Solving customer problems is the driving force for innovation at Siemens Milltronics. With a Research and Development staff of 65 that includes engineers, technologists and test technicians, the capacity for innovation is sustained by major investments in research and development. During the period 2000-2004, the company introduced more than 40 new or enhanced products, and has a growing percentage of sales from new products.
The company's track record of innovation goes back to its beginnings. Milltronics was founded in 1954 by an entrepreneur, Dave Weston, to engineer and sell electronic grinding controls to the mining industry. The company became well known in this industry and remains a strong competitor today with sales of belt scales, weighfeeders, flowmeters and process protection devices used to weigh and monitor bulk solid materials such as aggregates, ore, coal, grain, or powders.
The company pioneered the use of ultrasonic technology in tough liquid and bulk solid applications, and is now the world leader in ultrasonic level measurement technology. The turning point came in 1973, when Milltronics acquired the Raytheon Ultrasonic Air Ranging business, and began developing ultrasonic technology for measuring level in vessels, wastewells, and open water channels. Previously, plant operators had to rely on manual measurement methods such as dipsticks or floats. These were unreliable, labor-intensive, and required a lot of maintenance.
Development of these new ultrasonic products gave industry a non-contacting method for measuring level. Now they could use an ultrasonic transducer (sends and receives sound waves) along with an electronic monitor to interpret the echoes and calculate level, volume and flow measurements. Accurate, reliable level measurement was a breakthrough for industry, helping plants improve production efficiency.
The first ultrasonic product from Milltronics was the AiRanger III, which used analog technology. By 1984, Milltronics introduced the AiRanger IV, the world's first micro-processor-based ultrasonic system. Follow-up innovations included Echomax transducers, a full line of reliable ultrasonic sensors impervious to moisture, chemicals, and temperature extremes, and suitable for use in harsh environments.
Ultrasonic level measurement proved especially popular with water and wastewater plants, and Milltronics soon became the world's leading level measurement supplier for these industries. Driven by increasingly stringent environmental regulations, tighter budgets and higher energy costs, water plant operators are challenged to improve water quality, manage effluent and increase plant efficiency. The company responded with new products such as a transducer for confined-space regulated lift stations and, in 1999, EnviroRanger controllers designed especially for water applications. EnviroRanger was a breakthrough modular control system with advanced communications telemetry and SCADA integration capabilities. Further functionality was added in 2000 and 2002, making it a truly integrated system for complete, cost-effective remote monitoring and control of water and wastewater collection, distribution systems and watershed management.
A major breakthrough was Sonic Intelligence, the advanced echo-processing software that differentiates between true echoes from the material and false echoes generated by obstructions or electrical noise. The result is repeatable, fast and reliable measurement. It is one of many patents held by the company. Today, Sonic Intelligence is supported by field data gained in more than 20 years of experience with applications in many industries. This in-depth knowledge and experience is built into the software's advanced algorithms to provide intelligent processing of echo profiles.
In 1992, the company launched the award-winning Probe, the first instrument of its kind to combine electronics and sensor in one enclosure. It offered a cost-effective, easy-to-install solution, and it quickly became one of the company's best-selling products.
In 2004, during its 50th anniversary year, the company introduced a successor to the Probe -- SITRANS Probe LU, a 2-wire ultrasonic level transmitter that offers superior design, performance and features. At the same time, the company made this product available in a radar version -- the SITRANS Probe LR.
Siemens Milltronics expanded into radar technology during the 1990s, and has introduced numerous innovations to enhance the use of radar instruments for the process industries. This includes adapting its advanced ultrasonic signal-processing know-how into radar instruments to provide superior performance, particularly on difficult applications on solids. Innovations include the SITRANS LR 400, introduced in 2002, which uses high-frequency FMCW technology to provide reliable measurement even in extreme dust. Another example is the SITRANS LR 200 launched in 2003. It has a specially-designed rod antenna with Uni-body construction for excellent chemical resistance. Unlike competing products, LR 200 has threads and rod antenna made of the same material and hermetically sealed. This gives only one material compatibility to consider and ensures no chance of chemical ingress. Another innovation on the LR 200 is the swiveling head that makes it easy to install and position the display. The swiveling head feature proved very popular and has been incorporated into new radar products such as the SITRANS Probe LR.
As customer needs have developed, so has the company's approach to innovation. With today's increasing emphasis on environmental protection, for example, there are products to help customers save energy by controlling the runtimes of pumps in water treatment plants. The company's point level devices are used as high and low level alarms on chemical tanks to prevent overfilling and chemical spills. To prevent greenhouse gases from escaping from anaerobic digesters, Siemens Milltronics created a unique retractable antenna system that allows the radar level measurement device to be raised, inspected or removed without releasing gas into the environment.
The factory has also been innovative in its manufacturing methods, adopting flexible, flow manufacturing systems. The process-driven shop floor employs cross-functional teams to develop products, reduce defects and improve cycle time. More than 90% of the products made in Peterborough are exported to countries around the world.
At Siemens Milltronics, the spirit of innovation has continued for 50 years. Today, Siemens Milltronics is s leading provider of level measurement products using ultrasonic, radar, capacitance and other technologies. With on-going commitment and investment in research and development, innovation remains the driving force for the company's future.
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