SOLUTIONS FOR THE

SYNTHETICS INDUSTRY
 L E VE L . U P TO T H E M AX . C U STO M P RO D U C T CO NCEPTS A ND
M A IN T E N A N C E- F REE SO LU TIO NS
As an owner-managed, medium-sized company,
with an international sales network in over 90 Ac c ording t o t he high s t an dards of vari ous

countries and personal contacts available locally, indust ries, U WT’s t eam provi de s ext e n s i ve

UWT stands for a sustainable partnership at eye support for indiv idual re qui re m e nt s .

level - globally and regionally. Cust omer-orient ed plan n i n g e n abl e s t h e

dev elopment of t ailore d s ol ut i on s t h at are

The c ore c ompet enc e of U WT lies in lev el, effic ient ly and suc c ess ful ly i m pl e m e nt e d.

point, and interface measurement. We measure

bulk solids, from t he finest powder t o c oarse, Thanks t o in-house produc t i on an d a m ode rn

abrasiv e mat erials, as well as all t ypes of mac hine park , c ust om i s e d s ol ut i on s an d

liquids, inc luding high-v isc osit y past es and spec ific dev ic e adapt at i on s c an be re al i s e d.

foams.
U WT sensors are c omp l et e ly m ai nt e n an c e -

In t he field of point lev el measurement for free and operat e on t h e “i n s t al l an d forg et ”

bulk mat erials, U WT has ac hiev ed a spec ial princ iple. They are hig h ly c onfi g urabl e an d add

posit ion and set new st andards wit h t he rot ary value t o various applic at i on s .

paddle swit c h.

TO P Q UA L ITY M E ANS LO NG LIF ESPA N

IN N OVAT IV E S O LU T IO N S
SU C C E SSFU L
A N D D IG ITA L ISAT IO N U WT offers guarant eed “Made i n Ge rm any ”
qualit y. The high reliab i l i t y of t h e produc t s
Modern, high-qualit y t ec hnologies ensure a ensures high syst em avai l abi l i t y w i t h out
c ont inuous proc ess flow. U WT sensors are downt ime. Cont inuous i m prove m e nt proc e s s e s
designed wit h maximum proc ess c ompat ibilit y, and ext ensiv e t est ing g uarant e e a h i g h l eve l
TO G E T H E R
allowing seamless int egrat ion int o syst ems of safet y. Long-last ing , m ai nt e n an c e -fre e
and prov iding opt imal support . Addit ionally, produc t s wit h a 6-year g uarant e e al s o s ave
c omprehensiv e digit alisat ion is offered: t ime and resourc es.
c utt ing-edge eTools enable easy produc t
selec t ion, c onfigurat ion, and c ommissioning.
Int uit iv e operat ion and innovat iv e dev ic e
c ommunic at ion ensure smoot h operat ion.

Q UA L ITY C E RT IF IC AT E S

G LO BA L A P P ROVA L S

2 3
 SYN T H E T IC S IN D U ST RY In addition, bio-based plastics, made from

renewable resources, are gaining prominence as

The synthetics industry is at the heart of a they present a promising alternative to traditional
fascinating interplay between innovation and synthetics.
challenge. In a world driven by the constant

pursuit of efficiency, sustainability, and

technological advancement, plastics play a crucial L E V E L M E AS U R E MENT IN THE

role. From packaging to high-tech applications, SYN T HE T IC S IN D U STRY
plastics permeate nearly every aspect of our

daily lives, providing a wide range of solutions to In synthetics manufacturing and processing,

complex problems. precise level measurement helps ensure product

quality, minimise production downtime, and

enhance process efficiency.

