(0121) 58 222 58 SALES@PLUSAUTOMATION.CO.UK
© 2021- PLUS AUTOMATION LIMITED®
HELPING YOU #MAKE SENSE OF SENSORS
EXAMPLE APPLICATIONS
TO ILLUSTRATE THE WIDE-VARIETY OF APPLICATIONS SOLVED USING
CONTRINEX SENSORS, WE HAVE POSTED A LARGE SELECTION OF
EXAMPLE APPLICATIONS WHICH CAN BE SEEN BY CLICKING ON AN IMAGE.
BELOW ARE A SELECTION OF SOME OF THESE APPLICATIONS:
CUSTOMER VALUES
RELIABLE, CONTINUOUS SPEED MONITORING IN HARSH
ENVIRONMENT
FIT-AND-FORGET SENSOR SOLUTION
EFFICIENT, COMPACT DESIGN POSSIBLE FOR MOBILE TURNING
MACHINE
NO SENSOR-RELATED DOWNTIME• NO REPAIR COSTS THANKS
TO EXCEPTIONALLY LONG SENSOR LIFE
PRODUCT ADVANTAGES
EXTREMELY ROBUST, IMPACT AND ABRASION RESISTANT IP68/
IP69K RATED HOUSING.
CORROSION-RESISTANT, V4A/ AISI 316L STAINLESS-STEEL,
FOOD-COMPATIBLE BODY.
LONG OPERATING DISTANCE OF 7MM IN A SMALL & SLIM
STAINLESS-STEEL 20X 32X 8MM HOUSING.
ROBUST, METAL-CASED INDUCTIVE PROXIMITY SENSORS
SUITABLE FOR EASY INTEGRATION
FACTOR 1 - CONSISTENT SENSING, IRRESPECTIVE OF WHETHER
THE TARGET IS STEEL OR ALUMINIUM.
RELIABLE, COMPACT VIBRATION-RESISTANT SENSORS
IO-LINK INTERFACE INCLUDED FOR FREE – IDEAL FOR
INDUSTRY 4
APPLICATION - WASHDOWN RATED INDUCTIVES
TRUSTED TO HELP KEEP DAIRY SAFE
Contrinex’s Food-grade washdown rated inductive sensors are
trusted in the extremely strict hygiene regimes of dairies and
creameries. Their IP68/IP69K rated stainless-steel housings
withstand the aggressive cleaning chemicals and high-
pressure water jets in these harsh operating environments.
The robust and high-performance sensors are also trusted to
help maximise plant utilisation during round-the-clock
production.
CUSTOMER APPLICATION
Cleanliness is everything in food-processing facilities, and
nowhere more so than in the dairy industry. A single instance
of contamination during production can necessitate the
destruction of multiple batches of milk-based foodstuffs - or, if
undetected, result in illness among consumers of infected
products. It’s no surprise that for dairy-plant operators,
maintaining the strictest possible hygiene standards is an
absolute must.
Given the simultaneous need to maximise plant utilisation,
time-consuming cleaning methods are highly undesirable. To
avoid lengthy unproductive intervals between batches, food-
processing facilities commonly utilise clean-in-place (CIP) and
high-pressure washdown systems. Production equipment for
washdown areas must therefore withstand both aggressive
cleaning chemicals and high-pressure water jets as a matter of
course. This requirement extends to the sensors used
throughout these areas.
CUSTOMER SOLUTION
Contrinex’s Washdown range of food-grade inductive sensors
address these needs perfectly. Sensors from Contrinex’s ‘600
Series’ and ‘700 Series’ are certified to operate continuously
and reliably in harsh conditions.
Rated to IP68/IP69K, they are pressure-resistant up to 80 bar
(1160 Psi), corrosion-resistant and ideal for use in food and
beverage industries.
These fully embeddable inductive sensors sense the presence
and detecting the position of equipment or materials at each
stage requires sensors that are both accurate and responsive.
Contrinex Washdown inductive sensors are up to the task in all
respects. With a choice of one-piece M12, M18 or M30-diameter
one-piece AISI 316L /V4A stainless steel bodies (700 Series) or
M12-diameter AISI 316L/V4A stainless-steel body and PPS
(polyphenylene sulphide) FDA-approved sensing face (600
Series).
