food & beverage industry-magnetrol

I N D U S T R Y A P P L I C A T I O N S S E R I E S

Level and Flow Instrumentation for Food & Beverage Processors

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agnetrol® International,Incorporated HygienicSolutions specializes in

hygienic and non-hygienic leveland flow instrumentation usedthroughout the food, beverage, wine,spirits, and brewing industries.Magnetrol® hygienic measurementsolutions are of particular impor-tance in those applications wherethe highest standards of cleanabilitymust be maintained. MAGNETROLindustrial measurement solutionsare used in applications wherecleanability is not essential.

Hygienic Optimized SolutionsMAGNETROL hygienic process

measurement instrumentation isdesigned to help customers opti-mize productivity with processmeasurement instrumentation thatis engineered to meet the highestperformance standards in cleaningand sanitization.

CIP removes residual productto prevent contamination of aproduct and/or cross contaminationof products while sanitization killsmicroorganisms and denaturesproteins. Food industries rely onthe aggressive cleaning processesof Clean-in-place (CIP) andSterilize-in-place (SIP) to achievetheir cleaning and sanitization goals.

MAGNETROL hygienic productsoffer these benefits:

• Manufactured from stainlesssteel materials selected for theirmicrobial resistance and polishedto a surface finish that reduces thepossibility of bacterialadhesion.

• Seamless productdesigns without indenta-tions or incorrect radiiwhere bacteria can harborand which limit effectivecleanability.

• Products which can with-stand aggressive CIP and sanitiza-tion chemicals as well as steamsterilizing.

Hazardous Location ApprovalsLevel instruments for applica-

tions such as alcohol production,solvent extraction or solvent recov-ery may require explosion-proof(XP) requirements. Due principallyto the robust construction of itselectronics housing, an XP instru-ment has been certified to with-stand an internal explosion withoutallowing hot gases or flames toescape from the housing to triggeran explosion in the surroundingatmosphere. The single-compart-ment, hygienic Eclipse® (page 7) isan intrinsically-safe device. Inapplications where XP approvaland a hygienic probe are required,the twin-compartment ECLIPSE(page 6) with a 7XF hygienic probeis an ideal solution.

International ResourcesMAGNETROL instruments

provide you with measurementsolutions that are in the forefront oflevel and flow technology, solutionsthat have earned an industry-widereputation for robust construction,trouble-free set-up and a fastreturn on investment. You’ll alsoappreciate the engineering andservice resources of an internationalorganization that can be brought tobear on your application to ensurethe best, practical process meas-

urementsolutionsfor yourfood orbeverageprocess.�

MOptimize your

food processing

productivity with

level & flow solutions

from Magnetrol®

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Storage and Transport• Chemical InjectorsConveyors

• Piping Systems

• Pumps

• • Tanks, Silos

Other ProcessesAgglomerationAging, Brining, Curing

• Alkalization

• • Carbonation, Aeration

• • Carbonization

• CoagulationCoating

• Fermentation, GerminationSmoking

• • Sulphitation

Fermentation

Plant Utilities• Air

• Cleaning & Disinfecting

• Compressed Air

• • HVAC Systems

• Natural Gas

• • Processing Lubricants

• Vacuum Systems

• • Waste Treatment

• WaterWaste Treatment

Decontamination• High Pressure SterilizingInduction HeatingOhmic Heating

• Pasteurization

• SterilizationUHT Treatment

Agitated Pasteurization

Heating, Cooling• Baking

• Blanching

• Cooking, Boiling

• Cooling, Freezing

• • Dehydration

• Drying, Freeze Drying

• Frying

• MeltingRoastingTemperingCooking Vessel

Raw Materials HandlingHandling, UnpackingSorting, Screening, Grading

• Washing

• Brushing

Separation• Centrifugation

• Chemical Neutralization

• Crystallization, Sedimentation

• Cyclones, Hydrocyclones

• Deionization

• Extraction

• Membrane Separation

Level and Flow Applications for Food & Beverage Processing

Storage Tanks Rotary Washer

Typical Level and Flow control utilization is indicated for the process units below. Level = • Flow = •

Reduction, Mixing, Forming• Homogenizing, Conching

• Mixing, Blending, StirringCutting, Slicing, Chopping

• Grinding, Milling, CrushingForming, MoldingExtrusion

Mixing Vessel Food Centrifuge

Liquid Interface

Level Applications

Technical and specificationinformation is availableonline: magnetrol.com.

Introducing the full-featured thru-airradar with an affordable price point

Left: Model R82with a cast aluminumhousing and a poly-propylene antenna.

