In modern paper manufacturing, accurate monitoring of raw material levels in storage tanks is critical for ensuring production efficiency and consistent product quality. Precipitated Calcium Carbonate (PCC) is a widely used mineral additive in paper production, enhancing brightness, smoothness, and opacity of paper products. A major paper company in the Pacific Northwest region of the United States faced ongoing challenges in measuring PCC levels in their storage tanks and required a reliable continuous level measurement solution to optimize material handling and production control.
Challenges with Traditional 26 GHz Radar
The company had previously relied on 26 GHz radar sensors for PCC level measurement, but experienced frequent measurement lock-ups and signal instability, resulting in:
- Production delays due to equipment downtime
- High maintenance costs with frequent service calls
- Reduced accuracy in inventory monitoring and production scheduling
Frequent maintenance interventions and process interruptions prompted the company to explore alternative solutions, leading them to the domestic industrial radar experts at Shenzhen Jiwei Automations Ltd.
80 GHz Millimeter-Wave Radar Technology: A Breakthrough
After a detailed site survey, Jiwei engineers identified the limitations of 26 GHz radar for PCC powder measurement:
- Wide beam angle often picked up reflections from internal mixers, pipes, or tank walls, causing false echoes
- Low signal energy made it difficult to obtain stable reflections from low dielectric powders
- High dust concentration and airborne particles further reduced measurement reliability
To address these challenges, Jiwei recommended the JWrada®-34 Radar Level Transmitter, which offers the following key advantages:
- 80 GHz high-frequency millimeter-wave radar for narrow beam, focused energy, and minimal false echoes
- 76 mm lens antenna, capable of measuring distances up to 150 meters, suitable for large tanks or high-stack powder
- Smart echo learning adaptive algorithm, automatically identifying false echoes, separating multi-layer echoes, and dynamically tracking material surfaces
- Standard HART communication and built-in Bluetooth 5.0 module, integrated with the JW Tools App for wireless on-site commissioning, parameter configuration, and real-time monitoring
- Long-term stable operation under 220°C high temperature, steam, dust, and electromagnetic interference
- Certified explosion-proof, intrinsically safe, dust explosion-proof, and dust intrinsic safe (Ex db IIC T6 Gb; Ex ia IIC T6 Ga; Ex tb IIIC T80°C Db; Ex ia IIIC T200 80°C Da) for safe use in hazardous environments
Technical Features and Benefits of JWrada®-34
1. High Precision and Stability
The JWrada®-34 achieves ±1 mm liquid level accuracy and a powder level error of less than 0.1%. Even in environments with high dust concentration, steam, or foam, it delivers continuous, stable measurement output. Its narrow beam and focused energy ensure that only the product surface reflection is received, minimizing interference from tank structures or mixers.
2. Complex Process Adaptability
Equipped with a purge system and universal flange, the JWrada®-34 is ideal for challenging measurement conditions, including:
- Surface fluctuations caused by agitated powders or liquids
- High dust or airborne particle environments
- Steam, foam, and corrosive liquid atmospheres
The intelligent echo processing algorithm optimizes measurement performance according to actual site conditions, ensuring high-quality, precise measurement in complex scenarios.
3. High Temperature and Explosion-Proof Design
JWrada®-34 is capable of continuous operation at up to 220°C, suitable for steam, hot water, or high-temperature powder tanks. It meets national explosion-proof standards and is certified for gas and dust hazardous areas, ensuring safe operation in flammable or explosive environments.
4. Remote Commissioning and Data Management
With built-in Bluetooth and the JW Tools App, engineers can configure parameters, monitor measurement data, and perform on-site commissioning without opening the tank, significantly reducing operational risk. Through cloud connectivity, remote monitoring and parameter adjustment are also possible, improving operational efficiency and safety.
5. Strong Anti-Interference Capability
The JWrada®-34 maintains stable output in environments with dust, steam, agitation, vibration, and strong electromagnetic interference, ensuring reliable continuous level measurement.
6. Corrosion-Resistant Construction
The radar’s housing uses corrosion-resistant materials and includes a PTFE diaphragm, suitable for strong acid, strong alkali, or other corrosive media, extending service life and reducing maintenance costs.
Project Implementation and Results
Jiwei engineers provided the paper company with comprehensive technical consultation, device selection, and trial deployment. During the trial:
- A JWrada®-34 was installed on the top of each PCC storage tank
- Parameters and echo signals were configured via Bluetooth APP
- Cloud-based monitoring enabled continuous online level measurement
The results showed:
- Stable, reliable measurement with no lock-ups or interruptions experienced with 26 GHz sensors
- Accurate reflection of PCC levels despite dust, agitation, or steam
- Reduced need for frequent maintenance, significantly minimizing production interruptions
- Improved inventory control and production process management
Following the successful trial, the company purchased JWrada®-34 units for all PCC tanks and extended use to other applications within the facility, achieving high-precision, low-maintenance, intelligent level monitoring across the plant.
Conclusion
With Jiwei JWrada®-34 Radar Level Transmitter, the paper company achieved a reliable, precise, and maintenance-free solution for PCC storage tank level measurement. The combination of domestic 80 GHz millimeter-wave radar, smart echo processing, and full protective design ensures long-term operational reliability, even in high-temperature, high-dust, or foam-rich environments. Wireless commissioning and cloud monitoring further enhance safety and efficiency.
This case demonstrates the capability of JWrada®-34 to deliver stable, high-precision measurement in complex powder applications and highlights the competitiveness of domestic Chinese radar technology in high-end industrial measurement, making it a benchmark solution for modern paper production facilities.
radar level transmitter PCC storage tank level measurement paper industry powder level monitoring 80 GHz millimeter-wave radar non-contact level measurement Bluetooth wireless commissioning JW Tools App high-temperature powder measurementdomestic radar alternative to imported instruments
