Precise Level Measurement in the Mashing Process –
Using Radar Sensor and Capacitive Level Switch
In brewing, mashing is one of the most critical steps for ensuring the quality of the final product. Crushed malt is mixed with water and gradually heated – enzymes break down the starches into fermentable sugars. This process greatly influences both the alcohol content and the flavor of the finished beer. To maintain consistent high product quality, precise level monitoring in the mash tun is essential.
The challenge
High process temperatures, moving liquids, and heavy steam
The level in the mash tun must be measured accurately – despite intense foaming, high temperatures, and continuous stirring. Typical interference factors such as condensate on the sensor antenna, foam, or buildup on the tank walls must not affect the measurement. At the same time, the system used must be durable, low-maintenance, easy to integrate, and simple to clean.
Combined Radar and Capacitive Technology –
Stable Measurements Even in Challenging Conditions
To ensure reliable measurements despite agitators, steam, and temperature variations, sensors that go beyond standard are necessary. UWT offers the perfect combination with the NR 8300 radar sensor and the RF 8100 capacitive level switch – both specifically designed for hygienic applications in the food and beverage industry. These two technologies complement each other perfectly, delivering maximum process reliability and product quality during the mashing process – without compromise.
The UWT Solution:
NivoRadar® NR 8300 – Non-Contact, Robust and Process-Safe
For continuous level measurement in hygienic liquid processes, the is the ideal choice. This powerful 80 GHz radar sensor from the new NivoRadar® 8000 series features a fully encapsulated PTFE antenna and a chemically resistant flange connection – making it perfect for demanding applications, even with aggressive media, temperature fluctuations, and mechanical stress.
Its highly focused radar beam (only 3° beam angle) ensures reliable measurements even in narrow tanks, with agitators and internal installations. Commissioning is quick and convenient – either via the pluggable display, the UWT LevelApp, or PACTware.
Product-Specific Advantages
| • |
Non-contact 80 GHz radar technology for precise level measurement, even with steam, agitation, and foam |
| • | Foam, condensate, and agitator compensation for stable signals under real process conditions |
| • | PTFE-encapsulated antenna and chemically resistant materials for hygienic applications and aggressive media |
| • | Narrow 3° beam angle for pinpoint accuracy in small tanks with internal installations |
| • | Reliable operation up to +200 °C and 25 bar (+392 °F and 362.6 psi) process pressure |
| • | Certified according to SIL 2/3 and optionally available with intrinsically safe power supply |
| • | Maintenance-free, durable, and hygienic – designed for use in the food, beverage, and pharmaceutical industries |
Technical Highlights at a Glance
| • | Process temperature: –196 °C to +200 °C (–321 °F to +392 °F) |
| • | Process pressure: –1 to +25 bar (–14.5 to +363 psi) |
| • | Measuring range: up to 120 m (394 ft) |
| • | Housing material: Aluminium, Stainless Steel 1.4404 (316L) |
| • | Protection class: IP66/IP68, Type 6P |
| • | Wetted materials: Stainless Steel 1.4404 (316L), PFA, PEEK, FKM/FFKM |
| • | Installation options: ◦ Top of the tank ◦ On a nozzle ◦ Outside the tank |
The NR 8300 is part of the modular product family, designed for a wide range of applications in the food industry, chemical sector, water and wastewater management, pharmaceuticals, energy supply, and many other industries.
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Radar sensor
NivoRadar® - NR 8200 | Threaded antenna
Added Safety with the Capacitive Sensor RF 8100
For point level detection, the capacitive level switch is used as an additional safeguard. It is ideal for preventing overfill or dry run in hygienically sensitive applications involving liquids, pastes, foams, or sludges:
Product-Specific Advantages
| • | Easy calibration and resistant to buildup |
| • | FDA-compliant, hygienically sealed, and process-safe |
| • | Robust design, even under mechanical stress from agitators |
| • | Digital electronics with integrated display and user menu, fully programmable |
| • | Encapsulated electronics with high operational reliability thanks to “Active Shield” Technology |
| • | Durable construction with PFA shielding for high chemical resistance |
Technical Highlights at a Glance
| • | Measurement tasks: Point level and interface detection |
| • | Versions available: Rod or cable design |
| • | Process temperature: –40 °C to +200 °C (–40 °F to +392 °F) |
| • | Process pressure: –1 to +35 bar (–14.5 to +508 psi) |
| • | Minimum sensitivity: DK ≥ 1.5 |
| • | Housing type: Explosion-proof enclosure |
| • | Wetted materials: Stainless Steel 1.4404 (316L), PFA, PEEK, FKM, FFKM |
| • | Installation options: ◦ Top-mounted ◦ Side-mounted ◦ Angled in a cone ◦ On a nozzle |
Discover more applications in the food industry
Whether in the processing of fruits, vegetables, nuts, flour, sugar, milk powder, spices or other food industry products – UWT offers reliable sensor solutions for a wide range of processes along the entire food and beverage value chain.
You can find all solutions at a glance in our industry brochure:
