Food & Beverage industry-Magnetrol

INDUSTRY

APPLICATIONS

SERIES

Level and Flow Instrumentation for Food & Beverage Processors

Optimize your
food processing
productivity with
level & flow solutions
from Magnetrol®

2

M

agnetrol® International,
Incorporated Hygienic
Solutions specializes in
hygienic and non-hygienic level
and flow instrumentation used
throughout the food, beverage, wine,
spirits, and brewing industries.
Magnetrol® hygienic measurement
solutions are of particular importance in those applications where
the highest standards of cleanability
must be maintained. MAGNETROL
industrial measurement solutions
are used in applications where
cleanability is not essential.

Hygienic Optimized Solutions
MAGNETROL hygienic process
measurement instrumentation is
designed to help customers optimize productivity with process
measurement instrumentation that
is engineered to meet the highest
performance standards in cleaning
and sanitization.
CIP removes residual product
to prevent contamination of a
product and/or cross contamination
of products while sanitization kills
microorganisms and denatures
proteins. Food industries rely on
the aggressive cleaning processes
of Clean-in-place (CIP) and
Sterilize-in-place (SIP) to achieve
their cleaning and sanitization goals.
MAGNETROL hygienic products
offer these benefits:
• Manufactured from stainless
steel materials selected for their
microbial resistance and polished
to a surface finish that reduces the
possibility of bacterial
adhesion.
• Seamless product
designs without indentations or incorrect radii
where bacteria can harbor
and which limit effective
cleanability.

• Products which can withstand aggressive CIP and sanitization chemicals as well as steam
sterilizing.
Hazardous Location Approvals
Level instruments for applications such as alcohol production,
solvent extraction or solvent recovery may require explosion-proof
(XP) requirements. Due principally
to the robust construction of its
electronics housing, an XP instrument has been certified to withstand an internal explosion without
allowing hot gases or flames to
escape from the housing to trigger
an explosion in the surrounding
atmosphere. The single-compartment, hygienic Eclipse® (page 7) is
an intrinsically-safe device. In
applications where XP approval
and a hygienic probe are required,
the twin-compartment ECLIPSE
(page 6) with a 7XF hygienic probe
is an ideal solution.
International Resources
MAGNETROL instruments
provide you with measurement
solutions that are in the forefront of
level and flow technology, solutions
that have earned an industry-wide
reputation for robust construction,
trouble-free set-up and a fast
return on investment. You’ll also
appreciate the engineering and
service resources of an international
organization that can be brought to
bear on your application to ensure
the best, practical process measurement
solutions
for your
food or
beverage
process.
I

Level and Flow Applications for Food & Beverage Processing
Typical Level and Flow control utilization is indicated for the process units below. Level = • Flow = •

Raw Materials Handling

Storage and Transport

Handling, Unpacking
Sorting, Screening, Grading
• Washing
• Brushing

• Chemical Injectors
Conveyors
• Piping Systems
• Pumps
• • Tanks, Silos
Rotary Washer

Storage Tanks

Reduction, Mixing, Forming

Separation

• Homogenizing, Conching
• Mixing, Blending, Stirring
Cutting, Slicing, Chopping
• Grinding, Milling, Crushing
Forming, Molding
Extrusion

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•
•
•
•
•

L
Le iqui
ve d I
l A nte
pp rfa
lic
ati ce
on
s

Centrifugation
Chemical Neutralization
Crystallization, Sedimentation
Cyclones, Hydrocyclones
Deionization
Extraction
Membrane Separation

Food Centrifuge

Mixing Vessel

3

Decontamination

Heating, Cooling

Cooking Vessel

• Baking
• Blanching
• Cooking, Boiling
• Cooling, Freezing
• • Dehydration
• Drying, Freeze Drying
• Frying
• Melting
Roasting
Tempering

• High Pressure Sterilizing
Induction Heating
Ohmic Heating
• Pasteurization
• Sterilization
UHT Treatment

