When you first think about level measurement and what it does for us, you normally tend to think, complicated applications and big industrial projects (well I used to anyway), and you don’t link it to things we have in everyday life. Without level measurement technology, items and products we use/need/eat everyday may not be produced. OK, this may sound over the top, but, without basic technology like level switches and transmitters we cannot produce things as simple as food, milk, water, even beers & spirits. All ingredients going in to things, like food and drinks need to be monitored for level control.
If we look into the process of making crisps, for example, VEGA supply level instruments to a major crisp manufacturer in the Midlands, which I had the privilege to visit. Our instruments help to make the whole production more efficient and a high quality product possible to send out to consumers like us.
If we looked at the process of making Corn Tortilla Chips, you’ll find many of our level instruments help along the way, from the raw product, in this case corn to the end flavoured corn chip we all enjoy, especially a crisp addict like me. Our VEGAPULS radar level transmitter monitors the level of the raw corn in silos outside and in the agitated, steam heated cooker kettles, this close control is critical to optimising the product quality and consistency. The key element is to monitor the water and lime level in the kettle, making sure there is enough to cover the raw product and cook it thoroughly and also to maintain a certain level for the next batch of corn to save on energy costs. Without level monitoring, the liquor level could become low and not cook it properly lowering the quality and the taste of the product from the very beginning. The VEGAPULS works by sending out continuous stream of extremely short microwave pulses by an antenna system, which is then reflected off the product surface. The elapsed time period between the transmission and reception of the signal is then measured and calculated as a distance and is converted to a level measurement, it is this data that then determines the amount of water and lime that is needed in the cooking kettles. This method reduces energy losses, saves water, optimises energy input and enables recovery/recycling of materials on the process by keeping a certain level of the water and lime so new water isn’t heated up every time. All important factors for cost savings and the environment.
The corn is now softened and cooked, this is then milled and made into a dough, this stage of the process is where our VEGASON comes in. Our ultrasonic sensor monitors the level of corn dough being fed into the machine that rolls and cuts into the famous tortilla chip shape, this is done by sending short ultrasonic impulses which reflect back of the product surface back to the transducer, the measurement is calculated in the same way as the radar sensor. The VEGASON will take this measurement and will help determine the speed of which the dough is fed onto the conveyor by speeding up and slowing down the feed, it will stop overflow and warn when there is not enough mixture to make the product.
Once the tortilla chips are rolled and cut they then have to be toasted and cooked. Again our VEGAPULS help keep the optimum level and temperature of the oil which will cook the corn chips perfectly. If this level is not monitored and maintained this will either undercook the chips by having too much oil or overcook the chips by having too little and the oil getting to hot. This level measurement method if what helps keep the Tortilla Chips at consistent high consumer quality.
The second part of the Blog will be available next week, discussing the use of level measurement in the final stages of flavouring and the finishing quality of the product. Also, how level measurement can help towards being environmentally friendly…
Check out the rest of our website at some of our application stories in different industries, use the link Case Studies or look through each instrument category for instrument specific applications.
Related posts:
- Level Measurement Technology in the Food Industry – Food for Thought! Part 2 of 2
- Radar Level Transmitters for Sea Level, Tide Gauging and River Level Measurement.
- New housing for level and pressure transmitters in food and pharmaceutical industry
- Level Measurement With Radar in the Paper Industry
- VEGA Radar measures the Thames