Flow control during milk-product processing
Most milk products, whether made from pasteurised or raw
milk, undergo a number of common manufacturing
operations during the early stages of production. Central to
these are two aspects of process manufacture that require
reliable, accurate flow-control systems: transportation and CIP.
In each case, food-grade washdown inductive sensors ensure
that the correct operating sequence is followed.
Process engineers use dedicated stainless-steel pipework to
transport liquid ingredients from one operation to the next.
Typically, fluid flow is managed using control valves fitted with
electrical, hydraulic or pneumatic actuators. Depending on
process requirements, two-way or multi-port valves, often
rotary-shaft types, deliver raw milk from holding tanks to each
process station in sequence, maintaining specified flow rates
and volumetric limits.
600 Series Washdown sensors for position sensing
Contrinex’s 600 Series Washdown sensors provide low-cost,
high-performance sensing of the position of a rotary-valve
actuator where the PPS sensing faces are not required to
withstand extremes of temperature or pressure, and the 2mm
sensing distance of these M12-diameter devices is ideally
suited to the application. These sensors interface directly with
a range of industrial process controllers and provide cost-
effective confirmation of control-valve status around the clock.
Once processing of each batch is completed and all process
vessels are drained, closed-loop CIP cleaning is initiated. In
many instances, plant managers rely on flow-transfer panels to
ensure separation of CIP and process flows; a flow-transfer
panel utilises a multi-port manifold that provides a physical
break between flow streams in accordance with good
manufacturing practices (GMPs). Connection between ports is
effected manually by means of U-shaped jumper pipes with
positional feedback from inductive sensors mounted on the
panel.
700 Series Washdown sensors for presence sensing
Manual connection carries with it a greater risk of direct
contact between assembled parts. Contrinex 700 Series Full
Inox Washdown sensors provide optimum resistance to
mechanical shocks, while offering the option of extended
sensing distances.
Multiple M30-diameter devices, positioned at predetermined
locations on each panel, sense the presence of a locating
feature on each jumper pipe, confirming that the correct ports
are interconnected before CIP cleaning is initiated. These units,
with corrosion-resistant one-piece stainless-steel housings and
a 20mm sensing distance, protect against impact damage and
also withstand accidental contact with aggressive CIP
cleaning solutions.
700 Series Washdown sensors for positional sensing
The need for accurate position sensing doesn’t end there.
Downstream processing in soft-cheese production is equally
dependent on highly reliable washdown inductive sensors for
effective control of day-to-day operations.
Curd-making is the fundamental process in cheese
production. Typically, soft-cheese curd is made in large
stainless-steel vats, where milk is mixed with a curdling agent
and heated gently, resulting in the separation of curd from the
whey. Automated knives cut the curd particles to the correct
size, following which the vat is tipped to discharge firstly the
whey, followed by the curd. Carefully controlled tipping is
essential to prevent damage to the curd. The vat rotates slowly
about a horizontally oriented support shaft.
Washdown inductive sensors from the 700 Series Full Inox
family, mounted immediately adjacent to one side of the vat,
detect the position of a cam on the shaft, confirming the
degree of angular rotation at pre-set intervals. These M18-
diameter one-piece stainless-steel devices, with a 10mm
sensing distance, match the requirements perfectly.
700 Series Washdown sensors for filling and packaging
Later, during filling and packaging operations, high-volume
soft-cheese production also relies heavily on position sensing.
Sealed tubs of cheese are conveyed from filling stations in
single lanes; pneumatic cylinders, mounted beside each
conveyor, divert multiple tubs into packing areas in
preparation for layering. In these situations, it is essential to
control the position of the ram accurately; failure to
synchronize cylinder extension with conveyor movement
results in damage to products and, potentially, to equipment.
Two M12-diameter 700 Series washdown sensors from the
Contrinex Full Inox family, embedded in the wall of each
cylinder, sense the presence of the ram as it reaches the limits
of its travel in each direction. These highly robust devices
withstand pressures of up to 80 bar (1160 psi) and operate
reliably and accurately while exposed to the working pressures
inside the cylinder.
