Case Study: Sanitary Milk Tank Level Sensor

Case Study: Ultrasonic Milk Tank Level Sensor

Background

Accurate level monitoring in dairy storage tanks is crucial for operational efficiency and product quality. A facility sought a new level sensor to monitor their 6000 gal horizontal milk storage tanks measuring 8.5 feet (2.5 meters) in height.

Surface foam, condensation, and steam from clean-in-place (CIP) processes created significant challenges for level sensing. Existing ultrasonic sensors frequently lost their signal, leading to unreliable readings.

milk tank level sensor

Solution

The facility installed a new high-power sanitary ultrasonic level sensor from ABM to address these challenges. Key sensor features include:

  • Self-Adjusting Technology: Automatically adapts to changing tank conditions with no user involvement.
  • Self-Cleaning Design: A highly active driver knocks off condensation from the transducer face, improving measurement reliability and eliminating maintenance needs.
  • Hygienic Transducer: Made from 316L stainless steel with a surface finish exceeding No.4 dairy standards.
  • CIP Compatibility: Custom-designed transducer withstands CIP processes for up to 30 minutes at temperatures up to 130°C (266°F) and pressures up to 5 bar (72.5 psi).
  • Sanitary Installation: Simple mounting with a 2″ tri-clamp fitting.
milk tank level sensor

Results

The ABM sanitary ultrasonic sensor delivered consistent, accurate level readings despite challenging tank conditions such as foam, condensation, and steam. The self-adjusting and self-cleaning features eliminated false readings and maintenance issues that plagued the previous system.

Since installation, the facility has experienced improved process reliability, reduced downtime, and greater confidence in product quality. The operations team reported high satisfaction, noting:

“The sensor works great; it is a huge improvement over the other brand we installed originally.”

This upgrade not only resolved persistent sensor failures but also supported seamless integration with the facility’s existing processes, improving overall efficiency in milk storage management.

Conclusion

ABM’s sanitary ultrasonic level sensor significantly improved level monitoring in the facility’s milk storage tank. Faced with challenges from surface foam, condensation, and steam, ABM’s self-adjusting technology and self-cleaning design addressed these issues effectively, ensuring consistent and accurate measurements without maintenance needs. A reliable milk tank level sensor has helped to improve operational efficiency in the dairy facility.

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