarifies the beer. The limit level is detected in the diatomaceous earth storage tank. If necessary, diatomaceous earth is added to the diatomaceous earth filter via water inflow. The degree of contamination of the diatomaceous earth filter is monitored by an electronic differential pressure measuring system.
Food Industry
After the wort has been cooled down to the appropriate temperature in the wort cooler, it is pumped into the fermentation tanks. The fermentation process is then started by adding in yeast. The yeast converts the malt sugar dissolved in the wort into carbonic acid and alcohol. To ensure optimal fermentation in the tank, the following key parameters are measured: hydrostatic pressure for determining the level, overpressure for CO2 content monitoring and limit level for overfill or dry run protection.
Food Industry
After fermentation and after a large part of the yeast has already been removed in the separator, the green beer is placed in storage. Here it is continuously cooled. The green beer is then pumped into the filtration system. In the green beer storage tank, the overpressure, the limit level and the actual level are continuously monitored.
Food Industry
The malt is prepared for mashing in the malt mill. Wet or dry malt mills are used depending on which brewing process is being used. During the milling process it is important to have a continuous flow of malt. If the mill is operated without malt, wear increases, which can lead to breakdowns and outages. To prevent the mill from running empty, the limit level is monitored.
Food Industry
The crushed malt is mixed with brewing water to create the mash. The mixture is heated in the mash tun and the natural enzymes convert the insoluble grain starch into soluble malt sugar. During the process, all the malt ingredients important for the beer are transferred to the brewing liquor. The end product is then clarified, separating the enriched brewing liquor from the solids. Continuous level measurement is required during the cooking process.
Food Industry
A hot caustic solution is required for fast cleaning. It is heated in the storage tank and then flushed into the production equipment. The tank is wrapped in a steam heating jacket that serves to control the temperature inside the tank. The level measuring system is used to control filling and discharge. Level detection prevents the tank from overfilling or running empty.
Food Industry
Hops, malt and raw fruit sugar are required as raw materials for the brewing process. The raw materials are stored in large silos. To ensure continuous supplies for production are maintained, the level must be constantly monitored.
Food Industry
In the production of purified water, the process begins with tap water being fed into the steam separator. The tap water evaporates there and is fed into the condenser. Evaporation is effected by a heat exchanger supplied with saturated steam. To ensure that the heat exchanger is always covered with tap water, reliable level detection is required. The pressure inside the steam separator must be kept constant in order to achieve maximum efficiency.
Food Industry
The yeast is grown and stored in small storage tanks at an optimal temperature, then added to the fermentation tanks as required. To ensure ideal storage, the minimum and maximum limit levels as well as the pressure in the tank are monitored.
Food Industry
Beer is continuously delivered into the filler supply tank of the bottling machine. Reliable level measurement is important for an optimal filling process. A point level sensor is used to also prevent dry run.
Food Industry
Purified water is used for the CIP cleaning of the production equipment. This water is produced through filtration and distillation and then stored temporarily in tanks. Absolute sterility and cleanability are essential criteria for all device components that have direct contact to the medium. This also applies to the instruments for level and pressure measurement in the tank.
Food Industry
In the wort cooler, the wort is cooled down from approx. +100 °C to 8 - 15 °C. The yeast is added in a subsequent process. Reliable pressure measurement is required to maintain an optimal process in the wort cooler.
Food Industry
Hops give beer its typical beer aroma. Proper dosage of the hops is therefore enormously important for the flavour of the finished product. Wort and hops are mixed together and cooked in the wort kettle. To ensure reliable control of the hops dosage and cooking process, level and pressure measurements are integrated in the process.
Food Industry
After leaving the fermentation tank, the green beer is fed to the separator. There, a large part of the yeast is removed before filtration. To ensure a continuous supply to the separator, the pressure in the green beer supply line is monitored. A level detection system monitors the separated yeast, which settles in the lower part of the separator, and controls the cleaning process.
Food Industry
The aluminium cans are sterilised with steam at a temperature of 120 °C and a pressure of 3 bar in an autoclave. Then, while the cans are still in the autoclave, they are cooled down with water to a temperature between 35 °C and 40 °C. They are dried and further cooled before being stacked in the warehouse. To enable a safe, optimal autoclaving process, pressure and limit level are measured.
Food Industry
The so-called Brix value (expressed in Brix degrees) is controlled in a concentrator. This value indicates the proportion of solids in a liquid (density). A certain Brix value is required, for example, to produce an optimal tomato concentrate. The liquid circulates in a spiral tube, from which the concentrate is obtained. The liquid content is extracted via evaporation in a special chamber. Electronic differential pressure measurement ensures accurate density measurement.
