Level measurement with radar transmitters: How Döhler saves time and money with VEGA measurement technology
In modern production processes, precise level measurement is crucial for efficiency, cost control and process security. Reliable measurement methods are therefore also essential in the beverage industry, where large quantities of liquid raw materials are processed. Those who rely on outdated, manual processes risk not only shortages and overfilling, but also considerable time losses.
Döhler, an international manufacturer of semi-finished products for the beverage industry, made an impressive transition to modern level measurement technology. By introducing radar level transmitters from the VEGA BASIC series, the company was able to optimise its production processes for the long term – a prime example of digitalisation and automation in the process industry.
The challenge: 105 tanks without real-time monitoring
At its site in Oosterhout in the Netherlands, Döhler operates a large raw materials storage facility with 105 tanks for liquids that many well-known beverage brands – sold in supermarkets or served in restaurants – use as the basis for their recipes. The tanks range in capacity from 50 to 1,000 cubic metres and hold fruit concentrates, “Not from Concentrate” (NFC) and other liquid ingredients.
Until recently, the tank levels were measured by hand. To do this, employees used a single portable VEGA radar transmitter, placing it on the filling port of each tank. The measured values then had to be transferred manually to Excel and converted to volume. This method had several disadvantages:
- Time-consuming: The measurements took up valuable working hours.
- Inaccurate: Tanks without platforms couldn’t be measured, so levels had to be estimated.
- Production risks: Measurement data errors often led to overfilling or bottlenecks and unnecessary tanker trips.
Project engineer Niels van den Hooven sums it up perfectly: “Sometimes we thought there were 25 tonnes 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: Fixed radar level transmitters from VEGA
The wired-connected radar transmitter VEGAPULS C 23 reliably measures in real time levels in tanks over 15 metres high.
In search of reliable and efficient level monitoring technology, Döhler turned to measurement specialist VEGA. Thanks to previous positive experiences with a portable VEGA transmitter, the decision was made to permanently install fixed radar level transmitters. VEGA customer advisor, Lode Simons, worked closely with Döhler to find the right transmitters for a customised 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 are used:
- VEGAPULS C 23 – for measuring ranges up to 30 meters.
- VEGAPULS 31 – for measuring ranges up to 20 meters.
Unlike the high-end VEGAPULS 6X transmitter, these two transmitters from the VEGA BASIC series are designed for less complex applications, but still offer the same accuracy and reliability. Since there is no foam generation in Döhler’s tanks, the liquid surfaces are stable and the agitators are located on the sides of the tank, the conditions are perfect for the VEGAPULS BASIC series.
VEGA BASIC series: Radar technology for standard applications
The compact VEGAPULS 31 radar transmitter ensures efficient and reliable level measurement in tanks up to 20 metres high.
The VEGA BASIC series was specially developed for applications under moderate process conditions, such as those at Döhler. VEGAPULS radar transmitters deliver highly precise measurements and combine the advantages of state-of-the-art radar technology with a cost-efficient, robust construction, which makes them virtually maintenance free. They are thus particularly suitable for standard processes in the food and beverage industry, where reliable level transmitters are needed that do not explode investment budgets.
Special features of the series:
- State-of-the-art 80-GHz radar technology.
- Available in standardised configurations.
- Flexible integration into process control systems with interfaces like 4 ... 20 mA, Modbus or HART.
- Bluetooth interface for easy configuration and diagnostics.
- Optional integrated display.
- Can be supplemented with pressure transmitters and level switches for comprehensive process monitoring.
Installation and integration: Fast, secure and future-proof
Installation of the first 15 transmitters went smoothly – the systems were up and running within just three days. The biggest challenge was the cabling, as many control panels are installed close to ground level and long cables had to be laid all the way to the top of the tanks. However, with the help of VEGA experts for calibrating the transmitters and external contractors for welding and cabling, Döhler was able to integrate the measuring systems quickly and reliably.
Particularly advantageous:
- Simple calibration by VEGA.
- Trendwatch tool for precise volume calculation and real-time visualisation of levels.
- Training of personnel to enable them to resolve errors on their own, recognise when urgent action is required and make optimal use of the transmitters.
As a result, Döhler now has a comprehensive monitoring system that considerably simplifies both production planning and logistics.
All advantages of radar level transmitters at a glance
The switch to VEGAPULS BASIC transmitters brought Döhler a lot of advantages in complying with today’s production standards:
- Real-time transparency: All tanks can be looked into digitally at any time.
- Time savings: Employees no longer have to carry out measurements by hand.
- Error prevention Precise measured values avoid overfilling and misplanning.
- Cost efficiency: Less working time, less material loss, optimised tanker trips.
- Maintenance free: The transmitters are robust and require virtually no maintenance.
- Future-proof: Integration into digital systems and Industry 4.0 strategies.
Level measurement as the key to increased efficiency
The introduction of fixed radar level transmitters at Döhler demonstrates how modern level instrumentation can influence production processes, especially when they are completely digitalised. With the VEGAPULS BASIC series, the company has not only eliminated measurement by hand and reduced operating costs, but also taken process reliability, resource planning, efficiency and transparency to a new level.
At a time when digitalisation and automation are major factors in determining competitiveness, the example of Döhler shows that: Level measurement with radar transmitters is not an optional add-on, but a central component of today’s process industry.
And this is particularly true for companies in the beverage industry, which is characterised by fluctuating raw material availability, high quality requirements and tight time frames, as well as for other industries:
Investing in intelligent level sensing technology today lays the foundation for sustainable success in tomorrow’s production.
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