Jiwei PRO Series Radar Level Meter in Pharmaceutical Applications
1. Project Background
In modern pharmaceutical production, liquid level measurement is critical for ensuring process safety, product quality, and operational stability. During the production of vaccines, injectables, and biological preparations, liquid raw materials are highly sensitive to temperature, pressure, and container hygiene. Accurate level control in storage tanks, mixing tanks, and reactors directly impacts dosing precision, production efficiency, and equipment safety.
Traditional level measurement methods, such as float switches and magnetic level gauges, often encounter issues:
- Insufficient measurement accuracy: Readings can be affected by viscosity, foam, or vapor.
- Frequent maintenance: Mechanical wear, corrosion, or scaling increases cleaning and calibration requirements.
- Difficulty meeting hygiene standards: Contact-type devices struggle to fully comply with strict GMP requirements.
Good Manufacturing Practice (GMP) is a system of standards ensuring product quality and safety. It requires rigorous control over all aspects of production, including facility environment, personnel, equipment, and quality management. Production environments must be clean and organized to prevent cross-contamination; personnel must be trained and follow hygiene practices; equipment should be easy to clean and maintain; processes must be traceable. All materials, intermediates, and finished products must be inspected before use or release, with complete documentation maintained throughout production. In short, GMP ensures products are safe, stable, and controlled.
To address these challenges, the client—a well-known pharmaceutical company—sought a high-precision, low-maintenance, and hygienic level measurement solution.
2. Customer Requirements
The client’s main requirements included high measurement accuracy, hygienic design, system compatibility, and operational reliability. Level measurement error needed to be within ±2 mm to ensure precise and consistent dosing.
Equipment must comply with GMP standards, feature hygienic design, and allow quick cleaning and disassembly to prevent cross-contamination. Long-term operational stability and low maintenance were also critical to reduce downtime and operational costs.
The level measurement system should seamlessly integrate with the existing SCADA system for automated control, real-time monitoring, and data tracking. The equipment must remain reliable under complex conditions, including foaming, viscosity changes, and temperature fluctuations.
3. Solution
Shenzhen Jiwei Automations Ltd. provided the PRO Series JWrada-31 radar level meter, which meets the high standards required by pharmaceutical production:
- Non-contact microwave radar measurement
JWrada-31 uses 80 GHz high-frequency FMCW radar, offering higher measurement resolution and focused signal performance. It provides stable and accurate level measurement under complex conditions such as foam, vapor, and high temperature without contact with the liquid, preventing corrosion, scaling, and cross-contamination. The signal processing algorithm maintains ±1 mm accuracy even with 15 cm foam, vapor, or high-viscosity liquids. - Wide temperature and pressure adaptability
Suitable for liquid temperatures from -40°C to 220°C and maximum working pressure of 40 bar, optimized for pharmaceutical reactors and mixing tanks to ensure long-term stable operation. - Hygienic design
Equipped with GMP-compliant sanitary flanges and smooth surfaces, allowing easy cleaning and sterilization without disrupting the production environment. - Low maintenance design
Non-contact measurement reduces mechanical wear and corrosion. Monthly maintenance is reduced from twice a month (traditional devices) to once or less, while maintaining high stability. - System integration capability
Supports 4–20 mA, HART, and Modbus outputs, seamlessly integrating with DCS/SCADA systems for automated monitoring, alarms, and data logging, supporting digital factory initiatives.
4. Implementation and Application Data
JWrada-31 enables stable level measurement of pharmaceutical liquids and reduces manual intervention.
- Mixing Tank A: Diameter 1.2 m, height 2.5 m, liquid temperature 20–80°C, foam approximately 15 cm.
- Reactor B: Diameter 1.5 m, height 3 m, liquid temperature 60–120°C, pressure 3 bar, high viscosity.
- Storage Tank C: 2000 L, intermediate liquid storage, temperature 25–40°C.
Comparison with previous devices (float/magnetic level gauges):
| Parameter | Previous Device | JWrada-31 |
|---|---|---|
| Measurement Error | ±5–10 mm | ±1 mm |
| Downtime | 5 times/month | 1 time/month |
| Maintenance Frequency | 2 times/week | 1 time/month |
| Foam Interference | Significant | Minimal |
| Data Real-time | No | Real-time to SCADA |
5. Jiwei’s Technical Advantages
Shenzhen Jiwei is one of the few Chinese manufacturers with independent R&D, in-house production, and complete quality control for radar level meters.
- National Certification: ISO9001 certified, recognized as a National High-Tech Enterprise.
- Independent R&D: Full in-house capabilities from design to production and sales, ensuring product innovation and quality control.
- Patents and IP: 4 invention patents and 4 software copyrights in level measurement.
- Global Partners: Clients include Sinopec, CATL, Tesla, BYD, and multiple pharmaceutical companies worldwide. Products are applied in chemical, energy, food, and pharmaceutical industries internationally.
- High Reliability: Products undergo strict temperature, pressure, corrosion, and long-term stability testing to ensure reliable operation under complex conditions.
- Professional Services: Full support from selection, installation, and commissioning to technical support and maintenance.
6. Customer Feedback
The production manager, Mr. Cui, noted that before JWrada-31, level measurements fluctuated under foam and temperature changes, causing dosing errors and frequent manual adjustments. After installation, signals stabilized, liquid level fluctuations decreased, and dosing accuracy improved, reducing operator intervention.
He added that the non-contact design simplifies cleaning and maintenance, reduces workload, and lowers cross-contamination risk. Integration with SCADA enables real-time monitoring, trend analysis, and automatic alerts, improving operational efficiency.
7. Conclusion
The JWrada-31 radar level meter enabled an upgrade from traditional mechanical level measurement to high-precision, low-maintenance, and digital level control in pharmaceutical production.
Jiwei PRO Series radar level meters improve production efficiency, ensure product quality, and reduce operational costs. With independent R&D, extensive patent portfolio, and global experience, Jiwei provides reliable and professional industrial automation solutions.
Shenzhen Jiwei Automations Ltd. continues to support customers in pharmaceutical, chemical, food, and energy industries with safe, intelligent, and reliable level measurement solutions, promoting industrial automation and digital transformation.