Food Industry
Foods often consist of a mixture of different raw materials. Mixers are used, for example, to mix solids into liquids. The resulting mixture is then further processed or used in downstream processes, if required, or directly packaged. The level switches are used to control the inlet valve and protect the vacuum pump from running dry.
Food Industry
Sodium chloride and calcium salts are stored in small plastic tanks. When necessary, these substances are added to the food as additives to regulate the pH value and consistency. The plant operator needs exact level readings from the tanks at all times to ensure timely replenishment.
Food Industry
The selected, peeled tomatoes are packed in metal cans with a capacity of up to 10 kg. The telescopic filler automatically feeds the tomatoes into the cans. The level of the tomatoes on the turntable must be measured so that there are enough tomatoes to fill the cans.
Food Industry
The washed tomatoes are fed into the steam drum on a conveyor belt. They are first heated to about 115 °C. In the next process step, the tomatoes are cooled in a vacuum, which separates the skin from the tomato. The skins are transported to a container via a special conveyor belt and the peeled tomatoes go to the next process step. Pressure sensors measure the steam as well as the vacuum in the pipelines. Level detection is required to monitor the level in the waste container.
Food Industry
Tomatoes are stored in the supply tank of the filling machine. Reliable level measurement is important for an optimal filling process. A point level sensor is used to also prevent dry run.
Food Industry
When correcting the pH value and adding ingredients; salt, sugar or citric acid are dissolved in water. Depending on the product, acids or bases are added to obtain the desired pH value in the final product. To ensure a continuous production process, reliable level measurement is required.
Food Industry
The empty cans enter the filling machine on a conveyor belt. As soon as an individual can reaches the appropriate position for filling, it is pulled in with the help of a pneumatic cylinder and filled under vacuum with natural tomato juice. The level of juice in the supply tank is monitored by a radar sensor. In each filling cycle, the same amount of tomato juice is sucked out of the supply tank. Reliable point level detection ensures that all cans are filled equally.
Food Industry
In the plate heat exchanger, the tomatoes are heated up to about +85 °C, depending on the product, so that all germs are killed. The tomatoes are heated in multiple sections, kept hot for a time and then cooled down again. This process is suitable for thermal treatment of tomato concentrate, pulp and juice. Reliable pressure measurement is required to maintain an optimal process in the heat exchanger.
Food Industry
In the pulper, the cores and skins are separated from the pulp of the tomatoes by means of centrifugal force. To ensure that this process runs efficiently and that there is no downtime, it is important to monitor the level precisely. Limit level detection in the waste container prevents overfilling.
Food Industry
Tomatoes are unloaded from the truck into the basin and, with the help of water, pumped through the washing line. Heavy materials such as stones and mud sink to the bottom and are caught by a flow in the opposite direction. The tomatoes are washed with high-pressure air blowers. The radar sensor enables accurate level measurement, ensuring an optimal flow of tomatoes.
Food Industry
In the agricultural industry, animal feed is usually stored in tall, slim silos. To ensure that there is always enough animal feed in stock, a reliable level measurement combined with wireless data transmission is a great business asset. A fully automatic notification of resupply requirement can trigger the sending of an order to the animal feed supplier.
Food Industry
A wide variety of aromas and flavourings are used in the food industry. The containers which store these ingredients until further processing often have small dimensions and internal obstructions. They are cleaned several times a day during batch changes. Level measurement is essential for cost-effective stocking of these ingredients.
Food Industry
The small batch filler vessels around 1 m high and 60 cm diameter alongside the production facility supply the filler heads of the tank. The products vary from conserve to peanut butter to chocolate spread, with varying viscosity and temperatures. The product density is also changing from each batch. The level system is required to enable an optimal filling of jars.
Food Industry
After the “conching” process the liquid chocolate is kept in large tanks for further processing. An agitator stirs the chocolate “mass” to maintain a uniform consistency and temperature in the vessel. A reliable level measurement is required in both the chocolate tank and the downstream filler hoppers to control the production process.
Food Industry
The delivered sugar beets are poured from trucks onto conveyor belts that transfer it to the washing and shredding facility. Multiple level sensors are required to monitor the loading of the beet as it goes on the conveyor belt to optimise the feed rate and energy usage.
Food Industry
In the production of spices, the spices are first mixed with water and oil to form a slurry. This is fed into an evaporator, where water is removed to turn it into a kind of syrup. The thickened spice syrup must have exactly the right density - so that it can be spread thinly onto metal sheets for oven drying, ready to be ground into powder. To ensure the optimal density of the spice syrup, it requires a continuous measurement during manufacture. The pressure in the feed pipe leading to the evaporator also requires careful monitoring to ensure a smooth-running production process.
