Know What’s in Your Silos Before It Becomes a Production Problem
Continuous level sensors help plants monitor real-time inventory in silos, bins, tanks, and vessels. CMT helps you select radar, plumb bob, interface, and inventory monitoring solutions for powders, pellets, granular materials, liquids, and other process applications.
What Is a Continuous Level Sensor?
A continuous level sensor measures material level over a range instead of simply detecting material at one point. These systems are commonly used for silo inventory, bin level monitoring, tank level measurement, production planning, material ordering, and process visibility.
Real-Time Inventory
Track how much material is in a silo or bin without climbing, guessing, or relying on manual checks.
Better Reordering Decisions
Reduce emergency material orders, production delays, and uncertainty around raw material levels.
Less Downtime Risk
Know when vessels are trending low before your process runs out of material unexpectedly.
Plant-Wide Visibility
Connect sensors to local displays, PLCs, HMIs, software, or cloud-based inventory tools.
Inventory Guesswork Creates Downtime, Safety Risk, and Expensive Surprises
Many plants still rely on manual silo checks, operator estimates, truck delivery guesses, or reactive purchasing. Continuous level measurement gives production, purchasing, maintenance, and management better visibility into the material that keeps the plant running.
Continuous Level Measurement Options Available from CMT
CMT can help you choose between non-contact radar, plumb bob systems, local displays, software, and communication accessories depending on your silo height, material, dust level, control requirements, and budget.
RadarRight™ Non-Contact Radar Level Sensors
RadarRight sensors provide continuous, non-contact level measurement for silos, bins, and tanks. Because the sensor does not touch the material, it is a strong solution for dusty environments, abrasive materials, and applications where maintenance access is difficult.
- Ideal for powders, pellets, bulk solids, and liquids
- Great for silo inventory monitoring without climbing
- Works well in many dusty and challenging environments
- Integrates with PLC, HMI, or plant control systems
- Minimal maintenance compared to contact technologies
Best For: Plants that want real-time inventory visibility without mechanical contact.
SiloPatrol® Plumb Bob Level Sensors
SiloPatrol systems provide reliable inventory measurement by lowering a weighted cable into the material, detecting the surface, and returning a measurement. This proven technology works extremely well in bulk solids applications where other sensors struggle.
- Highly reliable for powders, pellets, and granular materials
- Excellent for tall silos and changing material conditions
- Useful where dust or difficult material conditions make other technologies challenging
- Provides repeatable inventory readings for operations and purchasing
- Cost-effective alternative to radar in many applications
Best For: Bulk solids silos where reliable periodic inventory measurement is the priority.
Level Sensors Are Only Part of the System
Most plants don’t just need a sensor — they need a way to see, use, and act on the data. CMT helps integrate level measurement into your overall process, from the silo to the control room.
HMI2 Operator Interface
View level readings locally or in a control room with a clean, operator-friendly display.
Auxiliary Output Enclosure
Expand outputs, connect to plant systems, and integrate with PLC or automation infrastructure.
PLC & Plant Integration
Connect level sensors to your plant controls, alarms, and automation logic for real operating value.
Multi-Silo Visibility
Monitor multiple silos from one location for better inventory control and purchasing decisions.
Radar vs. Plumb Bob: Which Continuous Level Sensor Makes Sense?
The right continuous level sensor depends on the material, vessel height, dust, dielectric properties, desired accuracy, mounting conditions, output requirements, and whether the system needs local or remote visibility.
Radar May Be a Fit When...
- You want non-contact measurement
- The vessel is difficult or unsafe to access
- You need continuous analog output
- You are monitoring powders, pellets, or liquids
- The mounting location provides a clear measurement path
Plumb Bob May Be a Fit When...
- You want a proven inventory measurement approach
- The material is challenging for non-contact technologies
- You need periodic inventory readings instead of constant scanning
- The silo is tall or material behavior changes over time
- You want repeatable data for purchasing and operations
Common Continuous Level Sensor Applications
Continuous level sensors are used wherever plant teams need better visibility into what is stored, consumed, transferred, or reordered.
Raw Material Silos
Track incoming and outgoing material inventory for production planning.
Ingredient Bins
Improve visibility for batching, mixing, and dry ingredient systems.
Cement, Fly Ash & Minerals
Monitor dusty or tall storage silos used in heavy industrial applications.
Plastic Resin Silos
Track pellets, powders, regrind, and resin storage levels.
Feed, Grain & Food Plants
Support inventory control for bulk ingredients and process storage.
Multi-Silo Inventory Systems
Bring multiple vessel readings into a common interface or control system.
Continuous Level Sensor FAQs
What is the best continuous level sensor for bulk solids?
The best option depends on the material, silo height, dust level, desired accuracy, mounting location, and output requirements. Radar and plumb bob systems are both common choices for bulk solids inventory.
What is the difference between point level and continuous level?
Point level sensors detect material at one specific point, such as high level or low level. Continuous level sensors measure the material level over a range to provide inventory or process visibility.
Do radar level sensors work in dusty silos?
Radar can work well in many dusty applications because it is non-contact, but dust level, material behavior, vessel geometry, and mounting location should be reviewed before selecting a sensor.
When would I use a plumb bob level sensor?
A plumb bob can be a good option for many bulk solids inventory applications, especially when periodic measurements are acceptable or when the material is challenging for some non-contact technologies.
Can continuous level sensors connect to a PLC or HMI?
Yes. Depending on the model and system design, continuous level sensors can provide signals for PLCs, HMIs, local displays, software, or inventory monitoring systems.
Send Us Your Vessel and Material Details — We’ll Help Recommend the Right Continuous Level Sensor
Whether you need radar level measurement, plumb bob inventory monitoring, local display options, or multi-silo visibility, CMT can help you select the right system for your plant.