Why Point Level Sensors Are Critical in Dry Bulk Applications

20 Aug 2025

Prevent overfills, downtime, and material loss in silos, tanks, and hoppers with the right point level sensor

What Are Point Level Sensors?

Point level sensors detect whether material in a tank, silo, or hopper has reached a specific high or low point. In dry bulk applications, they provide essential alerts that help operations:

• Fill vessels safely to capacity without risking overfill
• Trigger replenishment before inventory runs dry
• Maintain process efficiency and equipment uptime
  

Why Point Level Sensors Matter in Dry Bulk

• Overfill prevention: Avoid spills, cleanup, and safety hazards
• Reliable replenishment: Stay ahead of low inventory alerts
• Inventory control: Optimize use of storage space
• Equipment protection: Prevent running empty or clogging
• Adaptability: Handle dust, aeration, abrasion, and varying material densities
• Durability: Built for high temperatures, corrosive environments, and vibration

Types of Point Level Sensors for Dry Bulk

Diaphragm Switches

Pressure-sensitive devices that trigger when enough material presses against the switch. Best for dry, free-flowing solids with minimal dust or aeration. Not recommended with pneumatic conveying due to potential false readings.

Rotary Paddle Wheel Sensors

A motor-driven paddle rotates freely until material prevents rotation, triggering an alert. Reliable across a wide range of materials and densities.

• Roto®: Simple, rugged, no calibration required.
• Roto-Bin-Dicator® PRO: Built-in fail-safe diagnostics, detects faults even when buried, universal power compatibility.

Radio Frequency (RF) Capacitance Probes

Measure changes in capacitance caused by material presence or absence—ideal for low dielectric materials and high-temperature or corrosive environments.

• VRF® II Series: Self-calibration, PRO-GUARD™ build-up compensation, adjustable sensitivity; available in standard and advanced models.

Vibrating Fork & Rod Sensors

Vibrating elements oscillate until covered by material, causing an output change. Unaffected by dielectric constant and highly sensitive to lightweight powders, including aerated or fluidized materials.

• Pulse Point™ II Series: Detects materials down to ~0.5 lb/ft³; ideal for powders too light for other technologies.

Accessories for Harsh Bulk Environments

• Lags: Move electronics away from hot vessel walls to protect components.
• Extensions: Reach deeper into a vessel or through thick silo walls to the ideal detection point.

View All Point Level Sensors

FAQs

What is the difference between point level and continuous level measurement?

Point level sensors indicate when material reaches a set point (high or low). Continuous level instruments provide a continuous measurement across the entire height of the vessel.

How do I choose the right sensor for my material?

Start with your material type and application conditions:

• General solids: Roto®
• Diagnostics/fail-safe: Roto Pro®
• Corrosive or high-temp: VRF® II
• Ultra-light powders: Pulse Point™ II

Need help choosing? Contact us today!