CHALLENGES
In the synthetics industry, level measurement

Despite their versatility, plastics today face various devices can be used in storage containers for raw

hurdles, ranging from environmental concerns to materials such as granules or liquids like plastic

regulatory requirements. The need to reduce the melt. They allow operators to monitor current

ecological footprint and develop more sustainable stock levels, plan replenishment in time, and

alternatives has pushed the industry to explore avoid shortages. Additionally, level measurement

innovative solutions. devices are employed in process plants to ensure

the correct quantity of material is present in

Simultaneously, issues of recyclability and processing or mixing stages, thus maintaining
waste management have come to the forefront, consistent product quality.
as the global community strives to improve the

lifecycle of synthetics and minimise their negative Given the variety of materials, different areas

environmental impact. of application, and specific requirements in

the synthetics industry, choosing the right level

measurement technology is crucial.

M AT E R IA L S U S E D

A wide variety of materials are used in the

synthetics industry, ranging from traditional

petrochemicals to bio-based and recycled raw

materials. Polyethylene, polypropylene, polyvinyl

chloride, and polystyrene are among the most

widely used synthetics for a diverse range of

applications.

4 5
 LE V EL A ND PO INT LE VE L
Me asure me nt Task
L E VE L & P O IN T L E V E L M E AS U R E M E NT

MEAS UREM EN T IN Me d ium

P L AST IC G R A N U L E S

STO RAG E S ILOS Me asuring Rang e

< 2 5 M | 82 F T

Plastics are often stored and transported O U R PRODU C T REC O M M E NDAT IO N : Pro ce ss Te mp e rat ure
in the form of granules or powders. Storage
< 8 0 °C | 1 76 °F
RN N R 3 100
silos enable efficient handling and storage of
these materials before they are fed into the Rot o n i vo ®
Pro ce ss Pre ssure
production process. Continuous monitoring of < 0. 8 BA R | 1 1 .6 P S I
NR
the fill level ensures that level sensors can
N i voR ada r ®
prevent overfilling or downtime.

NB
N i voB o b ®

CH A L LE NG E : N B 3 2 00

• Re lia b le p rev ent i o n of o v er f i l l i n g

or d ownt im e
RN 3 002
• Ef ficie nt m at e r i a l m a n a gem ent
• Va r iou s p roce ss c o n n ec t i o n s
• Com p lex w ir in g p at h s
• Ta ll, n a r row s i l o s
• Hig h m e ch a n ic a l l o a d s
• Low d ie le ct r ic c o n s t a nt (D K )
of t h e m at e r ia l

S O LU T ION :
• A b s olu t e re lia b i l i t y t h ro u gh a d va n c ed
safet y fe at u res
• Leve l vis u a lis at i o n a s a c o m p l et e
solu t ion is p oss i b l e
• Wid e ra n g e of p ro c es s c o n n ec t i o n s
• Sim p le a n d int u i t i v e i n s t a l l at i o n /
ad ju s t m e nt (Pl u g & Pl ay)
• St u rd ily a n d d u ra b ly c o n s t r u c t ed
m e a s u re m e nt t ec h n o l o gy
• Re lia b le a n d p rec i s e l ev el m ea s u rem ent
of p la s t ic g ra n u l es ev en u n d er
ch a lle n g in g e nv i ro n m ent a l c o n d i t i o n s

6 7
 LE V EL A ND PO INT LE VE L
Me asure me nt Task
L E VE L & P O IN T L E V E L M E AS U R E M E NT

MEAS UREM EN T Me d ium

P L AST IC G R A N U L E S

I N T E X TIL E S ILOS Me asuring Rang e

< 3 M | 9. 8 4 F T

Raw mat e r ia ls a re oft en s t o red i n t ex t i l e O U R PRODU C T REC O M M E NDAT IO N : Pro ce ss Te mp e rat ure
sil os. Fu ll a n d e m pt y d et ec t o rs a re s ew n into
< 8 0 °C | 1 76 °F
the tex t ile s ilos u s i n g a f l a n ge a n d t a ke o ve r NR
l evel cont rol. R a d a r s en s o rs c a n p en et rat e N i voR ada r ®
Pro ce ss Pre ssure
the tex t ile fa b r ic a n d c o nt i n u o u s ly m o n i t or < 0. 8 BA R | 1 1 .6 P S I
RN N R 4100
the fi ll leve l.
Rot o n i vo ®