Agitated Pasteurization

Other Processes

Fermentation

Agglomeration
Aging, Brining, Curing
• Alkalization
• • Carbonation, Aeration
• • Carbonization
• Coagulation
Coating
• Fermentation, Germination
Smoking
• • Sulphitation

Plant Utilities

Waste Treatment

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••
•
••
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••
•

Air
Cleaning & Disinfecting
Compressed Air
HVAC Systems
Natural Gas
Processing Lubricants
Vacuum Systems
Waste Treatment
Water

R82
MODEL

THRU-AIR RADAR
TRANSMITTER

Introducing the full-featured thru-air
radar with an affordable price point
FEATURES

APPLICATIONS

High Performance: Loop-powered,
26 GHz, non-contact radar transmitter performs liquid level and volume
measurements in enclosed vessels.

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

Digital Communications:
HART® digital communications.
User Interface: Menu driven 2-line,
16-character LCD and 4-button
keypad.
Simplified Operation: The R82
launcher orientation and echo rejection profiling are simplified for easy
use. The R82’s microwave beam is
rotatable for optimized operation.
4

Left: Model R82
with a cast aluminum
housing and a polypropylene antenna.
Right: Model R82 with
a thermoplastic
housing and a
Tri-Clover Tefzel®
antenna.

SIL 2

Technical and specification
information is available
online: magnetrol.com.

Convenient, Easy Configuration:
Configures with keypad, HART
digital communications, or
PACTware™ software. This allows
complete configuration via the local
user interface, or remotely with the
added capability of capturing echo
waveforms, and viewing trend data,
diagnostic conditions and all configuration parameters.

Media Capabilities: Liquids,
slurries, and viscous media.
Suitable for hygienic and CIP
applications.
Vessels: For measurement in
enclosed vessels; ideal for
general chemical storage, day,
batch and feed tanks, water
and wastewater tanks and
sumps and food & beverage
vessels.
Resistance: The fully-encapsulated horn antenna offers high
performance and is chemically
resistant to nearly all standard
process media.
Advanced Signal Processing:
Manages common disturbances such as false echoes
caused by obstructions, multipath reflections from tank sidewalls or turbulence caused by
agitators, aggressive chemicals,
or aerators.
Vapor Immunity: The R82
measures effectively even when
atmospheres above the liquid
are saturated with vapor.

MODEL

355

ULTRASONIC
TRANSMITTER

Our new transmitter’s Smart Electronics
improves measurement accuracy
FEATURES

APPLICATIONS

Technology: Echotel® Model 355 is a
versatile two-wire, loop-powered,
non-contact ultrasonic transmitter that
measures liquid level, volume, and
open channel flow.

Non-Contact: The Model 355
provides non-contact measurement in a wide variety of applications.

Advanced Electronics: The Model 355
has intelligent electronics that analyzes
the ultrasonic echo profile, apply temperature compensation, monitors for
electrical noise interference, reject
echoes from false targets, and then
processes the true echo from the
liquid surface.
Friendly Interface: The user interface
is a menu-driven, 4-pushbutton, 2-line
x 16-character display for convenience
and readability.

Top: The Model 355
with a cast aluminum
housing and Kynar®
transducer. Right: 355
with a Lexan® housing
and a polypropylene
transducer.

Simulated Display

Convenient Configuration: The Model
355 is configurable by either the user
keypad, HART communications, or
PACTware. The latter enables a complete configuration via the user interface, or remotely with the added capability of capturing echo waveforms, and
viewing trend data, diagnostic conditions and all parameters.

Versatility: Ideal for sumps,
wells, tanks, open channel flow
weirs and flumes. Ideal for
general industrial applications,
chemical storage tanks, batch
and day tanks.
Handles Difficulties: The
Model 355 advanced signal
processing provides extremely
reliable measurement even
when application difficulties like
turbulence or false echoes generated by agitator blades or
shafts, fill pipes or other tank
hardware are present.
Range: A powerful 60 kHz
ultrasonic transducer and
advanced digital signal processing is featured to reliably
measure to 20 feet (6 meters).
Narrow Beam: Model 355
transducers feature a 10° conical beam and 10" (250 mm)
blocking distance to maximize
measurement capabilities in
many applications.
Viscosity: Will measure highly
viscous media.

