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Reliable measurements in fiber glass sizing for optimal product quality

Continuous concentration measurement of quenching or release agents in fiber glass production with LiquiSonic® Ultrasonic technology. Reduce waste and optimize dosing in fiber glass sizing.

Real-time measurement

Continuous monitoring without delay

Maintenance-free

No moving parts or wear components

Highest accuracy

Precise measurement even under difficult conditions

Cost savings

Reduction of operating costs and waste

Challenges in fiber glass sizing monitoring

Typical challenges:

  • Inconsistent concentrations in sizing or release agents lead to uneven fiber quality

  • Optical measurement methods do not work with contaminated or turbid solutions

  • Manual sampling slows down the process and increases the risk of contamination

  • Over- or under-dosing causes material loss and waste

Typical problem situations:

  • Sizing bath contamination

  • Temperature fluctuations

  • Multicomponent systems

Fiber glass production requires precise dosing of sizing and release agents to ensure optimal fiber properties. Fluctuations in concentration can lead to quality issues or production downtime.

Our solution for precise concentration measurements


The LiquiSonic® System from SensoTech uses sound velocity measurement for precise determination of sizing concentrations in real-time. Independent of contamination, temperature influences, or optical properties of the solution.

Continuous inline measurement

Real-time monitoring of silane and film former concentration without sampling

Independent of contamination

Works even with turbid or particle-laden sizing baths

High measurement accuracy

±0.05 wt% accuracy in all measurements

Maintenance-free operation

No moving parts and fully encapsulated sensors


Technical details and background

The speed of sound in liquids directly correlates with the concentration of dissolved substances. The LiquiSonic® The measuring system measures this speed in real-time and provides a current measurement value every second. This fast response time enables effective process control and early detection of deviations.

Economic benefits

  • Reduced material and scrap costs:
    Optimized sizing dosages reduce the consumption of expensive silane couplers

  • Reduced quality defects:
    Fewer complaints/rework due to consistent quality

  • Increased production efficiency:
    Fewer plant downtimes through continuous process monitoring

  • Maintenance and personnel costs:
    Automated monitoring replaces manual sampling and laboratory analyses

Typical payback period: 12-18 months at medium production volumes!

Regulatory advantages

Compliance with quality standards

  • ISO 9001:2015 quality management system
  • DIN SPEC 35255 for composite processes
  • REACH regulation documentation
  • FDA-compliant materials available

Automated documentation

Complete recording of all process parameters for audits and certifications.

  •   Continuous data recording
  •   Trend and alarm functions
  •   Automatic reporting functions

Technical specifications

Measuring range

0 - 20 wt%

Measuring accuracy

typically ±0.05 wt%

Repeatability

±0.02 m/s

Temperature range

-40 °C to 200 °C

Pressure range

Up to 500 bar

Sensor length

Up to 3000 mm

Material & coating

Stainless steel, Hastelloy, PFA, PVDF, ETFE, ...

Digital transmission

Up to 1,000 m (more on request)

Interfaces

4-20 mA, Profibus, Ethernet, Modbus, Fieldbus, ...

Protection class

IP65 & Ex-Schutz verfügbar

Calibration

One-time factory calibration

Maintenance

Completely maintenance-free


Over 35 years of experience in concentration measurement

Since 1990, SensoTech has been a leading provider of inline measurement technology and has established itself as a specialist for precise concentration and density measurements.

Our systems are used worldwide, even in critical applications.

35+

Years of experience

1000+

Installed systems

50+

Countries worldwide

ISO 9001

Quality certified

Do you need further references or a custom feasibility study?

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Frequently asked questions

What is SensoTech?

SensoTech GmbH is a leading company in the field of process measurement technology based in Barleben, near Magdeburg, Germany. We develop and produce innovative solutions for monitoring and optimizing industrial processes. Our specialization lies in the precise measurement of concentrations, densities, and other parameters in liquids – in real-time and directly during the process.

What distinguishes LiquiSonic® from conventional measurement technology?

Unlike optical methods, which are influenced by color or turbidity, conductivity-based methods, which are sensitive to electrical conductivity, or density-based methods, which can be disturbed by temperature or gas bubbles, our ultrasonic method is independent of these influences.

The LiquiSonic® measurement technology also contains neither moving parts nor components that can wear out or be consumed. After installation, the measuring system is therefore completely maintenance-free. and drift-free.

The sensors offer digital signal transmission up to 1000 m and enable continuous inline measurement without sampling.

How is the release agent concentration measured?

Our system uses ultrasonic transit time measurement to determine the speed of sound in the liquid. The speed of sound directly correlates with the concentration of the quenching or separating agent and enables Measurement accuracies of ±0.05 wt%. The integrated temperature compensation ensures stable results even under fluctuating process conditions.

How quickly do you get measurement results for your separating agent concentration?

The system provides real-time measurements. Based on the measurements you receive an updated measurement value every second. This fast response time enables effective process control and early detection of deviations.

How does LiquiSonic® react to temperature fluctuations during glass fiber sizing?

Since the speed of sound, like all other physical quantities, is influenced by temperature, all our LiquiSonic® sensors are equipped with temperature sensors. This allows the influence of temperature on the measurement to be directly compensated Therefore, it is not necessary to integrate additional temperature sensors.

What process conditions can be covered during concentration measurement?

Our sensors operate reliably in a temperature range from -40 °C to 200 °C and pressures up to 500 bar. Various material options such as stainless steel, Hastelloy, or PFA coatings allow for the measurement of aggressive media. Explosion protection for Zone 1 and 2 is also available.

Can extreme operating ranges also be covered?

Yes, our sensors are designed for extreme conditions. In addition to the extended temperature and pressure range, we offer custom adaptations such as sensor lengths up to 3000 mm, special alloys for corrosive media, and various protection types, including optional explosion protection. Each sensor is individually configured according to your requirements configured.

Can different types of silanes be monitored simultaneously?

Yes, through multi-frequency measurements and special algorithms, different silane coupling agents such as aminosilanes, epoxysilanes, or vinylsilanes are measured selectively. In multicomponent systems, in addition to the speed of sound, a second physical quantity (e.g., conductivity) is used for the measurement.

How is the integration into existing automation systems carried out?

The system offers various digital interfaces (e.g., Profibus, Ethernet/IP, Foundation Fieldbus) as well as analog 4-20 mA outputs. The integration is seamless via standardized protocols.

Is adaptation to special pipelines or containers possible?

Yes, SensoTech manufactures sensors individually according to customer requirements.. All standard flanges, any installation lengths (up to at least 1000 mm, further lengths on request), various threads, and special geometries for crystallization containers or small pipelines are available.

Which materials and coatings are available for the sensors?

The sensors are available in various material- and media-resistant designs, including stainless steel and Hastelloy as well as chemically resistant coatings and plastics such as PFA, PVDF, and ETFE. This allows them to be used reliably in a wide range of liquids and demanding process environments.

What maintenance is required for reliable separation agent concentration measurement?

The system is completely maintenance-free.. There are no mechanical wear parts, seals, or optical windows that could be compromised. Regular calibration is not required - the sensors remain stable for years.

Related applications

The concentration measurement in liquids is based on the physical properties and composition of the medium. An ultrasonic signal is sent into the liquid and its exact transit time over a defined measurement path is recorded. From the determined sound velocity, the exact concentration of the dissolved components can be calculated.