RN 3 001

C H A LLEN GE:
• No d efin e d p ro c es s c o n n ec t i o n s
• Sh ort m e a s u r i n g d i s t a n c es
• No refle ct ion f ro m t h e c o nt a i n er b ott om
• Ch a lle n g in g ins t a l l at i o n c o n d i t i o n s

S O LU T ION :
• Wid e ra n g e of p ro c es s c o n n ec t i o n s
• Leve l s e n s ors fo r s h o rt m ea s u r i n g
di s t a n ce s
• Pre cis e m e a s u rem ent res u lt s
Leve l m e a s u rem ent t h ro u gh t h e
cont a in e r roof
• Int e r fe re n ce si gn a l s u p p res s i o n i n t h e
pre s e n ce of s t r u t s
• Se n s ors in lig ht wei ght d es i gn

8 9
 RYI N G SYST E M S
P O I N T L EVEL ME ASURE ME NT
Me asure me nt Task

I N T E R M E D I AT E
P O IN T L E VE L M E AS U R E M E N T

I N D RYING SYST E MS & Me d ium

P L AST IC G R A N U L E S,

I N T E R M ED IATE CONTAINE RS P L AST IC P E L L E TS

Me asuring Rang e
< 1 M | 3 .2 8 F T
The d r yin g of p la s t i c gra n u l es i s a c r u c i a l O U R PRODU C T REC O M M E NDAT IO N :
step in fu rt h e r p ro c es s i n g t o rem o v e
Pro ce ss Te mp e rat ure
m oist u re a n d e n s u re t h e q u a l i t y of t h e f i na l RN
< 1 20 ° C | 2 8 0 °F
product . At t h is st a ge, m i x i n g w i t h d y es , Rot o n i vo ®

stabilis e rs , or ot her a d d i t i v es c a n a l s o t a ke Pro ce ss Pre ssure

CN
pl ace . Leve l s e n s o rs c o nt i n u o u s ly m o n i t o r the < 0. 8 BA R | 1 1 .6 P S I
C a pa n i vo ®
content s of t h e res p ec t i v e c o nt a i n ers

RN 3 004

C H A LLEN GE:
• Flu ct u at in g p ro c es s t em p erat u re
an d re s id u a l mat er i a l m o i s t u re
• Confin e d in s t a l l at i o n c o n d i t i o n s
• Hig h p roce s s sp eed
• Cont in u ou s m at er i a l f l ow
• Va r yin g b u lk d en s i t i es

CN 712 0
S O LU T ION :
• Re s is t a nt t o t e m p erat u re a n d
m ois t u re flu ct u at i o n s
• Com p a ct d e s ign
• Ra p id re p rog ra m m i n g d u r i n g
m at e r ia l ch a n ges v i a I O - L i n k
• Fa s t re s p on s e t i m e
• Ad ju s t a b le s e n s i t i v i t y

10 11
 OSING & MIXING
P O I N T L EVEL ME ASURE ME NT
Me asure me nt Task
P O IN T L E VE L M E AS U R E M E N T

I N D OS ING A ND MIXING Me d ium

P L AST IC G R A N U L E S,

C O N TA INERS P L AST IC P OW D E R

Me asuring Rang e
< 1 . 5 M | 4. 9 2 F T
In an ex t r u s ion p l a nt , d o s i n g a n d m i x i n g O U R PRODU C T REC O M M E NDAT IO N :
conta in e rs a re oft en u s ed t o p rec i s ely
Pro ce ss Te mp e rat ure
m easu re a n d m ix raw m at er i a l s b efo re t h ey CN
< 8 0 °C | 1 76 °F
enter t h e ex t r u d er. Th e d o s i n g c o nt a i n er C a pa n i vo ®

ensu re s t h at t h e exa c t a m o u nt of raw Pro ce ss Pre ssure

RN
m ateria ls , s u ch a s p owd er o r gra n u l es , i s < 0. 8 BA R | 1 1 .6 P S I
Rot o n i vo ®
m easu re d for t h e ex t r u s i o n p ro c es s . RN 3 001