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


5

ENHANCED MODEL 705
GUIDED WAVE RADAR
TRANSMITTER

The industrial level transmitter that
is transforming level measurement
FEATURES

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

Eclipse® Model 705
shown with a Model
7XF-E Hygienic probe.
Also popular in process
food markets, the 7X5
Bulk Solids probe for
use in lighter solids
applications such as
grains and powders.

APPLICATIONS

Application Range: Virtually all
measurement and control applications including conditions
exhibiting visible vapors, foam,
coating or buildup, surface
agitation, bubbling or boiling,
high fill/empty rates, low level
and varying dielectric media or
specific gravity.

Digital Communications: HART,
FOUNDATION fieldbus™ or PROFIBUS PA
communications.
Convenience: No level change for
configuration; no field calibration is
necessary.
Strapping Table: 20-point table for
volumetric or flow measurement.
Coupling: Quick connect/disconnect
probe coupling.

6

Probe Capabilities: Designs to
+800° F (+430° C), 6250 psig (430 bar)
and full vacuum, cryogenic applications to -320° F (-195° C).
Probe Profiling: The single rod probe
can have multiple bends to profile to
any vessel shape, avoid internal vessel
obstructions and extend measurement
into the vessel bottom.

SIL 2


Media Capabilities: Liquids or
slurries; hydrocarbons and
water-based media with a
dielectric of 1.4–100.
Changing Media: Changing
specific gravity and dielectric
constant have little effect on
measurement accuracy.
Full Span: Measures to the
very top and bottom of the
probe (subject to media
dielectrics).
SIL 2: HART version hardware
is suitable for SIL 2 loops; Safe
Failure Fraction of 91%.

User Interface: 2-line, 8-character
LCD and 3-button keypad.
Dry Calibration Capability:
Save calibration costs and downtime
with our proven “test bench”
approach.

Fewer features and a lower
price make Horizon® Model
704 Guided Wave Radar ideal
for simple Food and
Beverage applications.

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

ENHANCED MODEL 705
GUIDED WAVE RADAR
HYGIENIC TRANSMITTER

Ultra-compact,
hygienic transmitter delivers
unsurpassed performance
FEATURES

APPLICATIONS

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

Application Range: Virtually all
hygienic level measurement
and control applications including CIP applications.

Digital Communications: HART or
optional FOUNDATION fieldbus and
PROFIBUS PA communications.
Convenience: No level change needed
for configuration; no field calibration
necessary.

Enhanced
Eclipse®
Model 705
Liquid Level
Transmitter
for Hygienic
Applications

Strapping Table: 20-point custom
table for volumetric or flow measurement.
Finish: 320 Grit (15Ra) electropolished
probe and 180 Grit (32Ra) housing.
Probe Materials: Available in 316 SS,
AL6XN and Hastelloy® C22®.

Media Capabilities: Liquids or
slurries; hydrocarbons and
water-based media with a
dielectric of 1.9–100.
Changing Media: Changing
specific gravity and dielectric
constant have little effect on
measurement accuracy.
Full Span: Measures to the
very top and bottom of the
probe (subject to media
dielectrics) and, therefore,
into the vessel bottom.

(Simulated display)

Probe Profiling: The single rod probe
can have multiple bends, allowing the
rod to be profiled to any vessel shape,
avoid internal vessel obstructions and
extend measurement into the vessel
bottom.

SIL 2: HART version hardware
is suitable for SIL 2 loops; Safe
Failure Fraction of 91%. FEMEDA report available upon
request.

SIL 2

Approvals: IS and Non-Incendive.
User Interface: 2-line, 8-character LCD
and 3-button keypad.
Dry Calibration Capability: Save
calibration costs and downtime with
our proven “test bench” approach.