Sensors with IO-Link communications interface
Plant-wide communication is another common requirement
for manufacturers and Contrinex offers the largest selection of
sensors with IO-Link integrated. IO-Link is a standardised
point-to-point serial connection protocol for sensors and
actuators, offering the advantages of digital communication
without the need for special cabling.
In dairy-food production, processes run continuously, with
remote diagnostics eliminating almost every need for manual
intervention. Interrogating an IO-Link-enabled device returns
its manufacturer ID and product ID, allowing systems
integrators to determine remotely that the right sensor is in
the correct location. Contrinex IO-Link washdown sensors
additionally feature an on-demand self-test function that
confirms error-free operation at all times.
Systems designers also have the capability to modify the
output signal. Delaying the switching pulse accommodates
any travel time between a sensor and its corresponding
actuation point, while stretching the pulse ensures that slave
devices with lengthy response times trigger reliably, even at
high throughput rates. Finally, each sensor provides an output-
status check derived from its factory calibration data. If the
output signal from a sensor falls outside a range that
corresponds to a sensing distance between 80% and 100% of
its nominal value, an alarm flag is triggered, highlighting the
need for investigation. For process engineers with demanding
deadlines, peace-of-mind is a valuable benefit.
Contrinex sensors for food industry
Contrinex 600 Series and 700 Series Full Inox washdown
sensors provide a robust, cost-effective and hygienic solution
for manufacturers of foods, beverages and pharmaceuticals,
whether on a local or multi-national basis. Stainless-steel
construction and the no-cost option of the industry-standard
IO-Link protocol ensures that best-in-class performance is
coupled with ultimate reliability in even the most demanding
circumstances.
CUSTOMER VALUES
MAXIMUM PLANT UTILISATION IN HYGIENIC PROCESSES
NO SENSOR-RELATED DOWNTIME
DIGITAL COMMUNICATION WITHOUT SPECIAL CABLING
OUTSTANDING PROCESS MONITORING AND CONTROL
CAPABILITIES
FAST, EASY SET-UP AND RECONFIGURATION
PRODUCT ADVANTAGES
CORROSION RESISTANT, FOOD-COMPATIBLE SENSORS
ENCLOSURE RATING IP68/69K• IO-LINK INTERFACE
EXTREMELY ROBUST FULL INOX TYPES (ONE-PIECE,
STAINLESS-STEEL HOUSING; ECOLAB CERTIFIED)
FACTOR 1 ON STEEL AND ALUMINIUM
Agriculture is using increasingly complex automation in its
machinery and an example application is in composting
machines. Contrinex’s uniquely robust V4A/ 316L stainless-steel
sensors are relied upon for operating reliably in the
challenging environment of the inside of the machine’s drive
rotor. Withstanding dust, humidity and high temperatures, the
sensors enable the machine to provide the fast drying of
materials and optimal decomposition with reliable sanitisation
being ensured.
CUSTOMER APPLICATION
The efficient turning of organic materials – loosening, lifting
and aerating – is vitally important in industrial composting.
Special mobile equipment ensures fast drying of materials,
optimal decomposition and reliable sanitisation, processing
between 500 and 6800 cubic meters of earth per hour.
A manufacturer has introduced machine speed monitoring by
sensor. A sensor located in the rotor counts the passing teeth
of a rotating mechanical disk. From the number of teeth per
second, the controller then calculates the final speed.
Perfect sensor operation is required under these particularly
harsh conditions. In addition to permanent vibration and
shaking, the inductive sensor is also constantly exposed to
dust, moisture, and temperatures from 70 to 80°C (158 to
176°F). Since the location of the sensor in the rotor is hard to
access, the sensor must be very durable and low maintenance
to avoid time-consuming repairs.