Right: Model R82 witha thermoplastichousing and aTri-Clover Tefzel®

antenna.

APPLICATIONSFEATURES

High Performance: Loop-powered,26 GHz, non-contact radar transmit-ter performs liquid level and volumemeasurements in enclosed vessels.

Digital Communications:HART® digital communications.

User Interface: Menu driven 2-line,16-character LCD and 4-buttonkeypad.

Simplified Operation: The R82launcher orientation and echo rejec-tion profiling are simplified for easyuse. The R82’s microwave beam isrotatable for optimized operation.

Convenient, Easy Configuration:Configures with keypad, HARTdigital communications, orPACTware™ software. This allowscomplete configuration via the localuser interface, or remotely with theadded capability of capturing echowaveforms, and viewing trend data,diagnostic conditions and all config-uration parameters.

Measurement Range: 15" to40 feet (0.4 to 12.2 meters).

Media Capabilities: Liquids,slurries, and viscous media.Suitable for hygienic and CIPapplications.

Vessels: For measurement inenclosed vessels; ideal forgeneral chemical storage, day,batch and feed tanks, waterand wastewater tanks andsumps and food & beveragevessels.

Resistance: The fully-encapsu-lated horn antenna offers highperformance and is chemicallyresistant to nearly all standardprocess media.

Advanced Signal Processing:Manages common distur-bances such as false echoescaused by obstructions, multi-path reflections from tank side-walls or turbulence caused byagitators, aggressive chemicals,or aerators.

Vapor Immunity: The R82measures effectively even whenatmospheres above the liquidare saturated with vapor.

R82M O D E L

THRU-AIR RADARTRANSMITTER

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Our new transmitter’s Smart Electronicsimproves measurement accuracy

Technology: Echotel® Model 355 is aversatile two-wire, loop-powered,non-contact ultrasonic transmitter thatmeasures liquid level, volume, andopen channel flow.

Advanced Electronics: The Model 355has intelligent electronics that analyzesthe ultrasonic echo profile, apply tem-perature compensation, monitors forelectrical noise interference, rejectechoes from false targets, and thenprocesses the true echo from theliquid surface.

Friendly Interface: The user interfaceis a menu-driven, 4-pushbutton, 2-linex 16-character display for convenienceand readability.

Convenient Configuration: The Model355 is configurable by either the userkeypad, HART communications, orPACTware. The latter enables a com-plete configuration via the user inter-face, or remotely with the added capa-bility of capturing echo waveforms, andviewing trend data, diagnostic condi-tions and all parameters.

Non-Contact: The Model 355provides non-contact measure-ment in a wide variety of appli-cations.

Versatility: Ideal for sumps,wells, tanks, open channel flowweirs and flumes. Ideal forgeneral industrial applications,chemical storage tanks, batchand day tanks.

Handles Difficulties: TheModel 355 advanced signalprocessing provides extremelyreliable measurement evenwhen application difficulties liketurbulence or false echoes gen-erated by agitator blades orshafts, fill pipes or other tankhardware are present.

Range: A powerful 60 kHzultrasonic transducer andadvanced digital signal pro-cessing is featured to reliablymeasure to 20 feet (6 meters).

Narrow Beam: Model 355transducers feature a 10° coni-cal beam and 10" (250 mm)blocking distance to maximizemeasurement capabilities inmany applications.

Viscosity: Will measure highlyviscous media.


ULTRASONICTRANSMITTER

With 35 flume and weir curves stored in its electronics, the Model 355 easilyadapts to the overwhelming majority of open channel flow applications.

355M O D E L

Top: The Model 355with a cast aluminumhousing and Kynar®

transducer. Right: 355with a Lexan® housingand a polypropylenetransducer.


Simulated Display

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The industrial level transmitter thatis transforming level measurement

ENHANCED MODEL 705GUIDED WAVE RADAR

TRANSMITTER


Versatility: Two-wire, 24 VDC, loop-powered transmitter for liquid level,interface, or volume measurement.

Digital Communications: HART,FOUNDATION fieldbus™ or PROFIBUS PAcommunications.

Convenience: No level change forconfiguration; no field calibration isnecessary.

Strapping Table: 20-point table forvolumetric or flow measurement.

Coupling: Quick connect/disconnectprobe coupling.

Probe Capabilities: Designs to+800° F (+430° C), 6250 psig (430 bar)and full vacuum, cryogenic applica-tions to -320° F (-195° C).

Probe Profiling: The single rod probecan have multiple bends to profile toany vessel shape, avoid internal vesselobstructions and extend measurementinto the vessel bottom.

User Interface: 2-line, 8-characterLCD and 3-button keypad.