C H A LLEN GE:
• Hig h a m b ie nt t em p erat u re
• Ra p id m at e r ia l f l ow
• Confin e d in s t a l l at i o n c o n d i t i o n s

CN 7120
S O LU T ION :
• Tem p e rat u re -res i s t a nt at a m b i ent
tem p e rat u re s u p t o 80 °C (1 76 ° F)
• Re lia b le a n d fa s t p o i nt l ev el d et ec t i o n
• Du ra b le m e a s urem ent t ec h n o l o gy
• Com p a ct d e s ign

12 13
 P O I N T L EVEL ME ASURE ME NT
Me asure me nt Task
P O IN T L E VE L M E AS U R E M E N T

D U RI NG G RINDING AND CRUSHIN G Me d ium

P L AST IC G R A N U L E S

P RO C ES S ES Me asuring Rang e
< 1 M | 3 .2 8 F T

The g r in d in g of p l a s t i c gra n u l es i s a p ro c ess O U R PRODU C T REC O M M E NDAT IO N : Pro ce ss Te mp e rat ure

in which t h e g ra n u l es a re c r u s h ed i nt o
< 8 0 °C | 1 76 °F
sm al l e r p a rt icle s o r p owd er. Aft er p ro c es sing, RN
the p la s t ics a re c o l l ec t ed i n b u f fer Rot o n i vo ®
Pro ce ss Pre ssure
conta in e rs . Point l ev el s en s o rs m o n i t o r t he < 0. 8 BA R | 1 1 .6 P S I
MN
fil l l eve l d u r in g t hi s p ro c es s .
Mo n o n i vo ® RN 3 001

RUSHING
C H A LLEN GE:
• Mat e r ia l b a ck l o g
• Confin e d in s t a l l at i o n c o n d i t i o n s
• Cont in u ou s m at er i a l f l ow
• Ha rs h p roce s s c o n d i t i o n s
• Va r yin g m at e r i a l p a rt i c l e s i ze

MN 4020
S O LU T ION :
• Re lia b le a n d fa s t p o i nt l ev el d et ec t i o n
• Com p a ct d e s ign
• Du ra b le m e a s urem ent t ec h n o l o gy
• Me a s u re m e nt i n d ep en d ent of m at er i a l
pa rt icle s ize

14 15
 P O I N T L EVEL ME ASURE ME NT
Me asure me nt Task
P O IN T L E VE L M E AS U R E M E N T

I N T HE FEED HOPPE R - FE E DIN G Me d ium

VA R IO U S P L AST IC S

I N TO TH E EXT RUSION MACHINE Me asuring Rang e

< 1 M | 3 .2 8 F T

The p re p a re d p la st i c gra n u l es a re p o u red into O U R PRODU C T REC O M M E NDAT IO N : Pro ce ss Te mp e rat ure
the hoppers or feed devices of the extrusion
< 8 0 °C | 1 76 °F
m ach in e . Point lev el s en s o rs m o n i t o r t h e CN
continu ou s m at e ri a l s u p p ly, en a b l i n g a n C a pa n i vo ® Pro ce ss Pre ssure
u n int e r r u pt e d p ro d u c t i o n p ro c es s . Th e < 0. 8 BA R | 1 1 .6 P S I
ex tr us ion m a ch in e t h en m elt s t h e gra n u l es
an d fo r m s t h e m int o a c o nt i n u o u s m a s s ,
kn own a s t h e ex t r u d at e.

