In the beer brewing process, level measurement is a critical factor for ensuring stable production and maintaining product quality. Beer tanks often contain thick foam layers, with complex liquid properties and fluctuating temperature and pressure. Traditional differential pressure level measurement usually requires two pressure transmitters, increasing cost, maintenance complexity, and susceptibility to foam and process disturbances. To address these challenges, Jiwei Automations offers a comprehensive solution for beer tank level measurement, combining the Ring-11 tuning fork level switch for point-level control with the JWrada® radar level meter for continuous measurement. Depending on the customer’s budget, the devices can be used individually or together for optimal performance.
I. Application Background and Challenges
Beer tank level measurement faces the following main challenges:
- Severe foam interference: During fermentation and stirring, thick foam layers are generated, which can trigger false readings in traditional level meters.
- Wide temperature range: Beer fermentation and storage processes experience temperatures from +3°C to +120°C, with certain high-temperature stages requiring heat-resistant equipment.
- Pressure fluctuations: Tank pressures vary from 0 to 5 bar, requiring level measurement devices to handle pressure changes.
- Strict hygienic requirements: Measurement devices must prevent contamination to ensure the beer remains sanitary during production.
- High humidity environment: Condensation may occur due to temperature differences inside and outside the tank, requiring devices to resist moisture and operate stably over long periods.
Based on these conditions, Jiwei Automations proposes a dual-layer solution: using the Ring-11 tuning fork level switch for high/low point control and the JWrada® radar level meter for continuous monitoring, allowing flexible selection according to budget and process requirements.
II. Advantages of Ring-11 Tuning Fork Level Switch in Beer Tanks
The Ring-11 tuning fork level switch is an ideal solution for beer tank level measurement due to its high reliability, food-grade hygiene, and strong anti-interference capabilities. Key features include:
- High reliability design
Ring-11 operates based on frequency change detection, ensuring stable measurement even in environments with vibration, foam, bubbles, or changing medium properties. It provides long-term stability and reliable point-level monitoring in harsh industrial conditions. - Food-grade hygienic standard
Equipped with sanitary clamp connection and polished surfaces, Ring-11 fully meets food-grade standards, preventing contamination and ensuring hygienic safety in beer production. - Ultra-short fork design
The 40mm fork length allows installation in narrow spaces such as pipes and tanks, easily handling complex environments for level measurement. - Reliable measurement of low-density liquids
Precisely tuned forks can measure liquids with densities as low as 0.5 g/cm³, suitable for beer and fermentation liquids. - Strong anti-interference capability
Measurement remains accurate under foam, bubbles, stirring, vibration, or viscous liquid conditions. - High-temperature resistance
The device withstands process temperatures up to 400°C, suitable for high-temperature stages in beer production. - Multiple signal output options
Supports relay, two-wire, NAMUR, and transistor outputs, allowing seamless integration with various automation systems for local or remote control. - Certified safety compliance
Ring-11 is SIL2/3, 3C, CE, EAC certified and features intrinsic safety and explosion-proof capabilities (gas & dust dual protection), meeting global safety standards.
Using Ring-11 ensures precise high/low point control in beer tanks, unaffected by foam, stirring, or liquid viscosity changes.
III. Application of JWrada® Radar Level Meter for Continuous Measurement
For processes requiring continuous beer tank level monitoring, the JWrada® radar level meter provides a high-precision, non-contact measurement solution.
Key advantages include:
- High-precision measurement
Using 80GHz FMCW radar technology, it achieves ±1mm accuracy with up to 60m range and no blind zones. The narrow beam concentrates energy for precise measurement, even in low dielectric constant liquids with thick foam. - Strong interference resistance
Proprietary echo processing algorithms handle false echoes, multi-layer echo separation, and dynamic tracking, ensuring accurate measurement in stirring, steam, foam, and dust. - Non-contact measurement
Radar probes avoid liquid contact, preventing scaling, corrosion, and wear, extending equipment life and reducing maintenance costs. - High-temperature and explosion-proof capability
Suitable for up to 220°C operation and certified for gas and dust explosion-proof environments, meeting beer production safety requirements. - Bluetooth smart configuration
Integrated Bluetooth module enables wireless configuration, real-time monitoring, and remote control via the Jiwei SmartControl® app. Parameters from one device can be copied to multiple units, saving setup time. - Flexible operation
Manual operation with LCD and buttons allows on-site adjustments; the app provides more features and seamless software upgrades. - Global replacement capability
JWrada® radar level meters have successfully replaced VEGA products multiple times, representing China’s most competitive radar solution for the global market.
JWrada® ensures continuous, stable beer tank level monitoring even in high-foam, high-humidity, and high-temperature conditions, providing reliable data for process optimization and automation control.
IV. Combined Application Benefits of Ring-11 & JWrada®
When budget permits, combining Ring-11 tuning fork level switches and JWrada® radar level meters achieves optimal beer tank level measurement:
- High/low point safety control: Ring-11 provides immediate alert and control for upper and lower liquid limits.
- Continuous level data: JWrada® provides real-time level curves for production analysis and optimization.
- Reliable interference resistance: Both devices withstand foam, bubbles, and vibration, ensuring stable measurements.
- Hygienic and non-contact design: Ring-11 is food-grade, JWrada® is non-contact, protecting liquid quality and extending device life.
- Flexible system integration: Supports multiple signal outputs for PLC, DCS, or MES integration, enabling intelligent scheduling and automation.
This combined approach ensures both safety and data accuracy, supporting automated beer production, process optimization, and reduced operational costs.
V. Typical Beer Tank Process Parameters
| Measuring Task | Level Measurement |
|---|---|
| Measuring Point | Beer Tank |
| Measuring Range | Up to 5 m |
| Medium | Beer |
| Process Temperature | +3 … +120 °C |
| Process Pressure | 0 … +5 bar |
| Special Challenges | Thick foam, humid environment, stirring |
With Ring-11 and JWrada® combined, beer tanks can achieve precise point control and continuous monitoring, unaffected by foam or density changes.
VI. Application Results and Customer Benefits
- Enhanced production safety
Ring-11 ensures high/low point alarms, preventing overflow or dry running of beer tanks. - Continuous, precise monitoring
JWrada® provides real-time level curves, even under thick foam and surface fluctuations, supporting process optimization. - Reduced maintenance costs
Both devices are interference-resistant, heat-resistant, and durable, lowering maintenance frequency and extending service life. - Hygienic and safe for food production
Ring-11’s food-grade design and JWrada®’s non-contact measurement guarantee sanitary operation in beer production. - Flexible automation integration
Supports multiple signal outputs for PLC, DCS, and MES integration, enabling smart process scheduling. - Quick installation and setup
JWrada® allows parameter configuration via Bluetooth, with setup per device in 2–5 minutes, efficiently supporting multiple units. - Strong scalability
The system can handle larger tanks, more measuring points, and complex processes as production scales, ensuring long-term applicability.
VII. Conclusion
Beer tank level measurement is crucial for safe, hygienic, and efficient brewing processes. For high-foam, high-humidity, high-temperature, and complex environments, Jiwei Automations provides a comprehensive solution:
- Ring-11 tuning fork level switch ensures point-level safety with fast response and high anti-interference capability.
- JWrada® radar level meter provides continuous monitoring with non-contact measurement and intelligent echo processing.
- Combined use guarantees safety, accurate data, process optimization, and reduced operational costs.
This solution has been successfully implemented in multiple domestic and international breweries, replacing traditional pressure-based measurement methods and imported products, achieving stable, reliable, hygienic, low-maintenance, and highly automated beer tank level measurement, creating significant value for customers.
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