Viscosity Monitoring

Viscosity is one of the most important process variables in mixing operations and one of the most difficult to measure continuously without dedicated inline instrumentation. Inline viscometers add cost, maintenance burden, and contamination risk, while manual sampling introduces lag and inconsistency.

Load Controls' power sensors provide continuous, non-contact viscosity monitoring by measuring mixer motor true power draw in real time. As product viscosity rises or falls inside the vessel, the resistance on the mixer motor changes in proportion and that change registers immediately as a shift in power draw. This gives process engineers a reliable, real-time viscosity indicator without any contact with the product, without additional instrumentation inside the vessel, and without interrupting the mixing process. All sensors are non-invasive, install at the motor control panel, output standard 0–10V, 4–20mA, and Modbus signals, and are manufactured in the USA to ISO 9001:2015 standards.

Q: How accurate is power-based viscosity monitoring compared to a dedicated viscometer?

Power-based monitoring provides highly sensitive relative monitoring, detecting viscosity changes reliably and consistently. For absolute viscosity measurement it complements rather than replaces a calibrated viscometer.

Q: Can the sensor track viscosity changes across the full duration of a batch cycle?

Yes. Load Controls sensors provide a continuous output throughout the entire batch cycle, giving a complete picture of how viscosity evolves from start to finish.

Q: Does power-based viscosity monitoring work across different mixer types?

Yes. Any mixer or agitator driven by an electric motor can be monitored for viscosity changes using Load Controls sensors, regardless of mixer geometry or configuration

Industrial facility using true power monitoring to optimize energy efficiency and equipment performance. Aerial view of industrial buildings surrounded by greenery

Optimise Energy with
True Power

Find Out More