APPLICATION - ‘TURNING OVER AN OLD-LEAF’
- COMPOST TURNING MACHINE
CUSTOMER VALUES
SAFE, RELIABLE OPERATION IN A HOSTILE WASHDOWN
ENVIRONMENT
NO RISK OF CROSS-CONTAMINATION BETWEEN PROCESSING
AND CLEANING SEQUENCES
EASY INTEGRATION WITH EXISTING PLANT-WIDE CONTROL
SYSTEM
COST-EFFECTIVE SOLUTION REQUIRING MINIMAL
MAINTENANCE
PRODUCT ADVANTAGES
IP68/ IP69K RATED HOUSING, FOOD-COMPATIBLE BODY
EXCEPTIONAL RESISTANCE TO SHOCK AND VIBRATION
AFFORDABLE HIGH-PERFORMANCE SENSOR WITH EXCELLENT
RELIABILITY
During manufacture of dairy products, raw milk travels
between successive processes through stainless-steel
pipework. Rotary-shaft control valves maintain process
sequences correctly, ensuring that no cross-contamination
occurs during CIP cleaning after each batch is completed.
Robust washdown inductive sensors, mounted on existing
rotary actuators, monitor control-valve status around the clock,
providing real-time positional feedback to a plant-wide control
system in a simple, cost-effective manner.
CUSTOMER APPLICATION
At a European dairy-processing plant, milk products, made
from pasteurized or raw milk, require hygienic transportation
between successive operations. Process engineers use
stainless-steel pipework to transport liquid ingredients from
one operation to the next. Fluid flow is managed using control
valves fitted with electrical, hydraulic or pneumatic actuators.
Multiple rotary-shaft valves deliver raw milk from holding
tanks to each process station in sequence, maintaining
specified flow rates and volumetric limits. Once processing of
each batch is completed and all process vessels are drained,
closed-loop CIP cleaning commences. Accurate, repeatable
valve sequencing is essential to prevent any chance of cross-
contamination between processing and cleaning sequences.
A robust, highly reliable sensor system, capable of
withstanding the harsh washdown regimes in force, is needed
to monitor control-valve positions during processing. Where
possible, sensors must be mounted on existing rotary
actuators, and real-time communication with existing plant-
wide control systems is mandatory.
APPLICATION - WASHDOWN INDUCTIVES
MONITOR DAIRY VALVE STATUS
Customer Solution
Sensing the position of a rotary-valve actuator is a routine task
for Contrinex Classics washdown inductive sensors. These
sensors interface directly with a range of industrial process
controllers and provide cost-effective confirmation of control-
valve status around the clock.
A purpose-designed bracket, mounted on the top surface of
each actuator, holds two sensors; these are positioned with the
sensing faces vertically aligned, one above the other, and
facing the actuator shaft. NAMUR-compatible (VDE/VDI 3845)
mountings on the actuators provide a known datum for the
sensors.
A solid plastic disc, mounted on the shaft, carries two or more
stainless-steel targets, positioned at 90 degrees to each other
around the outer peripheral surface of the disc. Each target
occupies either an upper or a lower position corresponding to
height of one of the sensors. As the shaft rotates, opening and
closing the valve, the targets pass in front of the sensing faces,
triggering the sensors.
These M12-diameter devices, rated to IP68/IP69K, have all-
metal bodies with PBTB sensing faces and vacuum-
encapsulated electronics; each features an industry-standard
PNP normally open output. Fully embeddable, and with a
sensing range up to 2mm, they are well suited to the hostile
operating conditions of a washdown environment.
Each sensor has an integral M12 connector, interfacing with
the customer’s control system via a TPE-S-sheathed cable.
Reliability is excellent; the system is simple and cost-effective.
THE INNOVATIVE 700-SERIES INDUCTIVE SENSOR FAMILY ALSO INCLUDES ENHANCED CORROSION
RESISTANCE WITH THE ‘WASHDOWN’ 316L/ V4A STAINLESS-STEEL VERSIONS.
ENHANCED CORROSION RESISTANCE WITH ‘HAMMER-PROOF’ ROBUSTNESS GIVES A SENSOR THAT
SURVIVES A PIRANHA ATTACK OR HELPS BUILD RELIABLE MACHINES FOR CHALLENGING ENVIRONMENTS
- IMAGINE HOW THEY CAN REDUCE DOWN-TIME.
