Paper Mill Relies on 80 GHz Radar – for Reliable Level Measurement in the Presence of Foam and Solids
In paper production, process water is continuously recirculated – a task that requires reliable level measurement technology. At a traditional paper mill in the UK, repeated measurement failures occurred in one of the site’s backwater tanks. The previously installed ultrasonic system from another supplier was unable to provide accurate readings, as heavy foaming and solid deposits on the surface disrupted the signal.
To permanently resolve these challenges, the company approached UWT UK Ltd. in search of a reliable and practical alternative.
The mill is one of the UK’s established paper manufacturers, known for its high quality standards, FSC®-certified production and strong focus on sustainable processes. For uninterrupted operation, the facility required a level measurement solution that was low-maintenance, precise, and easy to integrate – ideally with clear visualisation and minimal impact on ongoing processes.
The Challenge: Foam, Solids and a Compact Tank
The plastic tank, with a filling height of around 4m, was relatively small – a typical scenario where ultrasonic technology quickly reaches its limits. The surface was unstable due to foam, and signal reflection was further impaired by solid build-up and condensation.
The Solution: NivoRadar® – NR 7100 with 80 GHz FMCW Technology
The team at UWT UK Ltd. recommended the compact NivoRadar® – NR 7100, a high-performance radar sensor using 80 GHz FMCW technology. Its non-contact measuring principle ensures highly accurate level detection – even with unstable surfaces and in high humidity environments.
Radar – NR 7100 reliably replaces the previously overburdened ultrasonic technology
Benefits in Practice
The 80 GHz radar sensor emits a high-frequency signal with a narrow beam angle of just 8°. The NR 7100’s high sensitivity allows for precise level measurement – even in the presence of heavy foaming and turbulent water surfaces.
It operates reliably and without interference even in compact plastic tanks with limited installation space. Measurement accuracy is unaffected by condensation in the tank environment, as the sensor is resistant to moisture.
Thanks to its standardised 4–20 mA output, the device can be easily integrated into existing control systems.
In addition, the certified level sensor reliably meets all relevant environmental requirements. It helps ensure that liquid levels are safely monitored, regulatory limits are observed and, in turn, watercourses are effectively protected.
The solution is further enhanced by the web-based UWT Level App, which enables simple visualisation as well as convenient commissioning and monitoring.
On-Site Service – A Solution That Fits
Alongside the right sensor technology, the team at UWT UK Ltd. placed great importance on a personal and practical service approach. The project began with an on-site visit to assess the application and analyse the requirements in detail.
Graeme Hughes, Sales Manager at UWT UK Ltd., supported the customer throughout the process – from selecting the individually configured sensor to installation and parameter setting.
The service was completed with a tailored training session on how to use the UWT Level App, ensuring straightforward visualisation and user-friendly operation.
“Our goal is to support our customers with reliable technology and outstanding service – so that their processes run smoothly and safely,” says Graeme Hughes.
The installation went smoothly, and the sensor has since delivered reliable performance – maintenance-free, precise and stable over the long term.
Conclusion
Whether in paper production or water treatment – process reliability starts with the informed and professional advice and the right level measurement technology. This application clearly demonstrates how the NivoRadar® – NR 7100 performs reliably even under challenging conditions involving foam, moisture and limited space.
Combined with hands-on local service, the result is a solution that convinces not only on a technical level but also through a collaborative approach.
This is exactly what UWT – The Level Company stands for: delivering dependable level measurement solutions for liquids, bulk solids, pastes and foams – whether through standard products or tailor-made systems.
Our customers can always count on three core values: Technology, Performance and Partnership – for level measurement at the highest standard.
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