Dry Calibration Capability:Save calibration costs and downtimewith our proven “test bench”approach.

Application Range: Virtually allmeasurement and control appli-cations including conditionsexhibiting visible vapors, foam,coating or buildup, surfaceagitation, bubbling or boiling,high fill/empty rates, low leveland varying dielectric media orspecific gravity.

Media Capabilities: Liquids orslurries; hydrocarbons andwater-based media with adielectric of 1.4–100.

Changing Media: Changingspecific gravity and dielectricconstant have little effect onmeasurement accuracy.

Full Span: Measures to thevery top and bottom of theprobe (subject to mediadielectrics).

SIL 2: HART version hardwareis suitable for SIL 2 loops; SafeFailure Fraction of 91%.

Fewer features and a lowerprice make Horizon® Model704 Guided Wave Radar idealfor simple Food andBeverage applications. PACTware software provides a graphic interface whereby

all functionality can be visualized quickly, safely and conveniently.

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SIL 2

Eclipse® Model 705shown with a Model7XF-E Hygienic probe.

Also popular in processfood markets, the 7X5Bulk Solids probe foruse in lighter solidsapplications such asgrains and powders.

Technical and specificationinformation is availableonline: magnetrol.com

Ultra-compact,hygienic transmitter deliversunsurpassed performance

EnhancedEclipse®

Model 705Liquid LevelTransmitterfor HygienicApplications(Simulated display)


Versatility: Two-wire, 24 VDC, loop-powered transmitter for liquid level,interface, or volume measurement.

Digital Communications: HART oroptional FOUNDATION fieldbus andPROFIBUS PA communications.

Convenience: No level change neededfor configuration; no field calibrationnecessary.

Strapping Table: 20-point customtable for volumetric or flow measurement.

Finish: 320 Grit (15Ra) electropolishedprobe and 180 Grit (32Ra) housing.

Probe Materials: Available in 316 SS,AL6XN and Hastelloy® C22®.

Probe Profiling: The single rod probecan have multiple bends, allowing therod to be profiled to any vessel shape,avoid internal vessel obstructions andextend measurement into the vesselbottom.

Approvals: IS and Non-Incendive.

User Interface: 2-line, 8-character LCDand 3-button keypad.

Dry Calibration Capability: Savecalibration costs and downtime withour proven “test bench” approach.

Application Range: Virtually allhygienic level measurementand control applications includ-ing CIP applications.

Media Capabilities: Liquids orslurries; hydrocarbons andwater-based media with adielectric of 1.9–100.

Changing Media: Changingspecific gravity and dielectricconstant have little effect onmeasurement accuracy.

Full Span: Measures to thevery top and bottom of theprobe (subject to mediadielectrics) and, therefore,into the vessel bottom.

SIL 2: HART version hardwareis suitable for SIL 2 loops; SafeFailure Fraction of 91%. FEME-DA report available uponrequest.

ENHANCED MODEL 705GUIDED WAVE RADAR

HYGIENIC TRANSMITTER

PACTware software provides a graphic interface wherebyall functionality can be visualized quickly, safely and conveniently.

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SIL 2


Model 960 Only

HYGIENIC ULTRASONICLEVEL SWITCH

Echotel® Models960 and 961Liquid LevelSwitches for

HygienicApplications

(Housing cover shown removed)

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Compact, hygienicswitches excel in difficultliquid level applications

MODEL-SPECIFIC FEATURES960/961 FEATURES

Technology: Pulsed signal for superiorperformance in difficult conditions.

Immunity: Excellent immunity fromsources of electrical noise interference.

Self-Testing: Extensive self-testing ofelectronics, transducer, piezoelectriccrystals, and EM noise.

Time Delay: Adjustable time delay forturbulent liquids.

Extended Range: Tip-sensitivetransducer measures level to within 1⁄4"of the vessel’s bottom.

Housing: Deep drawn 304 SS.

Finish: 240 Grit (20 Ra) electropolishon transducer surface.

EXCLUSIVE 960 FEATURES:

Output: Features AS-i®

(Actuator Sensor-Interface)output, a digital bus communi-cations for high or low singlepoint level measurement.

AS-i Bus: AS-i is a versatile,low-cost cabling solution that isa digital replacement for tradi-tional hard wiring of fielddevices. The AS-i bus systemprovides a digital serial inter-face with a single unshieldedtwo-wire cable for power anddata transfer.

EXCLUSIVE 961 FEATURES:

Output: Relay output or mAcurrent shift output.

Approvals: Intrinsic safetyapprovals with the two-wireloop-powered version.

APPLICATIONS:

• High level alarm• Overfill protection• Low level alarm• Pump protection• Flow alarm• Leak detection

Above: Also utilizing PulsedSignal Technology, Echotel®

Models 940 and 941 arecompact Ultrasonic LevelSwitches that perform highor low level measurement ina wide variety of liquid Foodand Beverage applications.Right: Echotel® 960 SeriesSwitches are also availablein a non-hygienic, XP version.

Hygienic high and low level alarm applications.

TD2 FEATURESMEASUREMENT PRINCIPLE

The Thermatel® sensor consists of twoRTD elements. One is the referenceand the second is heated to a temper-ature above the process temperature.

The electronics detect the temperaturedifference between the two elements.The temperature difference is greatestin air, then decreases when coolingoccurs due to a change in media. Anincrease in the flow rate furtherdecreases the temperature difference.

Diagnostics: Continuous diag-nostics with fault indication,temperature compensation,narrow hysteresis and fastresponse time.

Calibration: Easy and quick.

Immunity: Not affected by tem-perature, pressure or viscosity.

Output: Relay plus a non-linearmA output signal can be usedfor trending, diagnostics andrepeatable flow/level indication.

All-Electronic: No moving partsmake THERMATEL switchesvirtually maintenance free.

Alarm Status: Viewable inalarm status window.

TD2 APPLICATIONS:

Flow: General hygienicflow/level switch applicationsinclude foam detection, CIPoperations, and potable &purified water systems.

Level: The TD2 can be usedin applications where a highviscosity liquid might plug upan ultrasonic transducer gap.

Thermatel®THERMAL DISPERSION

SWITCH


As a level switch, Thermatel® providessuperior performance in thick liquidapplications which can plug othermeasurement devices.

General hygienic flow switch applications include foam detection, CIPoperations and product present switch. Air flow measurement is essen-tial within most filling operations.

Thermatel® TD2Level, Flow orInterface Switchfor HygienicApplications(Housing cover shown removed)

The TD2 Level, Flowor Interface Switch isalso available in anindustrial, non-hygienicversion.

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A hygienic control with theversatility of a flow, level orinterface switch

APPLICATIONSTECHNOLOGY

Technology: The Digital E3 is anadvanced, intrinsically safe two-wireinstrument utilizing buoyancy principleto detect and convert liquid levelchanges into a stable output signal.

Engineering: The linkage betweenthe level sensing element and outputelectronics provides a simplemechanical design and construction.The vertical in-line design of thetransmitter results in low instrumentweight and simplified installation. Theinstrument comes in a variety of con-figurations and pressure ratings forvaried applications.

Digital Advances: The Digital E3Modulevel® has microprocessor-basedelectronics with HART compatibleoutput, in addition to the standard4-20 mA output. E3 supports theFDT/DTM standard and PACTwarePC software for additional configura-tion and trending capabilities. Userinterface is a 2-line, 8-character LCDand 3-button keypad.

Self-Test: Continuous self-test with22 mA or 3.6 mA fault indication fullycompliant with NAMUR NE 43.Comprehensive diagnostics withfaults, warnings and status history.

Approvals: IS, XP and Non-Incendiveapprovals by FM, CSA, ATEX, IEC.

Media: Liquids, clean or dirty,light hydrocarbons to heavyacids (SG=0.23 to 2.20)

Vessels: Process & storage,bridles, bypass chambers,interface, sumps and pits upto unit pressure & temperatureratings.

Conditions: Most liquid levelmeasurement and controlapplications including thosewith varying dielectric, vapors,turbulence, foam, buildup,bubbling or boiling and highfill/empty rates.

Steam: The E3 is ideal forsteam-production systems.Live steam is used for heating,cooking, blanching, sanitizing,and sterilizing a large numberof foods. The production ofsuperheated water under pres-sure suitable for direct foodcontact called ‘culinary steam’requires food-grade equipment,clean water, and hygienic con-ditions where food contact ispossible.

Measurement Range:From 14 to 120+ inches(356 to 3048+ mm).

Interface Level: E3 MODULEVELis capable of tracking the inter-face level of two immiscibleliquids with different densities.

Modulevel®DIGITAL E3 DISPLACER

TRANSMITTER


Live steam is used to process a large numberof foods as in this tomato processing facility.

Modulevel® DigitalE3 DisplacerTransmitter

E3MODULEVEL

®

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SIL 2

An advanced transmittersuitable for utility and culinarysteam applications

APPLICATIONSMLI FEATURES

Technologies:Atlas™ utilizes float-based technologyfor reliable visual indication.Aurora® combines float and leading-edge Guided Wave Radar measure-ment in a single, redundant indicator.Jupiter® is a float-based, high-accuracy,Magnetostrictive transmitter.

