Radar and pressure sensors improve measurements for family-owned distillery

The VEGAPULS 69 is specifically designed for bulk solids level measurements. The radar sensor emits a radio microwave signal toward the product surface, which is then reflected to the radar antenna. The sensor electronics use the time of flight to calculate a measurement, and it does all of this without ever touching the product its measuring.

The radar sensor’s 80 GHz transmission frequency gives the radar a tighter focus than other radar sensors using a lower frequency. This enables the radar to measure all the way to the bottom of the silo – even one as tall as five stories. Additionally, more of the radar signal reaches the product surface, so the radar receives a stronger return signal to provide a more reliable output.

When it comes to buildup and dust, superior electronics within the VEGAPULS 69 allow the radar to “see through” anything that accumulates on the sensor antenna. During filling when dust is most prevalent, the radar sensor ignores any dust clouds because the radio microwave signal moves right through them, never affecting the measurement.

With four new non-contact radar level sensors installed and providing accurate, maintenance-free level measurements, the distillery’s attention turned to another challenging measurement, and this one was a pressure measurement closer to the end of the distilling process.

The evaporator is a pressurized vessel that removes moisture from spent grain leftover from the distilling process. The grain is then sold to farmers as feed for livestock. To remove all the moisture, air from the evaporator is removed and the pressure drops to a full vacuum.

The distillery uses a differential pressure measurement to control the process in the evaporator. However, spent grains commonly got stuck in the impulse lines, clogging the lines and resulting in measurement errors. Again, regular maintenance and cleanings were necessary, so VEGA recommended using two VEGABAR pressure sensors in an electronic differential pressure (EDP) system.

With electronic differential pressure, two different pressure sensors – a primary and a secondary – are connected by a small electrical cable to do the same job as a single dual-sided transducer. The sensor electronics within the primary sensor use the outputs from both sensors to calculate a differential pressure measurement.

Additionally, many VEGABAR pressure sensors use ceramic measuring cells instead of the traditional metallic measuring cells. Ceramic is abrasion-resistant, so pressure sensors with these cells can withstand harsh environments like the grains in the bottom of the evaporator vessel. Plus, ceramic pressure cells are drift-free and require fewer routine calibrations.

Using electronic differential pressure eliminates any impulse lines, and therefore, the possibility of those lines getting clogged or the necessity to regularly check and clean them. Once the distillery factored in the ceramic cells, the costs of routine maintenance and process shutdowns virtually disappeared, and the distillery is now getting the same measurement more reliably than ever before.

The distillery has worked with VEGA for many years now, so when the distillery runs into a problem relating to any of their level and pressure measurements, VEGA is their first call. When a pressure sensor failed in the distillery’s equalization tank early one morning, they reached out to their local VEGA contact.

Fortunately, their VEGA connection had a spare VEGAPULS C 21 radar level measurement sensor. While it wasn’t a direct replacement in terms of technology, it was just a matter of learning more about the process and discovering whether the sensor could work in their application. After a brief discussion that morning, VEGA was in their facility that afternoon, and the distillery had a working level measurement only a few hours after the original had failed.

As these two family-owned businesses have worked together, they’ve watched both their working relationship and their companies grow. VEGA has learned more about the distilling process and what it requires from its instrumentation. And the distillery has been able to optimize their process with accurate, more reliable level and pressure measurement instrumentation.

As the distillery looks to the future, they’re planning to upgrade their current equipment and expand their distilling capabilities. This will be the first major capital investment the company has made in well over 50 years, and as they grow their operation, VEGA will be right there to assist with any level and pressure measurements throughout the facility.