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Dye tank level measurement supports replenishment and shortage detection, but it does not by itself verify the quantity transferred into a textile recipe. A correct level assigned to the wrong tank or batch is also unusable. Keep the measurement tied to tank identity, chemical duty and the route serving the process.
Group tanks by conditions, not by appearance
Two identical vessels may hold a low-viscosity additive and a foaming dye mixture. Record the permitted chemical, concentration, temperature, agitation and cleaning procedure for each tank. A common purchasing specification is reasonable only where these duties and the mounting geometry have been checked as equivalent.
| Group | Review focus | Trial to retain |
|---|---|---|
| Dye mix | Agitation, foam and residue | The accepted target during mixing and after settling. |
| Additive | Composition and smallest usable reserve | Low-level comparison while supplying the process. |
| Make-up | Inlet turbulence and rapid level rise | Refill response with the actual valve sequence. |
| Changeover | Cleaning media and restored identity | Correct tank tag, parameter record and signal after service. |
Fit dye tank level measurement around the mixer
For compact vessels, the METRAVON MV-RD11S provides a 21 mm PTFE lens and 0.1-10 m published measuring interval. Its 14-degree beam needs a clear path, particularly at low level. Include the blade sweep, shaft, coil and fill pipe in the drawing.
Where a different antenna or range is needed, compare the MV-RD12, which lists a 32 mm PTFE lens and 8-degree beam. That comparison does not replace the chemical and seal review. Neither model should be promised to track liquid beneath every dye foam.
Preserve the link between level and recipe
At commissioning, verify the physical tank tag against the PLC channel and operator display. Record units, empty reference and any tank-volume conversion. Trend the level alongside the selected route, pump state and batch identifier so a later shortage can be traced to the correct source.
If the recipe requires a transferred mass, use the approved weighing or dosing measurement for that quantity. A level difference can be influenced by tank geometry, agitation, refill during transfer and density changes. Define how it is used as a plausibility check without presenting it as a substitute for batch weighing.
Inspect after cleaning, not only before production
Dried colour, crystals or a film near the antenna can change the return after a tank has been emptied. Provide a cleanable, accessible connection and a method compatible with the lens and seals. Avoid moving a contaminated instrument between tanks without the site's approved cleaning procedure.
After removal, restore the recorded mount and settings. Compare the first operating readings with the reference, including mixing and refill. Reusing the old parameter file is not enough if the nozzle, tank internals or assigned chemical has changed.
Recipe-system questions
Q1. Should every tank use the same damping?
No. Select filtering from the surface movement and response needed for that duty. A setting that steadies a mixing tank may delay a rapid refill alarm in a smaller additive tank. Test the selected response rather than copying it across the line.
Q2. What should happen when the level value stops updating?
The system should identify the stale measurement and invoke the agreed batch hold, alarm or other fallback. Operators must be able to distinguish an unavailable reading from a genuinely unchanged liquid surface.
Q3. What information reduces repeated quotation questions?
Send a tank-by-tank list of chemicals, drawings, mixer details and receiving inputs. Mark which tanks need only refill indication and which support recipe availability. This allows common configurations to be proposed without assuming all vessels have the same duty.
Summary
Keep the sensor selection and recipe identity in the same project record. Request a dye-house tank review based on verified duty groups, with distinct acceptance checks for measurement, cleaning and channel assignment.
