Comparing FlowJam, FlowJam S, and FlowJam Plus: Advanced Solutions for Material Flow Monitoring

Accurate and reliable material flow monitoring is essential in industrial environments for maintaining process efficiency and preventing costly downtime. Three leading products for continuous material flow detection are the FlowJam, FlowJam S, and FlowJam Plus sensors. Each offers unique features to meet specific application needs, from simple flow/no flow detection to advanced blockage monitoring in high-pressure or high-temperature environments.

1. FlowJam: Reliable Flow/No Flow Detection for Bulk Materials

The FlowJam sensor is a robust, contactless microwave device that detects material movement in challenging environments. Utilising the Doppler effect, it accurately monitors flow and detects material blockages without being affected by material deposits on the sensor surface. The FlowJam is suited for various industries, including steel, biomass, cement, and food processing, where continuous flow detection is critical for process integrity.

Key Features:

Microwave technology for contactless flow detection

Insensitive to material deposits, ensuring consistent performance

Usable up to 220°C and 20 bar with an adapter, and applicable for all line diameters

Ideal for aggressive or abrasive materials, as the sensor can be mounted outside non-metallic pipelines

Uses:

Raw meal cyclones in cement plants: The FlowJam prevents blockages by monitoring material flow through high-temperature environments (up to 600°C).

Coal injection in steel plants: Detecting jams in coal injection lances ensures smooth fuel distribution in blast furnaces.

2. FlowJam S: Advanced Trend Monitoring with High-Temperature Resistance

The FlowJam S builds on the strengths of the FlowJam, adding trend monitoring capabilities. This allows operators to track material flow over time and detect subtle changes, offering an early warning of potential blockages. It operates under extreme conditions, handling temperatures up to 1000°C with ceramic mounting, making it a go-to choice for high-temperature processes in cement, steel, and power plants.

Key Features:

Trend monitoring for early detection of material flow issues

Handles temperatures up to 1000°C with ceramic mounting and pressures up to 20 bar

It can be installed on pipelines with diameters up to 1200 mm

Insensitive to dust, powders, and granulates, offering broad application flexibility

Uses:

Gypsum plant screw conveyors: The FlowJam S monitors the discharge flow, ensuring uninterrupted material transport and quickly signalling flow interruptions.

Incineration and power plants: High temperatures and pressure conditions require the FlowJam S’s advanced durability and monitoring capabilities.

3. FlowJam Plus: Flow Detection with Added Blockage Monitoring

The FlowJam Plus offers everything the FlowJam provides, including an additional feature: blockage detection. This makes it a versatile tool for industries that need flow/no flow information and immediate alerts for blockages or material flow interruptions. It is beneficial at transfer points and material infeed locations, providing a detailed view of process efficiency.

Key Features:

Flow/No Flow and blockage detection in one compact sensor

Contactless operation with microwave technology, ensuring long-term reliability even in harsh conditions

Ideal for monitoring multiple points in a single process, such as transfer points or material feeds

Uses:

Biomass plants: Monitors material transfer between screw conveyors, ensuring that both conveyors are functioning correctly and material flow is uninterrupted.

Lime plant rotary feeders: The FlowJam Plus ensures the continuous flow of lime into rotary feeders by detecting whether the material reaches the correct sensor point.

Summary: Choosing the Right Sensor

While all three sensors—FlowJam, FlowJam S, and FlowJam Plus—are designed for contactless material flow detection, they cater to different needs. The FlowJam is ideal for simple flow/no flow detection in standard processes, while the FlowJam S offers added trend monitoring and is suited for high-temperature environments. The FlowJam Plus stands out for its blockage detection capabilities, making it a top choice for processes requiring extra oversight at transfer points or during material infeed.

Selecting the appropriate sensor for your application ensures continuous process monitoring, reduces downtime, and prevents costly blockages or equipment failures.