Therefore, high-stakes environments like the food & beverages (F&B), and life sciences industries demand a high degree of precision, as there is no tolerance for error. Consumer safety, operational efficiency, and product regulatory compliance are non-negotiable here, as even the slightest deviation can compromise outcomes or violate stringent regulations. Standards like 3A, EHEDG, and FDA govern the hygienic environment to ensure contamination-free production and product integrity.

Within this landscape, one of the key processes is level measurement. Accurate level monitoring ensures process efficiency and prevents overfills or dry runs. It also conforms to safety standards and guarantees operational safety. However, precise level measurement must contend with disturbances such as turbulent conditions, viscous media, or varying material properties. But how can industries achieve this precision in sterile settings without risking contamination or compromising reliability?

Find the answer in this article, which explores radar-based level measurement solutions specially designed for hygienic applications.

How is level measured with radar technology?

Radar technology has been used in defence and aerospace for years, but it has expanded its reach to hygienic industrial environments such as food & beverages (F&B), and life sciences. A popular example of this is the radar-based level transmitter. It is a non-contact method for determining the amount of a liquid or solid within a container. A radar transmitter system comprises an antenna, an operating interface, a signal processor, a receiver, and an in-built oscillator.

Radar level transmitters for closed tanks are generally based on two technologies: time of flight (ToF) and frequency modulated continuous waveform (FMCW). In FMCW, the transmitter continuously emits a high-frequency pulse towards the surface of the medium. This pulse is reflected from the medium and received by the receiver. The level of the medium in the tank is measured by calculating the shift in frequency between the transmitted and reflected wave.

In the case of ToF radar, the time taken by the pulse to travel from transmitter to receiver is calculated to measure the level.

However, both technologies are almost similar, except for the method used to calculate the distance (level).

Another important consideration when selecting a radar level sensor is the beam angle. This parameter tells you how close the radar level transmitter can be installed to the tank wall. The beam should never reach the tank wall, because it can interfere with the radar signal and may give inaccurate measurements.

The wider the beam, the lower the amplitude of the emitted signal that returns to the receiver of the level sensor after reflecting from the surface of the material inside the tank. Wide beams are more sensitive to obstacles within a tank and susceptible to interference from tank walls -especially in tanks that contain baffles, heat coils, or agitation.

Additionally, foaming within the vessel media or buildup accumulation on the radar antenna can interfere with the reflected signal and cause measurement inaccuracies.

On the other hand, transmitters with narrow beams offer promising measurement results with higher sensitivity. A narrow beam also simplifies the installation of the level transmitter on the tank. It allows the instrument to be installed close to the tank wall, making it easier to avoid obstacles and enabling more convenient service and maintenance.

Frequency is another factor that affects the beam angle of the signal emitted by the transmitter. Lower frequency transmitters generate wider beam angles, while higher frequency transmitters generate narrow beam angles. However, a wide beam angle may still be more suitable than a narrow one in some applications.