XTRUSION
CN 7121

C H A LLEN GE:
• Flu ct u at in g a mb i ent t em p erat u re
• Confin e d in s t a l l at i o n c o n d i t i o n s
• Hig h p roce s s sp eed
• Cont in u ou s m at er i a l f l ow

S O LU T ION :
• Tem p e rat u re -res i s t a nt at a m b i ent
tem p e rat u re s u p t o 80 °C (1 76 ° F)
• Com p a ct d e s ign
• Re lia b le a n d fa s t p o i nt l ev el d et ec t i o n
• Cos t-effe ct ive m ea s u rem ent
tech n olog y
• Act ive Sh ie ld Tec h n o l o gy t o p rev ent
build -u p

16 17
 BAC K F LOW D E T ECT ION
Me asure me nt Task
P O IN T L E VE L M E AS U R E M E N T

I N REG RA NU L ATION Me d ium

P L AST IC F L A KE S

Me asuring Rang e
< 1 M | 3 .2 8 F T

Waste or d efe ct iv e p ro d u c t s a re regra n u l ate d O U R PRODU C T REC O M M E NDAT IO N : Pro ce ss Te mp e rat ure
in a re s ou rce -effi c i ent m a n n er. Th e
< 8 0 °C | 1 76 °F
fin ish e d p la s t ic c o m p o n ent s a re c r u s h ed MN
an d tra n s p ort e d v i a c o nv ey o r b elt s t o t h e Mo n o n i vo ®
Pro ce ss Pre ssure
su bseq u e nt p rod uc t i o n s t ep s . C o l l ec t i o n < 0. 8 BA R | 1 1 .6 P S I
conta in e rs a re oft en u s ed fo r s o rt i n g, i nt erim
storag e , or m at e ri a l c o nt ro l . Po i nt l ev el
sensors p rev e nt o v er f i l l i n g of t h e c o nt a i ne rs
an d e n s u re a cont i n u o u s m at er i a l f l ow.

MN 403 0

C H A LLEN GE:
• Sh a r p -e d g e d p l a s t i c f l a kes
• Cont a m in at e d a n d wet b u l k m at er i a l s
• Ha rs h p roce s s c o n d i t i o n s
• Cont in u ou s m at er i a l f l ow
• Va r yin g m at e r i a l p a rt i c l e s i ze

S O LU T ION :
• Rob u s t a n d d ura b l e d es i gn
• Re s is t a nt t o m o i s t u re
• Me a s u re m e nt i n d ep en d ent of
m at e r ia l p a rt ic l e s i ze

18 19
 POINT LEVEL MEASUREMENT
Me asure me nt Task
P O IN T L E VE L M E AS U R E M E N T

DURING THE CONVEYING OF COOLED Me d ium

E N D P RO D U C TS

AND HARDENED END PRODUCTS M A D E O F P L AST IC

Me asuring Rang e
< 2 M | 6 . 56 F T
After t h e m olt e n p l a s t i c gra n u l es h av e b e e n O U R PRODU C T REC O M M E NDAT IO N :
sh aped int o t h e d es i red fo r m , t h ey a re c oo le d
Pro ce ss Te mp e rat ure
to h ard e n a n d a ch i ev e t h ei r f i n a l s t r u c t u re . MN
< 8 0 °C | 1 76 °F
This st e p is p a rt ic u l a r ly i m p o rt a nt t o en s ure Mo n o n i vo ®

the sh a p e s t a b ilit y of t h e en d p ro d u c t . Pro ce ss Pre ssure

The fi n is h e d e n d p ro d u c t i s t h en s t o red i n < 0. 8 BA R | 1 1 .6 P S I
conta in e rs a n d p rep a red fo r p a c ka gi n g. Point
l evel s e n s ors m on i t o r t h e c o nt ent s of t h e
conta in e rs g e nt ly t o av o i d d a m a ge t o t h e
m ateria l.

