Dr Rajat Goyal, Director, EIP Enviro Level Controls Pvt Ltd.

What are some of the latest products launched by EIP Enviro in the field of level measurement and how do they address current challenges in industrial process control?

EIP with its endeavour and passion to resolve most critical issues faced by customers in Silo level measurement, launched a high frequency based 3D-64 Radar Level Transmitter.

When we talk about solid level measurement meaning measurement of level and volume of bulk solids and powders stored inside closed silos and bunkers, we are principally talking about 3 uniquely distinct problems that exist for all the currently available technologies around the globe.

• Problem 1: Uneven surface profile of the material

• Problem 2: Heavy dust, and

• Problem 3: High maintenance of the current devices.

To summarise the problem, it is easier to say that none of the current solutions available for our customers can solve the above problems as few solutions fail to work in dust

like the ultrasonics and lasers, and the one that works in dust, the 80GHz Radar measures at only one point inside the silo leaving a significant portion of the silo unmeasured. The solution, though appears simple which is to measure at multiple points inside the silo, is complicated by the fact that having so many echoes and radar beams inside a silo will create cross interferences and is a technology challenge. This is where our patented MIMO technology accompanied by the fuzzy logic helps in  accurate signal identification amongst many radar beams inside the silo and hence the making of the world’s first multibeam 3D Radar which can measure at multiple points inside the silo and hence help provide an accurate level and volume of the contents stored inside the silo.

How has the product range evolved in recent years to meet the increasing demands of sectors like cement, steel, power, food processing, and chemicals?

The product range across industrial sectors such as cement, steel, power, food processing, and chemicals has evolved significantly in recent years. This evolution is driven by growing demands for sustainability, automation, operational efficiency, and adherence to regulatory standards.

As innovation continues to reshape the process industry, companies are increasingly focused on obtaining accurate inventory data while minimising maintenance downtime. In response to this need, our introduction of a unique, cutting-edge technology provides a reliable solution – enabling end users to accurately measure their inventory levels and make informed decisions for effective inventory management. This, in turn, helps reduce production losses and improve overall operational efficiency.

Can you highlight any recent industry-specific custom solutions that EIP Enviro has developed using advanced level sensing technologies?

Yes, we call it the clinker revolution.

Following the Covid lockdown, during our first visit to their grinding unit near our factory, the customer shared a persistent challenge with us. Their clinker silos – each with a diameter exceeding 30 metres – faced a recurring issue: no matter how many conventional single-beam radars they installed, they could never obtain reliable volume measurements. The systems lacked the ability to provide accurate volume data, and worse, they couldn’t inform the operator of the confidence or accuracy in the readings.

For the operators, volume – not just level – is the key parameter. Volume determines yield and throughput, and directly reflects whether the process is running optimally. To make informed decisions, operators need precise volume data they can trust.

Adding to the complexity was the harsh dusty environment inside the silos, which caused frequent maintenance issues with conventional systems – often requiring air purging and manual intervention.

The Solution

We introduced the customer to a breakthrough innovation: the world’s first 3D Multi-Beam Radar.

Unlike conventional radars, this system:

• Measures at multiple points within the silo

• Delivers high-accuracy level and volume data

• Generates a real-time 3D profile of the material surface

• Operates at 140 GHz, enabling reliable performance even in extreme dust – without the need for air purge or ongoing maintenance

The Results

1. Accurate, reliable volume data that operators can confidently use for process decisions

2. 3D visualisation of the material surface, enabling better understanding of uneven loading and material behaviour.

How is EIP Enviro incorporating artificial intelligence and machine learning into its level measurement solutions?

Our advanced visualisation software is at the forefront of integrating Artificial Intelligence (AI) and Machine Learning (ML) into level measurement solutions, significantly enhancing both accuracy and reliability.

EIP Enviro leverages AI and ML algorithms to process and analyse vast volumes of data collected from sensors. This intelligent data handling enables the identification of complex patterns and hidden correlations, resulting in more accurate predictions, deeper insights, and informed decision-making.

Key features and benefits include:

1. Advanced data processing & analysis: Harnessing AI/ML to transform raw sensor data into actionable insights by detecting trends, anomalies, and usage patterns.

2. Real-time monitoring & decision-making: Enabling continuous, real-time analysis of sensor data for immediate alerts, process adjustments, and improved operational responsiveness.

3. Predictive maintenance & operational efficiency: Anticipating equipment failures or maintenance needs through historical data analysis – minimising downtime, reducing costs, and optimising performance.

Could you share how predictive analytics or self-diagnostic capabilities are improving accuracy, safety, or maintenance schedules in your smart instruments?

Predictive analytics and self-diagnostic capabilities are playing a pivotal role in enhancing the performance of our smart instruments across multiple dimensions – accuracy, safety, and maintenance efficiency.

1. Improved accuracy through predictive analytics: Our smart instruments use AI-driven algorithms to continuously analyse data trends and detect subtle deviations from normal operating conditions

2. Enhanced safety: Self-diagnostic features allow the instrument to monitor its own health in real time. If a critical component starts to malfunction, the system:

• Flags warnings before a failure occurs

• Sends real-time alerts to operators and control systems

• Minimises the risk of incorrect readings that could lead to unsafe conditions

This is especially important in hazardous environments, where faulty level measurements could lead to overfills and spills.

In short, predictive analytics and self-diagnostics are transforming smart instrumentation from passive measuring tools into intelligent, self-aware systems that help operators maintain optimal performance, ensure safety, and significantly reduce lifecycle costs.

With the rise of Industry 4.0, how are your level measurement systems integrating with broader digital platforms like SCADA, DCS, or cloud-based monitoring?

With the rise of Industry 4.0, our level measurement systems are engineered to integrate seamlessly with broader digital platforms such as SCADA and DCS. This integration is enabled through standardised communication protocols like HART, Modbus, and Industrial Ethernet, ensuring interoperability and real-time data exchange.

Instrument data is also made available over the plant LAN, allowing for centralised visualisation and monitoring. This empowers management and maintenance teams with access to critical insights, supporting diagnostics, predictive maintenance, and advanced analytics for more efficient and informed decision-making.

What sets EIP Enviro apart from other players in the level measurement space, particularly in the AI-driven control systems market?

EIP Enviro stands out due to our deep expertise in combining robust, high-precision instrumentation with advanced AI and machine learning technology. Unlike many competitors who focus solely on hardware or software, we deliver fully integrated solutions that enhance process intelligence and operational efficiency.

Our instruments not only provide accurate, reliable level measurements but also leverage machine learning analytics to enable predictive maintenance, anomaly detection, and automated process optimisation. This proactive approach minimises downtime, reduces operational costs, and improves safety. Additionally, our commitment to open architecture and seamless integration with existing digital platforms – such as SCADA and DCS ensures that customers can scale and future-proof their operations effectively.

Dr Rajat Goyal brings over a decade of experience in Industrial Technology. After earning his B.Tech in Electronics Engineering and an MBA from SP Jain Institute of Management and Research (SPJIMR), Mumbai, he chose to join his family-managed business with a clear vision: to address critical challenges faced by customers in achieving accurate level and volume measurements, along with solving complex issues related to slurry density measurement.

Driven by a strong commitment to innovation, Dr Rajat Goyal has played a pivotal role in expanding EIP’s product portfolio through continuous new product development. His efforts have not only strengthened the company's technical capabilities but have also ensured that each product is tailored as a solution to specific customer needs.

In recognition of his contributions to both product innovation and market integration, Dr Goyal was recently awarded a Doctorate in Business Management from Logos University (USA) – an acknowledgment of his dedication to bridging technology with practical, customer-focused solutions.