Eliminating Inventory Guesswork In Bulk Sugar Storage

Overview

For food manufacturers, accurate inventory visibility is critical. When level measurements are delayed, infrequent, or unreliable, operators are forced to make production decisions based on estimates rather than real-time data.

A major cereal producer was experiencing this exact issue in a sugar storage silo. Their existing technology provided only periodic level updates and suffered from long response times, limiting visibility into actual inventory levels during filling and unloading operations.

Why It Matters

In bulk solids applications such as sugar, flour, grain, plastic pellets, and other dry products, poor level visibility can lead to:

• Unexpected material shortages
• Production interruptions
• Inefficient truck scheduling
• Overfills and inventory inaccuracies
• Reduced operational efficiency

The Solution

The facility implemented a Magnetrol Model R80 radar level transmitter to provide continuous, non-contact level measurement.

Using an existing nozzle connection, the transmitter was configured to account for rat-holing and uneven material profiles commonly encountered in bulk solids storage applications.

The Results

With continuous real-time level measurement, operators gained immediate visibility into changing inventory levels throughout filling and unloading cycles.

The result was improved process efficiency, better inventory management, and increased profitability through more effective silo utilization.

Key Benefits

• Real-time inventory visibility
• Continuous level measurement
• Improved filling and unloading efficiency
• Better production planning
• Reduced inventory uncertainty
• Reliable performance in bulk solids applications

Technologies Used

Magnetrol Model R80 Radar Level Transmitter