In a modern dairy processing facility, precise level measurement is essential for maintaining process control, hygiene standards, and product quality. Storage and balance tanks depend on accurate, stable level signals to prevent overflow, avoid dry running, and eliminate contamination risks.
BONNER was engaged to replace a faulty hydrostatic level transmitter that was producing intermittent and unstable readings, impacting overall plant performance.
The ChallengeThe existing level transmitter was no longer delivering reliable data, resulting in:
- Inconsistent tank level monitoring
- Mismatch between actual level and transmitter output
- Unstable 4–20 mA signal
- Reduced operator confidence in process control
- Increased risk to product quality and compliance
In a highly regulated dairy environment, these issues posed both operational and food safety concerns.
BONNER supplied installation, configuration, calibration, and commissioning services for a new Endress+Hauser HART level transmitter, ensuring optimal performance within a hygienic processing environment.
What We DeliveredRemoval & Installation
- Isolated the process and ensured safe working conditions
- Removed the defective transmitter
- Installed the new hygienic level transmitter with correct mounting and sealing
- Configured measurement range (4–20 mA scaling) to match tank requirements
- Set zero and span using HART communication
- Verified loop integrity and signal stability
- Calibrated transmitter to ensure accurate level measurement
- Performed functional testing under normal operating conditions
- Verified zero calibration (empty tank condition)
- Confirmed span accuracy across expected level range
- Simulated level conditions where possible
- Ensured stable output signal and correct PLC/DCS integration
The project was completed efficiently within a live production environment, minimising disruption to operations. Close coordination between BONNER engineers and the client ensured all work met strict hygiene and safety standards.
Why BONNER?Clients choose BONNER for critical process instrumentation projects because of our:
- Food Industry Expertise – Proven experience in dairy and hygienic processing environments
- Hygienic Instrumentation Knowledge – Expertise in specifying and implementing sanitary measurement solutions
- Compliance Assurance – Work aligned with food safety regulations and audit requirements
- Ongoing Support – Continuous technical support and trusted advisory services
- Strict Hygiene Standards – Equipment suitable for washdown and food-grade environments
- CIP (Clean-in-Place) Conditions – Resistance to high temperatures, pressure, and aggressive cleaning chemicals
- Foam & Product Build-Up – Managing measurement accuracy in milk, cream, and whey processes
- Traceability & Compliance – Full documentation for audit and food safety requirements
- Restored accurate and stable level measurement
- Improved process control and operational reliability
- Reduced risk of product loss and contamination
- Increased confidence in instrumentation performance
- Seamless integration with existing control systems
- Reduced Product Waste – Accurate level control prevents overfills and losses
- Water Savings – Optimised CIP cycles reduce water and chemical usage
- Energy Efficiency – Improved process control lowers pump runtime and energy demand
Client Feedback“They’ve reduced product losses, improved CIP performance, and gained better visibility across our processes.”
Looking for Reliable Level Measurement Solutions?
BONNER provides expert instrumentation, calibration, and process optimisation services for the dairy and food industries. Contact our team to improve accuracy, compliance, and efficiency in your plant.