Visual Indication:Orion Instruments® MLIs are availablewith either a flag assembly or a shuttleunit designed to provide level indica-tion visible from a distance of 100 feetusing high-visibility fluorescent colors.

Switches and Transmitters:Customers can specify either reed,snap action, or pneumatic switchesfor high, low, or high/low level controlas well as a dependable analogtransmitter for continuous levelmeasurement.

Digital Communications: MLIs areavailable that utilize HART or optionalFOUNDATION fieldbus digital communica-tions and PACTware software.

Accessories: To accommodateextremes in temperature, MLIs areavailable with frost extensions, heattracing and insulation blankets.

Food & Beverage:ORION INSTRUMENTS MLIsare adaptable to food gradelevel applications.

Applications: MLIs serve awide range of process andutility applications:• Feedwater Heaters• Industrial Boilers• Fuel Oil Storage• Oil & Water Separators• Flash Drums• Surge Tanks• Gas Chillers• Process Vessels• Steam and SIP Systems

Custom Installations: MLIssometimes provide the onlyviable form of level measure-ment and control for uniqueapplications requiring one-of-a-kind MLIs (below).

Technical and specificationinformation is available online:orioninstruments.com.

MAGNETIC LEVELINDICATORS

Below: Orion Instruments® MLIs at workin Food and Beverage environmentsthat include (left to right) a hygienicvessel, a fuel oil storage tank, and afermentation tank.

AURORA®ATLAS™

Float-basedMagnetic LevelIndicator with a

redundant GuidedWave RadarTransmitter

Float-basedMagnetic Level

Indicator

JUPITER®

Float-basedMagnetostrictive

Transmitter

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SIL 2

Visual Indicators built toughfor the most demandingapplications

CORPORATE HEADQUARTERS5300 Belmont Road • Downers Grove, Illinois 60515-4499 USA

Phone: 630-969-4000 • Fax: 630-969-9489magnetrol.com • [email protected]

EUROPEAN HEADQUARTERSHeikensstraat 6 • 9240 Zele, Belgium

Phone: 052 45.11.11 • Fax: 052 45.09.93

BRAZIL: Av. Dr. Mauro Lindemberg Monteiro, 185, Quadrante 16 • CEP 06278-010 • Osasco • São Paulo

CANADA: 145 Jardin Drive, Units 1 & 2 • Concord, Ontario L4K 1X7

CHINA: Plant 6, No. 191, Huajin Road • Minhang District • Shanghai 201108

DEUTSCHLAND: Alte Ziegelei 2–4 • D-51491 Overath

DUBAI: DAFZA Office 5EA 722, P.O. Box 293671 • Dubai, United Arab Emirates

INDIA: C-20 Community Centre • Janakpuri, New Delhi 110 058

ITALIA: Via Arese, 12 • 20159 Milano

SINGAPORE: 33 Ubi Avenue 3 • #05-10 Vertex • Singapore 408868

UNITED KINGDOM: Regent Business Centre • Jubilee Road • Burgess Hill, West Sussex RH15 9TL

Magnetrol & Magnetrol logotype, Orion Instruments & Orion Instruments logotype, Aurora, Echotel, Eclipse, Horizon, Jupiter, Modulevel and Thermatel are registered trademarks of Magnetrol International, Incorporated.HART is a registered trademark of the HART Communication Foundation. Hastelloy C22 are registered trademarks of Haynes International. PACTware is a trademark of the PACTware Consortium.

AS-lnterface and AS-i are registered trademarks of AS International. PROFIBUS is a registered trademark of PROFIBUS International.

Copyright © 2012 Magnetrol International, Incorporated. All rights reserved. Printed in the USA.

Bulletin: 41-181.1 • Effective: May 2010

AN INDUSTRY GUIDE TO LEVEL MEASUREMENT AND CONTROL FROM MAGNETROL

Other industry and special application brochures from MAGNETROL include:

• Chemical• Crude Oil Processing• Flue Gas Desulfurization• Interface Level Measurement• Life Science• Mass Flow Measurement• Modular Skid Systems• Natural Gas Processing• Nuclear Power

• Petroleum Refining• Power Generation• Pulp & Paper Mills• Renewable Energy• Steam Generation• Tank Bridle Level Measurement• Tank Overfill Prevention• Understanding Safety Integrity Level (SIL)• Water & Wastewater

PLEASE NOTE: The instruments recommended in these brochures are based on field experience withsimilar applications and are included as a general guide to level and flow control selection. Becauseall applications differ, however, customers should determine suitability for their own purposes.