Solution | Split-Type Level Sensor Solves Foam Interference and Space Constraints in Dairy Tank Level Measurement

In the dairy processing industry, accurate monitoring of tank liquid levels is essential not only for production efficiency but also for ensuring product quality and safety. A dairy plant customer encountered a series of problems when monitoring milk tank levels. Initially, they intended to use a standard ultrasonic level sensor, but they found that the foam generated during stirring or filling severely interfered with the ultrasonic signal, resulting in very unstable measurements. When they tried a differential pressure level sensor, they faced cleaning difficulties. Dairy production requires extremely high hygiene standards, and every tank must be thoroughly cleaned with no residue. The differential pressure sensor’s complex structure made disassembly and cleaning difficult—becoming a new pain point.

After multiple failed attempts, the customer switched to a float-type level sensor. However, new problems followed. The float probe rod was fixed to the top of the tank. When the lid needed to be opened for manual stirring or maintenance, the rod became an obstacle—disrupting operations and posing safety risks.

These real-world problems drove the customer to seek a more professional solution. Upon reaching out to SENTINEL Electronics, we assisted them in rethinking the approach to level measurement and jointly developed a solution to address foam interference and spatial constraints in dairy tank level measurement.

Upon receiving the customer's request, our technical team promptly conducted in-depth discussions and on-site assessments. Given the multiple constraints, we realized that traditional level sensor installations could no longer meet the requirements. Since the tank's top space was limited, hygiene was critical, and foam interference needed to be avoided—why not consider installing the sensor from the bottom?

SENTINEL's split-type level sensor offers a key advantage—its probe supports bidirectional measurement. This means we can measure from the bottom up, unlike traditional sensors that measure from top to bottom. This feature opened up new installation possibilities.

However, implementation was not easy. The tank's bottom space was extremely limited, and a standard integrated level sensor could not be installed. We quickly proposed a custom “split-type” solution: insert the split probe from the top and install it at the tank bottom. The electronics unit was connected via cable and flexibly deployed outside the equipment, free from spatial constraints.

This structure fulfilled the need for bottom-up level measurement while avoiding interference from the top. Additionally, the split design made maintenance and cleaning easier—each component can be independently disassembled and sterilized, significantly improving convenience and hygiene management.

In addition to level measurement, we also provided the customer with a probe module equipped with temperature monitoring. By integrating a high-precision temperature sensor into the probe, the customer could monitor the milk tank’s temperature in real-time without the need for an additional sensor. This integrated design not only saved costs but also simplified system wiring and maintenance.

This small design adjustment brought enormous value to the customer: they avoided purchasing a separate temperature monitoring system and eliminated the cleaning concerns for extra sensors—making on-site operations much simpler and more efficient.

Through this case, we not only solved the customer’s specific problems but also demonstrated our strengths in product customization, technical implementation, and responsiveness. From design and structural innovation to project delivery, the entire process took just one month. We proved through action that we are not just a sensor provider—we are a partner in on-site process optimization.

This collaboration showed the customer that “sensors aren’t generic—they are tools customized for specific working conditions.” Our technical team continues to create real value in the age of smart manufacturing through tailored solutions.

The advancement of industrial sensing technology lies not just in improved accuracy, but in a deep understanding of and effective response to real-world challenges. This case of milk level monitoring is a perfect example of “big challenges in small scenarios.” Our split-type level sensor, through structural innovation and application integration, helped the customer overcome monitoring difficulties while providing us with valuable technical assets.

For more information about SENTINEL products, please contact our sales staff or call 022-83726972. You may also visit our official website www.sentinel-china.com, which provides comprehensive product information, selection manuals, CAD and Eplan files, configuration documents, and tutorials to ensure you can easily access what you need.

Our professional technical team is always ready to provide customized support and efficient after-sales service, ensuring that every user’s interests are fully protected.