Accurate fill-level detection in silos, tanks and process containers is fundamental to safe, stable and efficient production – especially in industries such as food, chemicals and pharmaceuticals where precision is critical.

Yet many commonly used technologies, including radar, ultrasound, microwave or hydrostatic sensors, only provide indirect measurements. They calculate fill levels based on distance, pressure or surface reflection, making them vulnerable to inaccuracies caused by foam, caking, variable densities, temperature fluctuations or uneven material flow.

Industrial practice reveals these limitations clearly. At Solvay Fluor in Frankfurt, non-contact systems delivered inconsistent results because temperature and density variations disrupted readings. Only after retrofitting with PanCake load cells from Minebea Intec – global specialists in weighing and inspection technologies – did Solvay achieve accurate, reliable fill-level monitoring, reducing deviation to as little as 1.1% compared with around 2.5% previously.

Gravimetric level measurement eliminates these uncertainties by measuring the true mass of the container and its contents. Load cells such as PanCake or Inteco deliver linear, precise results across the full filling range, independent of media or container geometry. Because sensors are mounted externally, they avoid contact with aggressive, sticky or corrosive materials and require no perforation of the vessel. This is a major advantage in hygiene-sensitive applications, with load cells available in CIP/SIP-capable, cleanroom-ready designs developed according to EHEDG and FDA guidelines.

The PanCake load cell series is also engineered for easy integration. Installation requires no structural modifications, enabling rapid retrofitting on existing containers and offering up to 50% savings in acquisition cost compared with alternative technologies. With no moving parts, maintenance is minimal and accuracy remains stable for years, reducing lifecycle costs.

Certified for use in ATEX and IECEx environments, these gravimetric systems deliver maximum reliability even under extreme conditions. Their digital connectivity – via MiNexx weighing indicators and interfaces such as ProfiNet, Ethernet/IP or Modbus – ensures seamless integration into higher-level control architectures.