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Precisely measure rolling oil concentration
for maximum product quality

With LiquiSonic® ultrasonic sensors, you monitor rolling oil concentrations inline and in real-time.

Immediately detect concentration fluctuations and save up to 15% of your operating costs.

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±0.05% accuracy

Real-time measurement

Maintenance-free

Cost-saving

Why is rolling oil monitoring a critical challenge?

Fluctuating rolling oil concentrations directly affect product quality. They lead to surface defects, uneven material thickness, and increase scrap and rework. Batch deviations also occur, jeopardizing process stability. Precise concentration control is therefore crucial.

Worst case: plant shutdown with scrap

Our solution for precise rolling oil monitoring


LiquiSonic® rolling oil measurement system

The LiquiSonic® system continuously measures the sound velocity in your rolling emulsion and precisely determines the oil concentration, independent of color, turbidity, or temperature.

 

Measurement accuracy ±0.05 wt%

  • More precise than all optical methods

Inline measurement without sampling

  • Directly in the main line to the rolling mill

Hydraulic oil detection

  • Immediate warning in case of leaks

Completely maintenance-free

  • No moving parts, no calibration


Successfully measured rolling oils

ManufacturerRolling oilMeasurement rangeTemperature
Quaker Houghton
Quakerol NH 6786

0-15 wt%

20 - 70 °C
Quaker Houghton
Rolkleen 1553 E

0-20 wt%

50 - 80 °C
Henkel
Bonderite L-RO6530

0-5 wt%

40 - 60 °C
Henkel
Gerolub 71

0-20 wt%

50 - 80 °C
WIN Group
BW SYNROL-500K

0-10 wt%

55 - 65 °C
Fuchs Group
TRENOIL S838

0-5 wt%

30 - 60 °C
Castrol
Iloform RS 4060

0-10 wt%

30 - 60 °C
San-I Chemical
Yushiroble SER-100H

0-10 wt%

40 - 60 °C
...and many more!
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Technical details and specifications

Ultrasonic measurement principle in detail

Physical measurement principle

The LiquiSonic® system measures the absolute sound velocity in the rolling emulsion with a resolution of 0.01 m/s. The sound velocity is a distinct physical quantity that correlates with concentration, independent of density.

Independence from Disturbing Factors

Unlike other measurement methods, ultrasonic measurement is independent of:

  • Color and turbidity of the emulsion
  • Metal particles and impurities
  • Bubble formation in the medium
  • Lighting conditions and contamination
  • Electrical conductivity

Economic benefits

Cost savings:

  • Reduce consumption
  • Fewer laboratory analyses required
  • Reduction of production scrap

Amortization:

  • 8-12 months typical payback period
  • Vermeidung kostspieliger Anlagenstillstände

Risk minimization:

  • Reduktion ungeplanter Stillstände
  • Kontinuierliche Qualitätskontrolle
  • Predictive Maintenance statt reaktiver Maintenance


Individual sensor adjustments

SensoTech manufactures sensors individually according to your process requirements - from standard applications to extreme operating conditions.

Available material variants

  • Stainless steel 316L - Standard for most applications
  • Hastelloy C-276 - for aggressive chemicals
  • Titanium Grade 2 - for chloride-containing and abrasive media
  • PFA/PVDF coating - for highly corrosive applications

Flexible construction options

  • Installation lengths: 50 mm to 3000 mm (and more on request)
  • Process connections: all common flanges and threads
  • Pressure ranges: up to 500 bar
  • Explosion protection: ATEX Zone 1 and 2 available

Technical specifications

Measuring range concentration

0.1 - 100 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

Digital transmission

up to 1,000 m

Interfaces

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

Protection class

IP65 & Ex-Schutz verfügbar

Calibration

Factory calibration

Maintenance

Completely maintenance-free

Practical examples from the rolling industry

Aluminum cold rolling mill

A leading aluminum producer installed LiquiSonic® sensors to monitor its rolling emulsion with 2-8 wt% rolling oil content.

Challenge: Frequent quality fluctuations due to manual oil addition

Solution: Continuous inline measurement with automatic dosing

Result: Reduction in oil consumption, fewer surface defects

Steel rolling mill with hydraulic oil problem

A steel producer suffered from recurring hydraulic oil leaks that affected the quality of the rolling oil.

Challenge: Late detection of leaks led to annealing defects

Solution: LiquiSonic® with hydraulic oil detection algorithm

Result: Immediate warning of sudden oil ingress

Further success stories and references:

Detailed case studies and customer references are available from our sales team. Contact us for specific application examples from your industry.

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Your benefits at a glance


Surface quality

Consistent rolling oil concentration for perfect surface results

Shorter downtimes

Reduced setup and maintenance times through optimal process management

Fewer laboratory tests

Significantly fewer tests through continuous online monitoring

Longer service life

Longer use of the rolling oil emulsion possible

Seamless documentation

Automatic data collection for quality evidence

Cleaner rolled stock

Less rework due to optimized process parameters

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Frequently asked questions

How accurately does the LiquiSonic® system measure rolling oil concentrations?

The measurement accuracy for rolling oil concentrations is ±0.05 wt%. This is significantly more precise than conventional measurement methods, especially with contaminated or turbid emulsions. The ultrasonic technology is independent of color, particles, or gas bubbles in the medium.

Can existing systems be retrofitted?

Yes, LiquiSonic® sensors can be easily integrated into existing pipelines. Installation is usually done in the main supply line to the rolling stand. Various flange and thread connections are available.

Is calibration or maintenance required?

No, the LiquiSonic® system is completely maintenance-free. The sensors have neither moving nor wear parts, which do not require regular calibration. The factory calibration remains stable throughout the entire operating period, which has a positive impact on operating costs.

Which operating conditions can be covered?

The LiquiSonic® system is designed for extreme conditions. It can cover temperatures from -40 to 200 °C and pressures up to 500 bar. The sensors are completely maintenance-free and designed for continuous use in industrial environments.

For which types of rolling oil is the system suitable?

The system works with all common rolling oils and emulsions for steel, aluminum, copper, and other metals. Over 50 different rolling oil formulations have already been successfully measured. New oils can be characterized at any time in the SensoTech laboratory.

How quickly does the investment pay off?

Typical payback periods are between 6-12 months. Savings come from reduced oil consumption, less scrap, shorter downtimes, and optimized process management.

Which interfaces to process control technology are available?

The system offers all common industrial interfaces: 4-20 mA, Profibus, Ethernet, Modbus, Fieldbus, and others. Digital transmission is possible without interference up to 1,000 m. Integration into existing systems is straightforward.

What distinguishes SensoTech from other measuring device manufacturers?

SensoTech is a specialist in ultrasonic concentration measurement with over 35 years of experience. The patented technology, maintenance-free sensors, and customer-tailored, individual customization options for the sensors make us one of the leading providers in this field.

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