Powelectrics Supply Savoury Solution to Help Source, Solve and Save!

Posted on 18 Jun 2019

Powelectrics have delivered an Industry 4.0 ‘connected sensor’ solution to a global savoury snacks and confectionery business with manufacturing plants in the UK. They were looking for an IoT solution that could enhance the capabilities of local gauges and SCADA systems to improve efficiency and increase margins in a notoriously cost-driven industry.

Edible oils are an essential ingredient in many of their products.  The production sites can be extremely large, requiring a great deal of effort to visually check tank levels on local gauges. Even where SCADA systems are in place, they are only visible to local operatives, rather than to all the departments that would benefit from the data.

Our customer recognised that regular, reliable m2m tank level data could help will Production planning, because they would know there was enough oil in the tank to commence a production run.

Purchasing also benefits, because they can order full tanker loads, knowing that site tanks have the capacity take delivery. This avoids fines for sending back part-loads and reduces the number of deliveries, along with the associated disruption.

At the site shown in this image, Powelectrics installed level sensors on two large oil tanks. Vega PULS64 free space radar and a Vega coaxial wave guided radar were used. Non-contact sensors are preferable in food environments for hygiene reasons. The tanks were already in service and had very small entry points. VEGA sensors were able to accommodate that, without compromising accuracy.   https://www.vega.com/en/Products/Product-catalog/Level/Radar/

Our customer also took the opportunity to install temperature sensors, as the tanks are trace heated at 50-60 degrees to prevent oil becoming too viscous for production. Custom probes are fitted into tank thermowells and provide low level alarms to maintenance personnel if the trace heating fails. Issues can be rectified immediately, with minimal disruption to normal operations.

Powelectrics Metron telemetry is compatible with thousands of sensors. Our remote monitoring technology can accommodate any shape or height of tank and contents may be gas, liquids, powders and granules, even at extreme temperatures and pressures or highly corrosive products.

Powelectrics Metron2 devices are developed to respond to current and future customer needs. Units have an integral display, which helps with setup and test, as well as replacing costly local gauges. They can also be remotely configured via our software or set up prior for you to dispatch.

Metron2 available with external, battery and solar power options.  For this project we used external power, with a backup battery solution in case of power failure.

Metron2 offers 4 analogue inputs, optional 5 pulse inputs and 2 optional relay outputs. Supplied in a robust, weatherproof IP67 enclosure & operating from - 25 to +65°C, it is suited to many environments and applications.

The two tanks on this site are close together, which means only one Metron2 telemetry device is needed to measure level and temperature on both tanks, making it an extremely cost-effective solution!

For this IoT project, level data is reported hourly to MetronView, Powelectrics standalone cloud with customisable dashboards, reporting and alerts. Regular level and temperature data and alarms can be easily viewed by authorised personnel on any web-enabled device.

Removing the need for physical inspections means operations personnel can be deployed in more productive activities. The risk of running out of a key ingredient is reduced dramatically. The data also shows actual consumption, which can identify inefficiencies in production and issues with tank temperature can be identified and remedied immediately. Our customer also has historical data to analyse trends and plan deliveries and production runs.

Powelectrics connect the world of sensors and the Internet of Things offering 25 years’ sensor experience and our own IoT devices & cloud. Our solutions are employed in many industries including chemical, pharmaceuticals, Adblue, fuels, oils, LPG, lubricants, food and beverage, waste & recycling, landfill & leachate, agriculture, utilities, pumping and environment, rail and security.

We welcome the opportunity to discuss your application: +44 1827 310 666