Advantages of Non-Contact Level Sensors in Food Processing
As demand grows in the food and beverage industry, the pursuit of peak efficiency can feel never-ending. Research and Markets expects the food processing automation market to reach $45.55 billion by 2033, a significant increase from $24.55 billion in 2024.
With explosive growth on the horizon, system expansion—and optimization—is necessary to keep up with premiumization and fast-paced trends. Implementing level sensors streamlines inventory management by eliminating manual measurements and traditional spreadsheet-based data recording.
But in food production—from meat and dairy to snacks and frozen products—compliance with health and safety standards is of the highest importance.
Non-contact level sensors provide a solution, offering the benefits of automated inventory tracking while avoiding direct contact with ingredients that must be monitored and managed.
Benefits of Non-Contact Sensing
By streamlining processes and preventing cross-contamination, non-contact sensors enhance product quality, reduce waste, and improve productivity.
Continuous, Accurate Data: Say goodbye to guesswork; sensors measure ingredient levels over time, in storage vessels of many shapes and sizes
Safer Employees: Workers no longer need to climb bins, tanks, or monitor hoppers to track measurements, keeping them safely on the ground or in control rooms
Consistent Product: Sensors monitor ingredients during mixing, blending, or milling to ensure precise batch proportions
Reduced Downtime: Sensors maximize uptime by ensuring a continuous feed of materials and preventing overfills or dry runs
Low-Maintenance Needs: By avoiding contact with clingy solids, cakey slurries, or sticky liquids, non-contact sensors require less routine maintenance, saving time and reducing CIP labor requirements
Cost Savings: Balanced labor allocations, proper bulk ingredient ordering, and less out-of-spec product produce an improved ROI
Smart Sensors for Efficient, Contamination-Free Processing
Radar and ultrasonic sensors are well-suited for sanitary applications. Durable construction, proven reliability, and multiple measurement ranges support processing plants with options for level measurement that best fit their budgets and operational needs.
NCR-86 radar features a narrow, 80 GHz beam with accuracy within ≤1 mm.
Measures tanks and silos up to 393 ft. (120 m)
Reliable performance in harsh processing conditions including dust, steam, condensation, or humidity
Best utilized in bulk solid, pellet, powder, or liquid ingredients—such as in flour, sugar, or grain silos
Compact non-contact radars (CNCRs) are ideal in small or medium-sized process or storage vessels up to 98 ft. (30 m).
Non-intrusive design can be installed through existing openings
Battery-powered, pigtail-wired, and local display options available
Wireless, battery-powered CNCR-300 models deliver measurements directly to the cloud, enabling seamless integration into existing monitoring systems
Ultrasonic sensors provide precise, cost-effective liquid-level measurements in ranges up to 50 ft. (15 m).
Unaffected by optical characteristics of liquid ingredients, such as color or transparency
Rugged stainless-steel or PVDF plastic housings for harsh processes—including aspects of brewing, pasteurization, and oil production
Continuous operation in tank level, leak detection, and pump control applications
Hands-Off Labor, Hands-On Analytics
Automating measurements and controls helps workers focus their efforts on higher-value tasks, such as developing strategies for a more efficient, data-driven plant.
Remote monitoring software like BinCloud® gives operators the ability to view inventory in real-time, enabling a variety of in-depth analytics that plants can utilize for lean manufacturing, predictive replenishment, and stronger traceability.
Anywhere, Anytime Access: Data is available on-site or remotely via a phone, tablet, laptop, or PC—all with one login
Multi-Site Analysis: View levels in one bin, across one site, or multiple plants as needed; an easily scalable solution for both local and multi-national operations
Text & Email Alerts: Notify appropriate workers when critical high or low levels are reached, allowing for immediate action
Strengthened Logistics: Schedule orders, deliveries, or pick-ups for raw ingredients or finished product within the app, gaining complete control over your supply chain
Robust Reporting: With forecasted usage and historical reports, everyone from supply chain managers to finance planners can view the same data for optimal ingredient stock and cost analysis
Interconnected Production: Personalized user roles—including parent-child corporate structures—keep data secure and pertinent departments aligned
Helping Manufacturers Maximize Productivity in 2026
Quality, convenience, and flexibility are key within the food, beverage, and milling industries. Non-contact sensors offer the versatility to streamline inventory management, ensure safer worksites, and provide up-to-date data to production and logistics teams.
BinMaster sensors and remote inventory management software deliver comprehensive solutions for smarter, safer food processing operations.