PACTware software provides a graphic interface whereby
all functionality can be visualized quickly, safely and conveniently.
online: magnetrol.com

7

HYGIENIC ULTRASONIC
LEVEL SWITCH

Compact, hygienic
switches excel in difficult
liquid level applications
960/961 FEATURES

MODEL-SPECIFIC FEATURES

Technology: Pulsed signal for superior
performance in difficult conditions.

EXCLUSIVE 960 FEATURES:

Immunity: Excellent immunity from
sources of electrical noise interference.
Self-Testing: Extensive self-testing of
electronics, transducer, piezoelectric
crystals, and EM noise.
Time Delay: Adjustable time delay for
turbulent liquids.
Extended Range: Tip-sensitive
transducer measures level to within 1⁄4"
of the vessel’s bottom.

Output: Features AS-i®
(Actuator Sensor-Interface)
output, a digital bus communications for high or low single
point level measurement.
AS-i Bus: AS-i is a versatile,
low-cost cabling solution that is
a digital replacement for traditional hard wiring of field
devices. The AS-i bus system
provides a digital serial interface with a single unshielded
two-wire cable for power and
data transfer.

Housing: Deep drawn 304 SS.
8

EXCLUSIVE 961 FEATURES:

Echotel® Models
960 and 961
Liquid Level
Switches for
Hygienic
Applications

Finish: 240 Grit (20 Ra ) electropolish
on transducer surface.

Output: Relay output or mA
current shift output.
Approvals: Intrinsic safety
approvals with the two-wire
loop-powered version.

(Housing cover shown removed)

APPLICATIONS:
Above: Also utilizing Pulsed
Signal Technology, Echotel®
Models 940 and 941 are
compact Ultrasonic Level
Switches that perform high
or low level measurement in
a wide variety of liquid Food
and Beverage applications.
Right: Echotel® 960 Series
Switches are also available
in a non-hygienic, XP version.

•
•
•
•
•
•

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

Hygienic high and low level alarm applications.

Model 960 Only


Thermatel

®

THERMAL DISPERSION
SWITCH

A hygienic control with the
versatility of a flow, level or
interface switch
MEASUREMENT PRINCIPLE

TD2 FEATURES

The Thermatel® sensor consists of two
RTD elements. One is the reference
and the second is heated to a temperature above the process temperature.

Diagnostics: Continuous diagnostics with fault indication,
temperature compensation,
narrow hysteresis and fast
response time.

The electronics detect the temperature
difference between the two elements.
The temperature difference is greatest
in air, then decreases when cooling
occurs due to a change in media. An
increase in the flow rate further
decreases the temperature difference.

Calibration: Easy and quick.
Immunity: Not affected by temperature, pressure or viscosity.
Output: Relay plus a non-linear
mA output signal can be used
for trending, diagnostics and
repeatable flow/level indication.
All-Electronic: No moving parts
make THERMATEL switches
virtually maintenance free.

Thermatel® TD2
Level, Flow or
Interface Switch
for Hygienic
Applications
(Housing cover shown removed)

Alarm Status: Viewable in
alarm status window.
TD2 APPLICATIONS:

As a level switch, Thermatel® provides
superior performance in thick liquid
applications which can plug other
measurement devices.

The TD2 Level, Flow
or Interface Switch is
also available in an
industrial, non-hygienic
version.

Flow: General hygienic
flow/level switch applications
include foam detection, CIP
operations, and potable &
purified water systems.
Level: The TD2 can be used
in applications where a high
viscosity liquid might plug up
an ultrasonic transducer gap.

General hygienic flow switch applications include foam detection, CIP
operations and product present switch. Air flow measurement is essential within most filling operations.


9

Modulevel

®

DIGITAL E3 DISPLACER
TRANSMITTER

An advanced transmitter
suitable for utility and culinary
steam applications
TECHNOLOGY

Technology: The Digital E3 is an
advanced, intrinsically safe two-wire
instrument utilizing buoyancy principle
to detect and convert liquid level
changes into a stable output signal.

