Tank Fill Control – Smart Tank Level Monitoring with IoT
How Embedos HMI Technology increased Production for Leading Dairy Tank Manufacturer
Summary
A leading dairy tank manufacturer implemented Embedos Engineering’s advanced EB3025/EMA605 Volume Measurement System with 3.2″ HMI interface across their tank line, resulting in transformative improvements in production efficiency and customer satisfaction.
This case study examines how the tank level monitoring solution’s versatile calibration options, multi-liquid compatibility, and intuitive interface helped the manufacturer enhance their products’ functionality while delivering measurable value to dairy processors, fruit juice producers, and water treatment facilities nationwide.
The Challenge: Precision Volume Monitoring in Dairy Processing
The dairy tank manufacturer faced critical challenges in meeting the evolving needs of modern liquid processing facilities:
- Customers demanded precise volume measurement across various liquid densities and temperatures.
- Tank operators needed intuitive, easy-to-use interfaces for monitoring critical fill levels.
- Automated alert systems were required for preventing overflow and maintaining minimum volume thresholds.
- Remote monitoring capabilities were increasingly requested by processing facilities.
- Calibration processes needed to accommodate different sensor types and tank geometries.
- System setup had to be accessible to non-technical staff in dairy processing environments.
The Solution: Embedos EB3025/EMA605 Volume Measurement System with 3.2″ HMI
After evaluating multiple options, the manufacturer integrated the Embedos EB3025/EMA605 Volume Measurement System with 3.2″ HMI into their premium tank line, providing a comprehensive solution for liquid volume monitoring and control.
Key System Capabilities
- Precision Volume Measurement Technology
- Dual analog input channels (4-20mA) for professional-grade sensors.
- Secondary voltage input channels (0-10V) for versatile sensor compatibility.
- ADC averaging technology ensuring stable readings in dynamic processing environments.
- Real-time volume calculation based on custom tank parameters.
- Advanced Calibration System
- Three distinct calibration methods (Two Point, Zero Span, Manual) accommodating diverse sensor types.
- Custom calibration for unique tank geometries including cone-bottom designs.
- Dynamic parameter adjustment for varying liquid densities.
- Pre-programmed liquid type selection for common dairy products and other processing liquids.
- Intuitive User Interface
- 3.2″ color touchscreen HMI for clear status visualization.
- Percentage and absolute volume displays simultaneously.
- Visual tank level indication for at-a-glance monitoring.
- Customizable parameter names and units for application-specific deployment.
- Smart Alert System
- Dual relay outputs for high and low-level threshold alerts.
- Configurable hysteresis preventing relay chatter during level fluctuations.
- Integrated buzzer with acknowledgment feature for critical alerts.
- Visual alarm indicators for immediate status recognition.
- Connectivity Solutions
- Wi-Fi connectivity for remote monitoring and control.
- OTA (Over-The-Air) firmware updates ensuring system longevity.
- Network integration capabilities for plant-wide monitoring systems.
Implementation: Seamless Integration into Dairy Processing Equipment
The dairy tank manufacturer worked with Embedos Engineering to implement the volume measurement system across their product line, following these key implementation phases:
- System Configuration and Customization
- Factory preset configurations tailored to dairy processing requirements.
- Custom calibration procedures developed for various tank geometries.
- Liquid-specific density configurations pre-programmed for common dairy products.
- User Interface Customization
- Parameter names configured to match industry terminology.
- Units standardized to customer preferences (liters/gallons).
- Alert thresholds optimized for various dairy processing applications.
- Field Installation Support
- Simplified connection diagrams for electrical contractors.
- Pre-configured Wi-Fi settings for rapid deployment.
- Documentation developed specifically for dairy processing technicians.
- Staff Training Program
- Intuitive menu structure allowing step-by-step system configuration.
- Password protection preventing unauthorized parameter changes.
- Visual feedback for all user interactions reducing training requirements.
Results: Transforming Dairy Processing Efficiency
The implementation of the Embedos Volume Measurement System delivered significant benefits to both the tank manufacturer and their dairy processing customers:
- Enhanced Production Precision
- Increased measurement accuracy across various dairy products from skim milk to heavy cream.
- Automatic density compensation ensuring consistent readings regardless of product type.
- Reduction in product loss due to precise level monitoring during critical processing phases.
- Streamlined Operations
- Reduction in manual level checks required by processing staff.
- Automated alerts preventing both overflow incidents and pump dry-running conditions.
- Simplified calibration process reducing maintenance requirements.
- Improved Equipment Value Proposition
- Customer satisfaction ratings improved for equipped tanks.
- Service calls related to level monitoring decreased across the customer base.
- Industry Application Versatility
- Successful deployment across dairy, fruit juice, pharmaceutical, and water processing facilities.
- Single platform accommodating diverse liquid properties through simple configuration changes.
- Customizable interface allowing industry-specific terminology and units.
Technical Specifications Overview
The EB3025/EMA605 Volume Measurement System includes the following key specifications:
- Display: 3.2″ color touchscreen HMI.
- Analog Inputs: Dual 4-20mA current inputs (channels 1-2).
- Voltage Inputs: Dual 0-10V voltage inputs (channels 3-4).
- Outputs: Two relay outputs for high/low threshold alerts.
- Connectivity: Wi-Fi with OTA update capability.
- Power Requirements: 24VDC.
- Calibration Options: Two-point, Zero span, and Manual calibration modes.
- Customization: User-definable parameter names, units, and liquid types.
- Security: Password-protected configuration menus.
Setting New Standards in Liquid Processing Monitoring
The implementation of the Embedos EB3025/EMA605 Volume Measurement System has established a new benchmark for precision and reliability in dairy tank monitoring.
By addressing the specific needs of liquid processing facilities with an intuitive yet powerful solution, the manufacturer has significantly enhanced their market position while delivering measurable operational improvements to their customers.
The system’s versatility across various liquid types—from milk and cream to fruit juices and pharmaceutical liquids—demonstrates its value as a comprehensive monitoring solution for any processing facility where precise volume measurement is critical to quality and efficiency.
Want the Complete Technical Documentation for the EB3025/EMA605 Volume Measurement System?
Fill out the form below to receive comprehensive technical specifications, installation guides, and calibration procedures for implementing this advanced volume measurement technology in your specific liquid processing application.
- Detailed connection diagrams
- Step-by-step calibration instructions for various tank geometries
- Complete parameter reference guide
- Wi-Fi configuration and remote monitoring setup
- Maintenance and troubleshooting guides
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