Fork-11 Vibrating Fork Level Switch Replaces HITROL HTM-930 for Foam Pre-Expanders and Molding Machines
With the continuous upgrade of China’s foam plastics manufacturing industry, intelligent production lines are placing increasingly higher demands on the accuracy, stability, and reliability of level detection.
In particular, in foam pre-expanders and molding machines handling EPS and EPP raw materials, the extremely low density, high flowability, and frequent process disturbances make it difficult for traditional level detection devices to meet modern production control requirements.
Addressing this industry challenge, the Jiwei Fork-11 vibrating fork level switch has successfully achieved large-scale replacement of the imported Korean HITROL HTM-930 model in the domestic market. It has become a benchmark product for localized substitution in foam industry level detection applications.
Industry Background: Level Detection Challenges in Foam Pre-Expansion and Molding
Foam materials such as EPS (Expanded Polystyrene), EPP (Expanded Polypropylene), and EPO exhibit extremely low bulk density during pre-expansion and molding processes. The material density can be as low as 0.008 g/cm³ (approximately 8 kg/m³) or even lower.
Such characteristics create significant challenges for level detection equipment. Conventional mechanical switches, photoelectric sensors, and even standard capacitive level switches often suffer from false alarms, failure to trigger, or unstable signal drift under these conditions.
Foam materials in pre-expanders and molding machines present several distinctive characteristics:
- Ultra-low density requiring extremely high detection sensitivity
- Strong flowability and frequent disturbances from air flow, steam, and vibration
- Non-conductive and irregular solid particles unsuitable for capacitive or conductive measurement principles
Therefore, this application scenario requires two critical capabilities: ultra-high sensitivity and strong anti-interference performance. These are precisely the aspects where traditional vibrating rods and general-purpose level switches struggle to perform reliably.
HITROL HTM-930: Background and Replacement Pain Points
HITROL is a well-known Korean manufacturer specializing in level measurement instruments, including float switches, vibrating rods, and vibrating forks. The HTM-930 series has long been widely used in foam machinery as a standard level detection solution.
However, with expanding market demand and accumulated field feedback, several limitations have become apparent in long-term foam applications:
- Insufficient sensitivity under extremely low-density material conditions
- Limited resistance to airflow and vibration disturbances
- Long lead times and relatively high procurement costs
- Higher replacement and maintenance costs in large-scale deployment
As a result, foam equipment manufacturers urgently needed a domestic alternative capable of delivering improvements in performance, supply reliability, and cost efficiency. This demand created the opportunity for the large-scale adoption of the Fork-11 vibrating fork level switch.
Technical Advantages of the Fork-11 Vibrating Fork Level Switch
The Fork-11 vibrating fork level switch is independently developed and manufactured. Its core technology is based on precision-controlled fork vibration frequency and advanced signal processing circuits, enabling rapid response to minimal material damping changes.
Ultra-Low Density Detection Down to 0.008 g/cm³
One of the most significant advantages of the Fork-11 is its exceptional ultra-low density response capability. After extensive laboratory and field validation, it can reliably detect foam particles with densities as low as 0.008 g/cm³.
Even under minimal material accumulation or light coverage conditions, the Fork-11 ensures stable triggering and accurate switch output without drift or false alarms.
Strong Anti-Interference Performance
Unlike conventional devices that may be affected by steam, airflow, or mechanical vibration, the Fork-11 incorporates structural optimization and vibration control algorithms that effectively filter environmental disturbances. This ensures stable output signals in complex operating environments and maintains uninterrupted production rhythm.
Flexible Installation Options
The Fork-11 supports multiple installation configurations, including threaded and flanged process connections, enabling compatibility with various foam machinery designs and simplifying on-site installation and commissioning.
Low Maintenance and Long Service Life
With no mechanical wear components and anti-static design features, the Fork-11 offers reduced maintenance requirements and lower failure rates, contributing to improved long-term operational reliability.
Local Manufacturing and Supply Advantages
As a domestically manufactured product, the Fork-11 provides strong supply capacity, shorter delivery cycles, and timely technical support, significantly enhancing supply chain flexibility for equipment manufacturers.
Bulk Replacement Cases: From HITROL to Fork-11
As the Fork-11 gained recognition in the foam industry, numerous equipment manufacturers began adopting it as a standard configuration in pre-expanders and molding machines.
Hangzhou Fangyuan Plastics Machinery Co., Ltd.
As a leading enterprise in China’s EPS machinery sector and an industry standard participant, Hangzhou Fangyuan Plastics Machinery Co., Ltd. holds a prominent position in both domestic and international markets.
During comparative testing and on-site trials, Fangyuan’s technical team found that compared to the HTM-930, the Fork-11 provided faster response and more stable signal output when detecting low-density foam materials.
Based on these advantages, Fangyuan adopted the Fork-11 in its new-generation pre-expanders and molding machines, replacing the imported HITROL level switch and improving overall equipment reliability and customer satisfaction.
Deployment by Other Major Foam Equipment Manufacturers
In addition to Fangyuan, several large foam machinery manufacturers in China have also adopted the Fork-11 as a standard level detection component in new equipment deliveries.
These successful applications demonstrate that:
- The Fork-11 performs consistently in mass production environments
- Supply and after-sales support are more efficient compared to imported models
- Field feedback indicates improved stability and reliability
Applications cover key process stages such as pre-expanders, molding machines, thermoforming systems, and automatic packaging lines.
Practical Value and Customer Benefits
Improved Production Stability
In field operation, the Fork-11 provides stable material control signals, significantly reducing false empty or overflow conditions during low-density foam production and enhancing product consistency.
Reduced Failure Rate and Maintenance Cost
With strong anti-interference performance and durable design, calibration frequency and component replacement are minimized, reducing downtime and increasing line availability.
Enhanced Supply Chain Flexibility
The domestic manufacturing capability of the Fork-11 reduces dependency on imported components and long procurement cycles, improving equipment delivery efficiency.
Conclusion: A Proven Domestic Solution for Foam Industry Level Detection
With continuous advancement in domestic automation technology, the Fork-11 vibrating fork level switch has become a representative solution for replacing imported models in foam pre-expansion and molding applications.
From large-scale deployment by industry-leading equipment manufacturers to widespread market adoption, the Fork-11 demonstrates that domestic level detection technology can deliver high sensitivity, strong anti-interference capability, and reliable bulk supply performance.
For foam machinery manufacturers, selecting the Fork-11 as a core level detection component not only enhances equipment reliability but also optimizes supply chain efficiency—making it a strategic choice in the ongoing localization upgrade trend.