The Importance of Fill Level Monitoring

By Admin
Manufacturers, restaurants and stores that produce or sell large quantities of liquids or other products in bottles, glasses and other containers have t...

Manufacturers, restaurants and stores that produce or sell large quantities of liquids or other products in bottles, glasses and other containers have to make sure that they pour the right amount of product into each container.

One way to standardize this procedure is to use fill level monitoring. This is an important process, ensuring that all end-users of a particular product will receive the same amount, as well as facilitating a more accurate calculation of costs for the retailer or manufacturer.

What are the benefits of fill level monitoring? To understand that, first you need to understand exactly what fill level monitoring entails.

What is Fill Level Monitoring, Anyway?

Fill level monitoring refers to the process of filling packages to the correct height. It uses sensors, thermal imaging and X-rays to measure the proper level, and it serves as an alternative to check-weighing inspection which relies on scales to check the contents and quantities of packages and their components. Fill level monitoring has been proven to be a safer and more cost effective method of measuring contents.

Although there are situations where check-weighing inspection is the preferred option, fill level monitoring is still by and large the most commonly used process.


What are the Benefits of Fill Level Monitoring?

There are several benefits to choosing fill level monitoring for your filling procedures:

  • Reduces CostOverfilling packages can result in an unnecessary increase in costs. A fill level monitoring system makes it possible for manufacturers, retailers and restaurants to achieve greater accuracy in filling packages, which helps to reduce waste. It is especially important in countries that require manufacturers to be solely accountable for the products they produce and implement a system to ensure the quality and safety of their products. Additionally, fill level monitoring can minimize costs that are incurred as a result of production line malfunctions and dissatisfied customers.
  • Improves Manufacturing EfficiencyAnother advantage of using a fill level monitoring system is that it can significantly speed up the manufacturing process. It enables a manufacturer to produce more than 2,000 products per minute, while check-weighing inspection can only produce about 700 products within the same period of time. This makes it easier for the manufacturer to meet deadlines and keep up with demand.
  • Space Saver – A fill level monitoring machine can also help save space. It usually occupies only one cubic foot of space, while a check-weighing machine may take up between four and 14 cubic feet of space.
  • Provides a Safer Work Environment – A fill level monitoring system features two-dimensional X-ray imaging, and therefore, it is able to detect problems such as internal pressure issues and misaligned caps and lids. Additionally, the measuring equipment does not come into contact with the products, which ensures that they will be clean and safe for consumption. A non-contact fill level monitoring system is designed to be completely reliable, even under harsh working conditions.
  • The thermal imaging technology that is found in a fill level monitoring system can spot problems such as overheating in coolant tanks, which can help avert serious accidents.


In effect, fill level monitoring can contribute significantly to the efficiency, profitability and overall success of a manufacturing company, retail store or restaurant. Businesses that can benefit from this system should implement it as soon as possible. 


About the Author: John McMalcolm is a freelance writer who writes on a wide range of subjects, from social media marketing to Cloud computing.


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