Table of Contents
- Introduction: No More Guesswork in Cement & Fly Ash Silos
- Bulkquip, EFS Engineering & Cobar Concrete: Raising the Bar with Radar
- Why OPTIWAVE 1540 Is Built for Cement & Fly Ash
- Smarter Commissioning with OPTICHECK Level Mobile
- How It Works in Harsh Silo Conditions
- Install Fast, Stay Safe: Mounting and Commissioning
- Diagnostics On Demand: Keep Your Operation Flowing
- OPTIWAVE vs. The Field: Why It Wins Every Time
- Conclusion: Control, Safety, and Precision in One Package
Introduction: No More Guesswork in Cement & Fly Ash Silos
When you’re dealing with cement powder or fly ash, there’s zero room for error. Materials like these are dusty, abrasive, and unpredictable, making level measurement inside silos a serious challenge. Enter OPTIWAVE 1540, the radar level transmitter built for bulk solids and its smart sidekick, OPTICHECK Level Mobile, the wireless commissioning and monitoring app that takes level control to new heights. Whether you’re keeping cement ready for batching or storing fly ash for sustainability, the OPTIWAVE 1540 is about precision without the pain.
Bulkquip/EFS Engineering & Cobar Concrete: Raising the Bar with Radar
Bulkquip in conjunction with EFS Engineering is in the process of installing two OPTIWAVE 1540 radar level transmitters at Cobar Concrete, bringing cutting-edge radar tech to the heart of NSW’s concrete operations.
This upgrade ensures:
- Zero-contact level measurement
- Ultra-reliable readings in high-dust, low-reflective conditions
- Safer, smarter commissioning without climbing silos or stopping production
Why now? Because fly ash and cement silos demand more than just a level sensor—they need radar that can see through the storm.
Why OPTIWAVE 1540 Is Built for Cement & Fly Ash
Cement and fly ash aren’t just dusty, they’re notoriously hard to measure. Air pockets, bridging, and irregular fill patterns make them nightmare materials for traditional level transmitters. But the OPTIWAVE 1540 handles it all effortlessly.
Key Cement-Ready Features:
🔸 80 GHz FMCW Radar Technology
- Ultra-narrow 8° beam cuts through dust clouds
- Ignores internal obstructions like fill pipes, bracing, or access ladders
🔸 Front Flush PVDF Lens Antenna
- No buildup, no false echoes—flush lens stays clean even in fine powder
- Resistant to harsh, alkaline cement dust
🔸 High Dynamic Range
- Handles signal disruptions from swirling ash or cement during filling
- Maintains ±2 mm accuracy, even when the surface is irregular or in motion
🔸 Compact PVDF Housing (IP68 Optional)
- Sits comfortably on tight silo tops
- Withstands the corrosive effects of cementitious dust and water ingress
🔸 Non-Contact Means Non-Issue
- No wear, no contamination, no moving parts
- Perfect for abrasive and explosive environments
Smarter Commissioning with OPTICHECK Level Mobile
Tired of climbing silos or wrestling with setup tools? The OPTICHECK Level Mobile app is your new best friend.
Bluetooth® Setup, Verification & Monitoring — All from your smartphone or tablet.
What You Can Do with the App:
- Set up devices wirelessly
- Monitor real-time levels without halting operations
- Verify system health and generate instant reports
- Access KROHNE’s Product Information Centre (PICK) directly from your device
Whether you’re a production manager, area manager, or plant operator, this app puts complete control in the palm of your hand.
How It Works in Harsh Silo Conditions
In cement and fly ash applications, most sensors struggle with:
- Dust storms during filling
- Low reflectivity of fine powder
- Sudden fill changes and compaction
The OPTIWAVE 1540 doesn’t flinch.
It thrives with:
- Dusty airflows
- Rapid fill/empty cycles
- Condensation from temperature shifts
- Bridging and funnel flow zones
And thanks to its Tank Bottom Management (TBM) feature, it even delivers reliable data when the silo is nearly empty—no false echoes from the base.
Install Fast, Stay Safe: Mounting and Commissioning
Time is money. And installing a new sensor shouldn’t cost you a day’s worth of production.
Here’s Why This Device Works for Fast Installs:
- Compact design fits into DN40 / 1½” nozzles, no redesign needed
- Orientation kits and brackets for perfect alignment
- Works even through plastic silo roofs or non-conductive linings
With Bluetooth® setup, commissioning can be done by one person from ground level. No scaffolding. No shutdowns.
Diagnostics on Demand: Keep Your Operation Flowing
Built-in OPTICHECK diagnostics ensure your system is always on point.
Features Include:
- Live device health monitoring
- Self-checking sensors with drift-free operation
- Verification reports generated with one tap
- Detects changes or anomalies before they affect batching operations
In fast-paced environments like concrete batch plants, this proactive maintenance approach helps prevent downtime and material waste.
OPTIWAVE vs. The Field: Why It Wins Every Time
| Feature | OPTIWAVE 1540 | Conventional Radar |
| Frequency | 80 GHz | 24–60 GHz |
| Beam Angle | 8° | 15°–30° |
| Measurement Accuracy | ±2 mm | ±5–10 mm |
| Dust Handling | Excellent | Moderate to poor |
| Non-contact Measurement | ✅ Yes | ✅ Yes |
| Mobile App Integration | ✅ OPTICHECK Mobile | ❌ Often missing |
| Installation Ease | Easy (compact, lightweight) | Moderate to complex |
| Chemically Resistant Housing | ✅ PVDF | ❌ Not always available |
| Maintenance Requirements | Drift-free, no recalibration | Periodic recalibration needed |
In dusty environments like cement batching plants or fly ash silos, the OPTIWAVE 1540 stands alone—combining cutting-edge radar precision with app-powered convenience.
Conclusion: Control, Safety, and Precision in One Package
The installation of OPTIWAVE 1540 radar level transmitters by Bulkquip and EFS Engineering at Cobar Concrete marks a turning point in how silo levels are monitored in heavy-duty industries.
If you’re storing abrasive powders like cement or fly ash, this is your answer to:
- Safer setups
- Zero-contact measurement
- Smarter diagnostics
- Reliable data during any operating condition
With the OPTICHECK Level Mobile app, your entire team can manage device health, monitor levels, and commission sensors faster than ever—all from a smartphone.
Explore www.bulkquip.com.au for specs, manuals, and support.