MN 402 0

C H A LLEN GE:
• Va r ia b ly s ize d p l a s t i c p a rt s
• Hig h re s id u a l t em p erat u re
• Se n s it ive e n d p ro d u c t s

S O LU T ION :
• Non -cont a ct l ev el m ea s u rem ent
• Hig h s e n s it iv it y
• Tem p e rat u re -res i s t a nt at p ro c es s
tem p e rat u re s u p t o 1 5 0 ° C (3 0 2 °F)
• Prod u ct-fr ie n d ly t ec h n o l o gy

20 21
 LE V EL VIS UAL ISAT ION W ITH B E N E F ITS A N D R ESU LTS

T H E A PPROPR IAT E This project implementation by UWT offers the

plastic processor numerous advantages

MEAS UREM EN T TECHNOLOGY

Efficiency Improvement:
RN NB C O R E C O M P O N E N TS O F T H IS By centralising the capture and real-time display
An internationally active plastic processor faced Rot o n i vo ®
N i voB o b ®
C U STO M SYST E M S O LU T IO N of fill levels, production processes can be better
the challenge of capturing the exact fill levels planned and resources optimally utilised.
of the silo batteries at three production sites in The central monitoring of fill levels across multiple
real-time and making this information centrally silo batteries at various locations imposes
accessible. specific requirements on the communication and Cost Savings:
measurement systems: The precise level measurement and prevention of
Furthermore, the sensors had to operate reliably overfilling reduce material losses and production
and precisely, regardless of the varying properties downtime.
of the stored plastic granules, such as the Precision and Reliability:
dielectric constant (DK), dust generation, or The NivoBob ® 3100 level sensors provide accurate
fluctuating temperatures. measurement data that is independent of the Increased Operational Safety:
varying properties of the plastic granules. This The use of reliable sensors and a robust
reliability is crucial for obtaining consistent and communication network minimises the risk of
usable information. To prevent silo overfilling, the measurement errors and technical failures.
O U R SOLUTION full detector RN 3002 from the Rotonivo series
®

is employed. This sensor continuously monitors

Our customised UWT solution for this application the maximum fill level and issues timely alarms to
was implemented through a combined installation prevent overflow.
of the NivoTec ® 3500 for level monitoring, the
electromechanical float system NivoBob ® 3100 for
level measurement, and the full detector RN 3002 Real-Time Data Availability:
from the Rotonivo ® series. For efficient production planning, it is essential
that the fill levels are available in real time.
Communication between the level sensors and the
central visualisation occurs via a Modbus network.
This protocol ensures that the measurement data Application reports
is transmitted immediately and without delay.

Central Management:
The visualisation system NivoTec ® - NT 3500
provides a comprehensive display, allowing the
fill levels of all locations to be centrally managed
and monitored. Three silo systems have been
connected to the NT 3500 controller via gateways Application Database

and VPN tunnels, ensuring secure and reliable

data transmission. This enables management to
respond quickly to changes and make informed
decisions.

22 23
 LE V EL M ONITORING
A ND VIS UA L ISAT ION DISPLAY
Controller

N i voTec ®
Various technologies are available for level
display. Simple LED digital displays for evaluating NT 3500
a 4-20 mA signal can be integrated into control
cabinets or wall-mounted, ranging up to touch
panels and web server modules with visualisation
NivoTec ®
software. These can be configured on a project
Level monitoring and visualisation
basis and customised to meet customer
requirements.

UWT offers standardised products from the

115/230 VAC
NivoTec ® NT 4000 series, which meet many
requirements for level display and monitoring
at a competitive price. The NivoTec ® NT 3000 Level
NivoTec - NT 4600
®
visualisation Ethernet
series can be customised for individual customer
7 inch touch panel visualisation
projects. This web server solution meets all the
requirements of modern level monitoring.

NivoTec ® - NT 4700 Gateway

Level Indicator one container RTU/TCP

NivoTec ® - NT 3500 NivoTec ® - NT 4900

Custom project visualisation Level indicator for control cabinet

NivoTec ® - NT 4500 NivoTec ® - NT 9000 Internet Routed IP address

Standardised visualisation Local fill level display Worldwide access

24 25
26 27
 01.25

uwtgroup.com/en/productoverview

Westendstr. 5 I 87488 Betzigau I Germany

Tel +49 831 57123-0 I [email protected] 28