Food Industry
The different varieties of flour are most often stored in tall silos with very narrow chambers. Filling takes place regularly and is done pneumatically from the top. In order to produce the desired blend of different varieties at any time, a reliable level measurement in the individual silos is essential, even during filling. The process challenges include dust generation, strong air movement and a poorly reflecting product surface.
Food Industry
Barley is stored in malt houses in silos up to 20 metres high before it is processed into malt for production of beer. Filling the silos generates a lot of dust and the material cone geometry constantly changes during the filling and emptying process. A reliable indication of the level ensures the smooth operation by sending signals corresponding to the level or possible limit levels of the grain.
Food Industry
The ingredients for making ice cream are accurately weighed and fed into a mixing tank, where the "premix" is made. Afterwards, the premix is passed through the homogenizer at a pressure of about 140 bar and then pasteurized at 80 °C. The level in the premix vessel and the pressure in the pipeline leading to the homogenizer need to be continuously monitored to ensure continuous ice cream production.
Food Industry
Elderberries are first mashed up in order to produce a concentrate, from which food dyes are then made. The elderberry mash is refrigerated to maintain the product quality. Accurate level measurement and exact records of the process temperatures ensure hygienic operation.
Food Industry
The finished meat pellets and kibbles are fed onto a conveyor belt ready for packaging to be sold as pet foods. In order to ensure a continuous supply of meatballs, the conveyor belt requires careful monitoring.
Food Industry
Creatine is a naturally occurring substance in the body, but it is also produced synthetically. The ingredients are filled into an agitated reaction vessel. Mixing the ingredients generates an exothermic reaction during which the creatine is separated out. Continuous level monitoring ensures a reliable reaction process in the vessel.
Food Industry
Production of polyvinyl acetate – the base material for chewing gum – is carried out in a reaction vessel with a four stage agitator. The various raw materials begin to react when they are mixed by the agitator. To ensure smooth production, accurate level measurement is required.
Food Industry
The reactor is filled with concentrated fruit juice and heated. In order to achieve a higher density, the water content is reduced through evaporation. As soon as the required Brix (density) value is reached, the syrupy fruit juice concentrate is pumped out. The concentrate is then pumped over to a filling machine to be stored in barrels or to a cooling machine where it is hardened and granulated. Reliable density measurement is used to monitor quality in the production process.
Food Industry
Small vessels and hoppers are used as intermediate storage containers in which ingredients such as flour, yeast and salt are there, ready for manufacture into baked goods. Level measurement and point level detection ensure that the ingredients required have high levels of availability and replenish when needed to meet production demand.
Food Industry
Flour and sugar are the basic ingredients for many food products and stored in silos up to 20 metres high. The filling and emptying is often performed by pneumatic systems that transport the media from the large external silos and deposit them in smaller holding vessels for further processing. The filling and emptying processes are controlled by reliable level measurement. Pressure monitoring is also needed in the pneumatic conveying pipelines.
Food Industry
In the food industry, liquid media such as glucose, fruit juice or syrup must always be kept in stock. To get them ready for the production process, some liquids must be either pre-cooled or pre-heated, while still in the storage tanks. This is done by means of a water-filled ‘jacketed’ container wall that can be either cooled or heated. To ensure uninterrupted production, a reliable level measurement is essential.
Food Industry
Alcohol storage tanks are considered potentially explosive and are therefore kept in special rooms. When the alcohol is needed, it is pumped directly to the appropriate production vessel through a ”ring main” supply system. Reliable measuring instruments are required for dependable measurement of the level in the tank and for monitoring the feed pressure in the pipeline.
Food Industry
In beet sugar refining the raw sugar is heated and dissolved in water into liquor. There are typically several interconnected agitated vessels in this process, each one with a weir allowing the liquor to flow from vessel to vessel. During the dissolving process, sugar byproducts from the downstream refining process are reintroduced to enable sugars to be recovered. To ensure a continuous process, a reliable level measurement is required.
Food Industry
The process in a vacuum pan is designed to ensure the growth of sugar crystals. The syrup is cooked in a closed boiler with steam-heated tubes and the liquid is extracted. The intermediate product is magma, a mixture of crystal sugar and syrup. This mixture is then poured into a holding tank, the crystallizer. In the holding tank, the cooling and drying process creates a substance called massecuite, from which the sugar crystallizes. The level in the tank must remain constant, so a reliable level measurement is required here.
Food Industry
The thin juice extracted from sugar beet is thickened by the reduction of excess water in multiple stages at the evaporator station. This evaporation process is carried out under vacuum and heat. The liquid in the evaporator boils so violently that great amounts of vapour are formed. A level sensor is needed to monitor and control the thickening process.
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