Reliable wastewater level monitoring plays a vital role in efficient industrial water management, especially in automotive manufacturing, where production and cleaning operations generate process water throughout the day. At a manufacturing facility in India, UWT’s NivoRadar® NR 7200 radar level sensors provide continuous, non-contact measurement—helping automate pump operation, lower the risk of overflow and reduce maintenance needs.
Responsible water management in industry isn’t just about using less water. Wastewater must also be collected, monitored and transferred effectively to keep manufacturing running smoothly and ensure contaminated process water reaches the right treatment facilities.
Automotive production generates wastewater at several stages, including component cleaning, body pretreatment and cooling. Managing these streams calls for dependable level measurement and controlled pumping to prevent collection pits from overflowing.
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At an automotive plant in India, UWT has installed a non-contact radar level measurement system using its NivoRadar® NR 7200 sensors.
The installation shows how 80 GHz radar technology can support industrial wastewater management with continuous level monitoring, even in challenging underground environments.
The Challenge: Reliable Wastewater Level Measurement in Underground Pits
Automotive facilities generate process wastewater continuously through component production, cleaning and other industrial activities.
The wastewater flows into underground drainage and collection pits, where pumping stations transfer it to the plant’s central wastewater treatment facility.
At the Indian manufacturing site, these pits are located beneath the production halls. They are typically cylindrical concrete tanks, around 4 to 6 metres deep.
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The pits temporarily collect contaminated wastewater from cleaning stations, body pretreatment processes, and cooling circuits. The water is held there until it can be treated or neutralised.
Measuring levels in these underground installations can be challenging for conventional equipment. High humidity, condensation, and limited access can make reliable detection difficult. Contact-based systems may also need more maintenance when exposed to harsh wastewater conditions.
Accurate level monitoring is essential for effective transfer-pump operation and helps reduce the risk of wastewater overflowing from the collection pits.
The facility therefore needed a dependable, low-maintenance solution that could monitor levels continuously without contacting the wastewater.
The Solution: UWT NivoRadar NR 7200 Radar Level Sensors
To meet these needs, the automotive manufacturing facility installed several UWT NivoRadar® NR 7200 radar level sensors.
UWT India supported the plant operator throughout the project, from equipment selection and system planning through to commissioning.
The sensors continuously measure wastewater levels, providing the information needed to control pumping and keep wastewater transfer running reliably.
Powered by 80 GHz frequency-modulated continuous-wave (FMCW) radar technology, the NivoRadar NR 7200 measures liquid levels without touching the wastewater.
This non-contact approach is particularly useful in industrial collection pits, where residues, contamination, and thin oil films can build up on the liquid surface.
The radar technology supports reliable level detection in these conditions while reducing the maintenance associated with contact-based instruments.
Precise Radar Level Measurement in Confined Spaces
One of the key advantages of the NivoRadar NR 7200 is its narrow 8° radar beam.
The focused beam enables accurate level measurement in confined shafts and underground collection pits, where limited space or internal structures can complicate conventional measurement.
Its compact design also makes the sensor a good fit for installations with limited mounting space.
A 1½-inch PVDF process connection simplifies installation, while the chemically resistant material is compatible with a range of industrial media.
Built for demanding industrial environments, the sensor is designed to withstand moisture, condensation and other process conditions that can affect measurement equipment.
Selected configurations are available with hazardous-area approvals, including ATEX certification, for use in appropriately classified potentially explosive atmospheres.
For Zone 2 applications, an explosive atmosphere of gas, vapour or mist is not expected during normal operation. If one does occur, it is expected to be present only briefly. Equipment must be selected in accordance with the applicable hazardous-area requirements.
These features make the NivoRadar NR 7200 well suited to wastewater monitoring, where reliable measurement and flexible installation are essential.
Simplifying Configuration with the UWT LevelApp
Alongside its measurement capabilities, the NivoRadar NR 7200 is designed to make configuration and commissioning straightforward.
Technicians can configure the sensor with the UWT LevelApp, accessing device settings from a compatible smartphone or tablet.
This offers a convenient way to commission and adjust the instrument, especially when it is installed in an underground pit or another hard-to-reach location.
For the automotive wastewater monitoring application, the sensors were also fitted with an optional plug-on display.
The display lets operators check level readings right at the installation, while the LevelApp provides wireless access to the sensor for configuration and monitoring within its supported range.
Together, these features make measurement data easier to access and help streamline routine maintenance and commissioning.
The Result: Improved Wastewater Monitoring and Pump Control
With UWT NivoRadar NR 7200 sensors installed, the automotive manufacturer can reliably monitor wastewater levels in its underground collection pits.
Accurate level readings enable automated pump operation and controlled transfer of wastewater to the plant’s central treatment facility.
Continuous monitoring also helps prevent pit overflows and keeps the wastewater handling system running reliably.
Because the sensors measure without contact, they are less exposed to contaminated water, helping reduce maintenance needs compared with conventional contact-based systems.
For the manufacturer, this means more dependable wastewater management and fewer disruptions caused by maintenance.
Supporting Responsible Industrial Water Management
Reliable wastewater measurement plays an important role in responsible water management across industrial manufacturing.
As manufacturers work to make wastewater handling more efficient and dependable, non-contact radar offers a practical way to monitor liquid levels in demanding conditions.
The UWT installation in India shows how 80 GHz radar sensors can support industrial wastewater collection, automated pump control and efficient transfer to treatment facilities.
By combining continuous measurement with flexible installation and simple commissioning, the NivoRadar NR 7200 helps wastewater facilities operate more reliably and efficiently.
For automotive manufacturers and other process industries handling contaminated wastewater, accurate level measurement is vital to keeping operations running smoothly and preventing uncontrolled discharges.
For more information:
UWT GmbH
Email: info@uwtgroup.com
Website: www.uwtgroup.com
