Measuring liquid sugar levels

How does a pressure transmitter measure the level of liquid sugar?

The Flange-mounted pressure transmitter works based on the core principle of "pressure changes height". After being installed at the bottom of the storage barrel, the sensing element directly contacts the liquid sugar. The higher the height of liquid sugar, the greater the pressure generated on the bottom, both of which satisfy the physical formula P=ρ gh (P is pressure, ρ is liquid sugar density, g is gravitational acceleration, h is liquid level height). After the transmitter captures the pressure signal, it will automatically convert the actual height based on the preset syrup density, and then transmit it to the control system through a 4-20mA standard signal to achieve real-time height monitoring. The entire process does not require complex pipelines, signals are transmitted directly, and data is more accurate.

What is the difficulty of measuring syrup level?

The core difficulties in measuring syrup focus on three points:

High viscosity liquid level measurement

first, high viscosity. Liquid sugar has a much higher viscosity than ordinary liquids, making it easy to stick to the sensor surface, resulting in slow pressure transmission and channel blockage;

Easy Level measurement in crystallization-prone fluids

Secondly, it is prone to crystallization. When the temperature fluctuates or is left to stand, liquid sugar will precipitate crystals, which will directly render the measurement ineffective after wrapping the probe;

High temperature liquid level measurement

The third issue is high temperature, as the temperature of liquid sugar during production often reaches 80-120 ℃, which can affect the stability and service life of ordinary sensors. The combination of these three issues imposes particularly strict requirements on measuring equipment.

How to adapt sensor design to liquid sugar measurement?

High viscosity liquids such as liquid sugar, viscous oils, and slurries create a specific problem for pressure transmitters. Poor fluidity means the medium easily adheres to the inner walls of pipelines or equipment gaps. This buildup blocks the pressure pipes and sensing channels in ordinary transmitters, and it also leaves the probe prone to crystallization over time.

Direct Insertion Design Removes the Pressure Piping

The extended length transmitter avoids this with a direct insertion design. The sensing element goes straight into the medium storage container through the plug-in barrel, so there's no pressure piping in the path at all. Contact between the sensing element and the medium is direct, with no extra channels or dead corners for material to collect in. Thick syrup or molasses can't build up on the probe, and the pressure transmission path stays short and clear. This removes the blockage risk that ordinary transmitters face and keeps pressure and level readings continuous and stable.

Probe Material Built for High Viscosity Adhesion

For liquid sugar specifically, the probe is built from 316L stainless steel or Hastelloy alloy, with a polished surface finish that further cuts down on medium adhesion. Even under high viscosity conditions, the smooth surface keeps buildup from forming on the probe itself.

Ceramic Capacitor Element for Small Level Changes

The sensing element uses a high-sensitivity ceramic capacitor design, so it picks up small pressure changes and responds quickly even when the liquid level only shifts slightly.

Technical parameters of liquid sugar level transmitter

The parameters of this pressure transmitter fully meet the needs of sugar factories:

• The measurement range varies, such as 0-5m liquid level (0-50kPa pressure), 0-3 m and so on.
• It is compatible with different specifications of storage drums;
• Measurement accuracy ± 0.5% FS or even higher such as 0.2% , repeatability ± 0.1% FS, accurate and reliable data;
• Output 4-20mA standard signal, can be directly connected to the sugar factory DCS system, supports remote control;
• The protection level is IP67, and the shell is made of aluminum alloy material, which can cope with humid and dusty environments;
• The flange size and interface is customized by users, such as 3” size , 4” size and so on.