A smarter alternative for point level detection is rotary indicators, which allow operators to automate equipment, receive actionable alerts, and prevent unnecessary downtime.
BMRX rotary sensors from BinMaster provide reliable performance in a wide range of dry bulk solids. Monitor low-level conditions to prevent dry running equipment, detect high-level thresholds to prevent bin overfilling, and control material flow during manufacturing.
Simple Switches Provide Confidence & Control
Processing environments involve the frequent transfer of bulk materials. Without manual monitoring or the proper instrumentation, an operation becomes more susceptible to bin overfills and downstream dry runs.
Users must consider whether automation capabilities are a priority while choosing level sensors for a new or retrofit application. In addition, implementing fail-safe indicators can further protect equipment and prevent material waste in the case of power or mechanical failure.
With a rotary, process control is easy as wiring the sensor to a piece of equipment to start or stop a process without manual intervention. For example: a rotary is mounted on a bin sidewall, near the vessel’s roof. During bin filling, if the high-level threshold is reached or surpassed, the rotary will trigger a switch to turn off the auger.
Similar uses may include operating slide gates and valves or controlling bucket elevators. BMRX rotaries can also be installed in chutes or hopper cones to detect blockages and turn off the appropriate equipment—such as a conveyor—before costly incidents occur.
How Rotary Level Alerts Work
Rotary indicators deliver level detection based on a single factor: the presence or absence of material at a pre-determined point.
When bulk solids come in contact with the paddle, its rotation stops. This triggers the rotary to change its state, which then activates a horn, light, or alarm, or relay switch.
These sensors are often connected to plant alarm systems to enable immediate notification when timely attention is required. Typical alarm outputs might include a combination of:
- Audible horns
- External warning lights or stack tower lights
- Control room annunciator panels
- PLC or DCS alerts
Which Rotary is Right for You?
BinMaster rotaries are ideal for general point-level indication, basic process control, and high- or low-level alarms in both ordinary and demanding applications. However, the standard model may not meet operational requirements where enhanced control is essential.
Thus, BinMaster offers several rotary options best suited for different price points and application needs:
- BMRX-100: An economical bin indicator; offers level detection in a wide variety of dry bulk solids
- BMRX-200: Adds fail-safe operation for applications where dependable performance is critical
- BMRX-300: Includes a highly visible LED status light built directly into the sensor housing, plus full fail-safe functionality
With the BMRX-300, operators can quickly determine the sensor’s status from a distance without opening a control panel, tracing wiring, or climbing a bin. The visual LED status is especially valuable when monitoring multiple bins, as personnel can identify material conditions quickly while walking the plant.
This feature also eliminates extra wiring to a separate indicator light, simplifying installation and troubleshooting processes.
Applications Across Many Industries
BinMaster BMRX bin indicators are used throughout agricultural and industrial worksites to improve process reliability. International hazardous location approvals ensure safety and efficiency in even the most demanding environments.
- Agriculture: Monitor bulk crop storage, including grain, soybeans, corn, and seed
- Animal Feed: Control critical processes at feed mills; level indication for on-farm animal feed storage bins
- Bioenergy: Measure dried distillers grains (DDGS), wood pellets, and other biomass storage vessels
- Cement: Detect levels of aggregates or powders; receive immediate alerts for plugged chutes
- Grain Handling: Oversee levels of dusty or lightweight bulk solids used in milling, including flour, rice hulls, and middlings
- Plastics: Ensure proper stock of resin pellets and flakes for fast-paced plastics manufacturing applications
- Mining: Maintain bulk storage visibility and oversee conveyors moving minerals, ores, or other chunky bulk solids
Support Automation with BinMaster Sensors
Searching for a simple point-level switch or a cost-efficient process control tool? BinMaster provides a solution for virtually any dry bulk solids application.
From the economical BMRX-100 to the advanced BMRX-300 with its integrated status light, BinMaster rotaries promote automation, reduce downtime, and give operators the information they need to keep production moving.
