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Selecting the Right Technology for High Temperature Applications

A pharmaceutical company was having a problem with using rotary paddle level control technology in an application where the process temperature was in excess of 300° F. The units were failing quicker than they expected. They needed to look at a different solution for their high level control.

The company produces proprietary materials and ingredients used in the Pharmaceutical industry. Their process includes handling “ash” which is very fine and is produced at a point in the process where the material temperature is in the area of 350-375° F. The unit in question was mounted in a hopper that contains baghouse ash. The mounting orientation was from the side. While high temperature rotary units are available, the “ash” is so fine that it finds its way into the rotary units through the seal. This also seemed to impact the life of the rotary unit. The customer just wanted to get away from electromechanical units and they needed something that they were certain would operate reliably all the time.

Monitor recommended its TrueCap® Model MK2 state-of-the-art RF capacitance point level sensor. This unit, equipped with a 3/4 ” stainless steel process mounting connection is able to tolerate up to 400° F when the ambient air is at or below 122° F. In addition, the MK2 is extremely calibration stable, uses microcontroller technology and provides push-button calibration, automatic temperature compensation, a universal power supply, local indicating LED’s and automatic build-up immunity. Following the success of the 30-day trial period the company was so pleased with the performance of the TrueCap MK-2 that they immediately placed an order for another 2 units. The customer has said, “The units work great and they are very consistent. The MK-2 has more than met our expectation”. The customer further commented; “Working with monitor was a pleasant experience and their local representative went the extra mile to make sure we got what we needed for our application”.

Give Monitor Technologies a call and let us put our creative solutions to work for you!


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Spotlight: RF Capacitance Level Sensor
TrueCap Level SensorsTrueCap Light  
TrueCap® MK-2
Advanced RF Capacitance Level Probe

The TrueCap® Model MK-2 RF Capacitance point level probe is designed to provide a superior and stable sensitivity threshold making it suitable for a variety of powder / bulk solids and some liquid or slurry applications.

Advanced features of the Model MK-2 include:
> Automatic immunity to material build-up on the probe by its driven shield design
> Push-button calibration
> Enhanced temperature compensation
> Maximized reliability via smart sensing algorithms like “self-validating” fail-safe protection
> Visible status LED on ordinary location units
> Versatility through a variety of configuration options including: hazardous location version, split architecture design, quick-connect process connection, stub probe, cable extensions, solid extensions, Nylon® probes, Ryton® - equiv. probes, etc.

A practical application for the TrueCap would be to use this level sensor where a residual material build-up on a different sensor would cause a false material level indication.

Principle of Operation for the TrueCap RF Capacitance Level Probe:
The vessel wall and the active probe element establish an impedance reference between each other when exposed to air which has a dielectric constant of 1. When materials with a dielectric constant greater than 1 are in close proximity to the probe, the impedance of the sensing field between the sensor and the vessel wall will change. Once the amount of change exceeds a threshold that was electronically determined during the calibration process, an output relay will either be energized or de-energized depending upon the position of the fail-safe selector on the probe’s electronic circuit board. A change of as little as .5 pico-farad is all that is necessary for the probe to sense the presence of material.

Click here for more information on the TrueCap MK-2 Level Sensor or contact Monitor Technologies LLC at
Tel.: 800-766-6486 in the USA and
Tel.: 630-365-9403 worldwide.


>>Download TrueCap Product Bulletin #413

>>Click here to learn more about other Point Level Switches from Monitor Technologies


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