CLICK ON AN IMAGE TO VIEW THE BROCHURE OR VIDEO,
READ APPLICATION EXAMPLES BELOW, CLICK HERE TO
VIEW THIS SENSOR ON CONTRINEX’S WEBSITE, OR CALL
US TO HELP GUIDE YOU THROUGH SELECTION, ANSWER
QUESTIONS, OR TO HELP YOU #MAKESENSEOFSENSORS:
WASHDOWN 316L/V4A STAINLESS-
STEEL 700 SERIES INDUCTIVE SENSORS
CUSTOMER SOLUTION
Contrinex inductive sensors from the FULL stainless-steel
family, WASHDOWN range, are perfect for this application.
Made from a single piece of V4A stainless steel, including the
sensing face, they have no covers, caps or welding seams and
are the most robust inductive sensors on the market. They
resist shock, vibration, impact and abrasion and almost any
exposure to dirt, gases, or liquids such as oil, water and
cleaning agents. Functionally stable at temperatures from -25
to +85°C (-13 to 185°F), they are also insensitive to core
breakage.
Thanks to the long operating distances of these sensors (three
times greater than the norm) a compact and efficient design
was possible using the M12 size. A long operating distance
allows the sensor to be mounted well away from the rotating
disk’s passing teeth. Setup is also straightforward, as
installation tolerances are less critical. A sensor version with
plug connector was chosen to allow speedy replacement if
necessary.
316L/V4A WASHDOWN STAINLESS-STEEL INDUCTIVE SENSORS - ‘HAMMER HOME’ AN ADVANTAGE
PRODUCT ADVANTAGES
WORLD CLASS PERFORMANCE IN EXTREME ENVIRONMENTS
CORROSION-RESISTANT V4A/AISI 316L STAINLESS-STEEL
BODY
EXTREMELY ROBUST, IMPACT & ABRASION RESISTANT ONE-
PIECE, STAINLESS-STEEL HOUSING IP68/ IP69K/ ECOLAB®
FACTOR 1 WITH BOTH FERROUS AND NON-FERROUS
MATERIALS INCLUDING ALUMINIUM & BRASS FOR EXTENDED
SENSING
CAN OPERATE IN CLOSE PROXIMITY WITHOUT INTERFERENCE
IO-LINK INTERFACE INCLUDED – IDEAL FOR INDUSTRY 4
Exceptional performance combined with unique robustness, Contrinex’s Full stainless-steel WASHDOWN inductive sensors are
certified to operate continuously and reliably in the harsh conditions of the food, beverage and pharmaceutical industries, ensuring
uninterrupted production.
WASHDOWN sensors are available in totally impervious one-piece V4A / AISI 316L stainless-steel M12, M18 and M30 housings, which
are machined from a solid piece so their is no joint to the sensing face. They are therefore highly resistant to the corrosive chemicals
used for clean-in-place CIP or wash-down processes. - ECOLAB approved and IP68 / IP69K rated they are pressure resistant up to 80
bar, food safe and corrosion resistant.
WATCH THE VIDEO TO SEE THE UNIQUE
ROBUSTNESS DEMONSTRATED
WATCH THE VIDEO TO SEE THE UNIQUE
ROBUSTNESS SURVIVE PIRANHAS
WELCOME TO PLUS AUTOMATION LTD - EXPERTS IN SENSORS, WE WILL WORK TO HELP YOU
SOLVE YOUR APPLICATIONS, IMPROVE MACHINE PERFORMANCE & RELIABILITY AND REDUCE COSTS
USING CONTRINEX’S EXCEPTIONAL SENSORS - LET US HELP YOU #MAKE SENSE OF SENSORS
The ‘700’ Series ‘Extreme’ sensors are uniquely robust sensors
are typically demonstrated by Contrinex as being able to
repeatedly being used to hammer in nails. Even when their
front face is dented, the sensor continues to operate correctly.
Even under the harsh operating conditions of this application,
these sensors last several years and downtime attributable to
faulty sensors is minimal. Their long service life contributes to a
reduction in repair costs.