The Hidden Threat in Your Silo: How Puls's Vibrating Level Sensor Solves Plastic Granule Clogging & Bridging

In the high-speed world of plastic processing and chemical production, critical problems are often the ones that are overlooked.

If you rely on traditional measurement technologies, you are likely familiar with the frustration of false readings caused by bridging, rat-holing, or material buildup.

Today, we are looking at why conventional sensors fail in modern applications and how the Puls Vibrating Fork Silo Level Sensor offers a robust, maintenance-free alternative.

The Problem with Conventional Sensors

For decades, the industry relied on rotary paddle switches and capacitive sensors. While these technologies served their purpose, research and field data highlight significant failure points when handling low-density plastics or what industry experts classify as "sticky powder products."

1. The Rotary Paddle Trap

Mechanical Seizure: Fine dust enters the bearings, causing the motor to seize.

Cavitation & Bridging: Material can form a "bridge" or dome over the paddle. The paddle spins freely in the empty cavity, signaling "Empty" even when the silo is full, leading to disastrous overflows.

2.The Capacitive Drifting

Capacitive sensors measure changes in dielectric constants. They struggle significantly with:

Low-Density Materials:Many plastic regrinds are too light to trigger the sensor reliably.

Humidity & Moisture:Slight changes in humidity can cause false positive readings, signaling the silo is full due to material coating the probe, even when the level has dropped

The Solution: Puls Vibrating Fork Technology

To eliminate these false readings, Puls Electronic engineered the Vibrating Fork Silo Level Sensor. Designed specifically for reliability, it can be universally used for many materials —ranging from ultra-light powders to standard pellets.

How It Works

The sensor utilizes a tuning fork design that vibrates at a specific frequency. When the fork comes into contact with the medium (powder, granule, or pellet), the vibration is dampened. The electronics detect this change and instantly switch the output signal (Relay SPDT).

Why It Is the Superior Choice for 2025

Immunity to Buildup: The vibrating fork design naturally sheds material, ensuring resistance to adhesion. This makes it self-cleaning and ideal for sticky or abrasive substances.

Extreme Durability: Engineered for harsh environments, it withstands process temperatures from -50 to 250 °C and pressures from -1 to 25 bar.

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316L Stainless Steel Wetted Parts:All parts in contact with your product are made from high-grade 316L stainless steel, ensuring resistance to abrasion and corrosion.

Maintenance-Free:With no bearings to grease and a robust housing available in plastic, aluminum, or stainless steel (IP65 protection rating), it minimizes labor and service costs.

See It in Action at PlastEurasia 2025

Theory is one thing, but seeing the technology handle difficult materials live is another.

We are bringing a functional demo of the Vibrating Fork Sensor to PlastEurasia 2025. We invite you to see it for yourself.

📍 Location: Hall 7, Booth 722

📅 Date: 3-6 December 2025

Don't let a false reading stop your production line.

View Full Technical Specifications Here