Modulevel® Digital
E3 Displacer
Transmitter

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

Engineering: The linkage between
the level sensing element and output
electronics provides a simple
mechanical design and construction.
The vertical in-line design of the
transmitter results in low instrument
weight and simplified installation. The
instrument comes in a variety of configurations and pressure ratings for
varied applications.
Digital Advances: The Digital E3
Modulevel® has microprocessor-based
electronics with HART compatible
output, in addition to the standard
4-20 mA output. E3 supports the
FDT/DTM standard and PACTware
PC software for additional configuration and trending capabilities. User
interface is a 2-line, 8-character LCD
and 3-button keypad.

10

E3 MODULEVEL®

SIL 2

APPLICATIONS

Self-Test: Continuous self-test with
22 mA or 3.6 mA fault indication fully
compliant with NAMUR NE 43.
Comprehensive diagnostics with
faults, warnings and status history.

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

Vessels: Process & storage,
bridles, bypass chambers,
interface, sumps and pits up
to unit pressure & temperature
ratings.
Conditions: Most liquid level
measurement and control
applications including those
with varying dielectric, vapors,
turbulence, foam, buildup,
bubbling or boiling and high
fill/empty rates.
Steam: The E3 is ideal for
steam-production systems.
Live steam is used for heating,
cooking, blanching, sanitizing,
and sterilizing a large number
of foods. The production of
superheated water under pressure suitable for direct food
contact called ‘culinary steam’
requires food-grade equipment,
clean water, and hygienic conditions where food contact is
possible.
Measurement Range:
From 14 to 120+ inches
(356 to 3048+ mm).
Interface Level: E3 MODULEVEL
is capable of tracking the interface level of two immiscible
liquids with different densities.

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

MAGNETIC LEVEL
INDICATORS

Visual Indicators built tough
for the most demanding
applications
MLI FEATURES

APPLICATIONS

Technologies:
Atlas™ utilizes float-based technology
for reliable visual indication.
Aurora® combines float and leadingedge Guided Wave Radar measurement in a single, redundant indicator.
Jupiter® is a float-based, high-accuracy,
Magnetostrictive transmitter.

Food & Beverage:
ORION INSTRUMENTS MLIs
are adaptable to food grade
level applications.

Visual Indication:
Orion Instruments® MLIs are available
with either a flag assembly or a shuttle
unit designed to provide level indication visible from a distance of 100 feet
using high-visibility fluorescent colors.
Switches and Transmitters:
Customers can specify either reed,
snap action, or pneumatic switches
for high, low, or high/low level control
as well as a dependable analog
transmitter for continuous level
measurement.
Digital Communications: MLIs are
available that utilize HART or optional
FOUNDATION fieldbus digital communications and PACTware software.

ATLAS™
Float-based
Magnetic Level
Indicator

AURORA®

JUPITER®

Float-based
Magnetic Level
Indicator with a
redundant Guided
Wave Radar
Transmitter

Float-based
Magnetostrictive
Transmitter

Accessories: To accommodate
extremes in temperature, MLIs are
available with frost extensions, heat
tracing and insulation blankets.

SIL 2

Below: Orion Instruments® MLIs at work
in Food and Beverage environments
that include (left to right) a hygienic
vessel, a fuel oil storage tank, and a
fermentation tank.

information is available online:
orioninstruments.com.

Applications: MLIs serve a
wide range of process and
utility 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: MLIs
sometimes provide the only
viable form of level measurement and control for unique
applications requiring one-of-akind MLIs (below).

11

AN INDUSTRY GUIDE TO LEVEL MEASUREMENT AND CONTROL FROM MAGNETROL
Other industry and special application brochures from MAGNETROL include:
•
•
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•
•
•
•
•
•

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 with
similar applications and are included as a general guide to level and flow control selection. Because
all applications differ, however, customers should determine suitability for their own purposes.

CORPORATE HEADQUARTERS
5300 Belmont Road • Downers Grove, Illinois 60515-4499 USA
Phone: 630-969-4000 • Fax: 630-969-9489
magnetrol.com • info@magnetrol.com
EUROPEAN HEADQUARTERS
Heikensstraat 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

Food & Beverage industry-Magnetrol

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