Jiwei Radar Sensor Ensures Accurate Bulk Solids Measurement in Chocolate Production

Introduction: Reliable Level Measurement for Bulk Solids

High-quality chocolate production relies on precise, reliable, and efficient monitoring of raw materials. In chocolate factories, powdered ingredients like milk powder and lactose are stored in silos before being transferred to mixing units. Accurate level measurement in these silos is essential to maintain consistent product quality and ensure smooth production flow.

However, bulk materials present unique measurement challenges. Dust accumulation, internal silo structures, and varying reflective properties of powders can affect measurement accuracy. Environmental factors, such as temperature variations or airflow from pneumatic filling systems, may also interfere with traditional sensors. For factories seeking reliable measurement while reducing maintenance efforts, choosing the right level measurement instrument is critical.

Challenges in Bulk Solids Measurement

In modern chocolate factories, silos are often filled via compressed air, creating a dusty environment. The fine powders can settle on sensors, filters, and internal installations, leading to potential errors in measurement. Additionally, silos may experience slight overpressure during filling, requiring sensors to withstand temporary pressure changes. Previously, capacitive point level sensors and guided microwave sensors were used, but they often required frequent maintenance or produced inaccurate readings in dusty conditions.

Jiwei JWrada Radar Sensor: A Modern Solution

The Jiwei JWrada radar sensor is specifically designed for bulk solids applications. Operating at a high frequency of 80GHz, it delivers precise, non-contact measurement and is well-suited for challenging powder materials. Its key features include:

• High-frequency radar (80GHz): Narrow beam angle ensures accurate detection of poorly reflective bulk solids, minimizing interference from internal structures.
• Non-contact operation: Avoids direct contact with powders, reducing contamination and maintenance requirements.
• Wide dynamic range: Capable of measuring bulk solids at distances up to 150 meters, offering strong performance reserves for any silo height.
• Fast measurement cycle: Provides real-time data with ±1 mm accuracy, allowing precise monitoring of production processes.
• Adjustable swivel mount with rinsing air connection: Enables optimal alignment and clears dust from the antenna, ensuring consistent readings.
• Bluetooth wireless configuration: Operators can adjust and calibrate sensors remotely up to 25 meters using a smartphone or tablet, simplifying setup and maintenance.

Implementation in Chocolate Production

At the factory, JWrada sensors were installed in multiple silos approximately 11 meters high. The implementation involved:

• Swivel mount installation: The stainless steel holder allows the sensor to be aligned with a ±10° range, ensuring optimal signal focus.
• Angle calculation via Jiwei Smart Control: Operators enter silo dimensions into the Jiwei mobile Jiwei Smart Control, which automatically calculates the correct tilt angle for installation.
• Rinsing air functionality: Provides additional cleaning capability for dusty environments, maintaining sensor performance even in powder-heavy conditions.
• Bluetooth setup with PLICSCOM: The display and adjustment module allows easy parameterization, diagnostics, and real-time monitoring directly on the sensor.

Benefits Achieved

Since deploying JWrada radar sensors, the chocolate factory has observed:

• Highly accurate bulk solids measurement: Stable and precise readings of milk powder and lactose levels, ensuring consistent mixing ratios.
• Reduced maintenance: Non-contact operation and low sensitivity to buildup significantly lower the frequency of sensor cleaning and service.
• Remote monitoring and configuration: Bluetooth and PLICSCOM integration enable fast, safe adjustments without entering the silo area.
• Improved production efficiency: Accurate level data allows operators to optimize filling, mixing, and inventory management.
• Enhanced process safety: Sensors help prevent overfilling and ensure proper monitoring of silo contents.

Expanded Applications and Value

While this case focuses on chocolate production, Jiwei JWrada radar sensors are suitable for a wide range of bulk solids applications, including:

• Food and beverage powders (sugar, flour, cocoa)
• Chemical powders
• Cement and mineral powders

In all these industries, the combination of non-contact measurement, high-frequency radar, and wireless configuration reduces downtime and maintenance costs, while ensuring precise material handling.

Conclusion: Why Choose Jiwei JWrada Radar Sensors

For chocolate manufacturers and other bulk solids operations, Jiwei JWrada radar sensors provide a reliable, efficient, and cost-effective solution for level measurement. By delivering accurate, non-contact readings in dusty and challenging environments, simplifying setup with Bluetooth, and offering long-term performance, JWrada ensures both operational efficiency and product quality.

Investing in Jiwei JWrada not only improves measurement accuracy but also reduces operational costs and maintenance efforts, making it a trusted choice for modern production facilities seeking smart, reliable bulk solids monitoring.