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- 08/11/2025
- Article
- Analysing & automating
Sensors for bulk solids: What to expect at POWTECH TECHNOPHARM
Because you can only control what you have measured, sensors are an integral part of POWTECH TECHNOPHARM. This year, numerous suppliers will once again be presenting interesting solutions for measuring bulk solids.
Written by Armin Scheuermann
Judging by the number of product announcements from exhibitors, moisture measurement will be a clear focus of bulk solids analysis at POWTECH TECHNOPHARM 2025. This comes as no surprise, as without precise determination of moisture content, the quality, efficiency and safety of bulk solids handling suffer. Even slight fluctuations in moisture content can significantly affect the flow properties, miscibility or storage stability of a product. In sensitive production processes – such as in the building materials, food or pharmaceutical industries – inadequate moisture control not only leads to quality losses, but also to increased energy consumption, machine downtime or even safety-critical conditions such as dust explosions.
The BMMS humidity sensor from ACO Automation Components (Hall 10.0, Stand 10-634) is a compact solution that has been specifically developed for applications without a central evaluation unit. The sensor directly outputs an analogue 4–20 mA signal, making it ideal for integration into existing control systems. The integrated online calibration automatically compensates for installation influences, ensuring reliable humidity values even in decentralised systems.
Modular systems for complex requirements
If a large number of measuring points are required, ACO offers a scalable solution with the DMMS humidity measurement system: Up to 16 sensors can be connected to an evaluation unit via bus technology. The high flexibility – from continuous operation to batch measurement – and variants for the EX area make the system particularly interesting for large production environments. Automatic calibration at the installation site ensures consistent measurement results.
Liebherr-Mischtechnik (Hall 11.0, Stand 11-121) also supplies the Litronic-FMS II, a robust system for real-time moisture measurement. Up to 16 sensors with central evaluation are used here. The special feature is the capacitive high-frequency stray field as the measuring principle – known for its high reproducibility and precision. Extensive interfaces enable integration into any automation level.
For applications with high response time requirements and minimal maintenance, the IR3000 moisture sensor from MoistTech (Hall 10.0, Stand 10-148) can be recommended. Thanks to near-infrared technology, the sensor allows contactless, immediate moisture determination directly in the process line – a clear advantage for hygroscopic materials or in energy-intensive drying processes.
Safety in drying processes – CO detection meets moisture measurement
With the CO.Pilot (Hall 9, Stand 9-503), REMBE offers an intelligent system for combined CO and moisture measurement in industrial drying systems. Based on tunable laser absorption spectroscopy, the sensor detects smouldering fires and Maillard reactions – potential triggers for fires and explosions – at an early stage. At the same time, it provides valuable information on the moisture content of the process exhaust air, which increases the energy efficiency of the drying process.
Level measurement – contactless and process-reliable
Whether in silos, containers or process plants – reliable information about the current material level enables demand-oriented refilling, prevents overfilling or idle running and ensures continuous production. At the same time, level measurement plays a central role in inventory control, material flow monitoring and process documentation. Since bulk solids are often stored and conveyed under difficult conditions – such as dust, heat or changing material consistency – robust, maintenance-free and accurate sensor solutions are required.
VEGA (Hall 10.0, Stand 10-304) is presenting two powerful radar sensors for continuous level measurement: VEGAPULS 6X and VEGAPULS C 23. While the VEGAPULS 6X impresses with its universal configurability and variable antenna systems, the VEGAPULS C 23 scores with its high protection class and is an inexpensive solution for simple applications – such as in open silos or stockpiles. Both devices use proven 80 GHz technology and deliver precise measurement data regardless of material properties or process conditions.
Optical temperature and pressure sensors for high-temperature processes
WIKA (Hall 12.0, Stand 12-282) is presenting an exciting solution for the simultaneous measurement of temperatures up to 600 °C and pressures up to 70 bar with its new optical pressure and temperature sensor. The sensor is based on light interferometry in a glass fibre lens – a technology that has already been successfully tested in turbines and thermal reactors. Applications range from solar heat storage to synthesis gas processes and e-fuel production.
Metal detection for pharmaceutical bulk goods
CEIA (Hall 10.0, Stand 10-407) is launching the THS/PH210, a system for highly sensitive metal detection. It detects even the smallest contaminants in powders, tablets or liquids and meets the highest FDA requirements. The AUTO-QC function ensures automatic quality assurance during operation – a must for manufacturers with strict validation requirements.
Another major focus this year is once again particle sensor technology, which we report on in another article entitled ‘Selected Products’.
Author
Armin Scheuermann
Chemical engineer and freelance specialised journalist