A production line this big cannot afford surprises
Crushers, mills and conveyors are built to run continuously. When they stop, the consequences can extend through the entire production line, while the conditions they operate in are rarely forgiving: dust, abrasion, heat, hazardous areas and sites far from the workshop.
Gill sensing is built for exactly that, from oil debris monitoring and capacitive level sensing for difficult liquids to certified wind measurement and site weather monitoring.
We aim to respond in one working day.
The plant is the production line, and it has no spare
A quarry or a cement works is a single production line made of very large components. When a crusher, a mill drive or an overland conveyor stops, nothing downstream of it produces, and the replacement part is rarely on site.
That is a different problem from mobile plant. A machine can be swapped; a grinding mill cannot. The value is in seeing the failure coming far enough ahead to buy the part, plan the shutdown and take it in a window you chose.
Around the plant, the site has its own measurements. Dust and blasting are governed by wind. Stockpiles, silos and settlement ponds need level. Lifting stops at a wind speed. And a good deal of it happens in an area classified for dust or gas, where an ordinary instrument is not permitted.
The measurements behind a plant that keeps running
A mining, quarrying or cement site measures across the plant and the wider operation.
Oil condition. Level. Position. Wind. Rainfall.
A mill drive can deteriorate long before it stops. A slurry tank can become difficult to measure reliably. A gate position can be lost in dust. A lifting operation can depend on a wind limit that changes by the minute.
This is where measurement earns its keep: by giving the operation earlier, more useful information about what is happening.
WearDetect monitors ferrous debris in lubricating oil. LevelSlick measures difficult liquids without a mechanical float. Blade provides non-contact position feedback. WindSonic and WindObserver measure wind without moving sensing components.
But measurement also has to survive the environment in which it is made. Abrasive dust, slurry, humidity, wash-down, vibration and classified areas all place demands on the sensing technology itself.
The sensor has to be engineered for the duty, not simply specified for the measurement.
The part is not on the shelf
Mill drives and crusher bearings can be long-lead components. Seeing wear early creates time to plan the intervention.
WearDetect distinguishes fine from coarse debris.
The liquid destroys the sensor
Slurry, process water and dust-laden liquids are conductive, abrasive and coating.
LevelSlick is FEP coated, -40 to +85°C.
Parts of the site are classified
Coal, cement and mineral dust can create areas where uncertified instruments cannot be installed.
WindObserver IS holds ATEX, IECEx and UKEX.
Permission to work is weather dependent
Blasting, dust suppression and lifting can all depend on measured conditions and the record behind them.
WindSonic 75 measures 0 to 75 m/s.
Every production decision starts at a measurement point
A site measures at the plant and across the ground around it. Oil condition in drives. Level in silos, tanks and ponds. Wind at the face, stack and jib. Rainfall on the haul road and at the discharge point.
Primary crusher and feeder
The primary crusher is the first thing on a single production line, so everything downstream of it stops when it does.
- WearDetect fine and coarse ferrous debris in the crusher lubrication circuit
- Blade60 60 mm linear travel for gate and chute position
- Blade360 full 360 degree rotary, IP67, for diverters
Screening and classification
Screens run out of balance long before they run out of service, and the drive bearings are the part that gives the first signal.
- WearDetect real-time ferrous debris in the drive lubrication
- Bearing wear monitoring the application page for production line bearings
- Condition monitoring 0-10 V, 4-20 mA, CANbus or Modbus RTU output models
Overland conveyor drives
An overland conveyor is a long, slow, heavily loaded drive, which is the case vibration analysis handles worst and oil debris handles best.
- WearDetect debris monitoring on slow speed gearboxes
- Conveyor drive condition monitoring the application page for drive monitoring
- Gearbox wear monitoring slow speed gearbox condition monitoring
Kiln, stack and process emissions
A kiln stack is a permitted emission point, and the dispersion of what leaves it is a wind measurement before it is anything else.
- WindObserver 65 precision 2-axis wind for a fixed mast
- MaxiMet GMX551 wind, temperature, humidity, pressure, solar and rainfall in one unit
- Pollution monitoring the application page for environmental data capture
Silo and bin level
A silo that runs empty stops the plant and a silo that overfills is an incident, and both are avoidable with continuous level rather than a dip.
- LevelPro stainless steel, IP66 and IP68, 0-10 V or 4-20 mA, RS232 for configuration
- LevelSlick FEP coated for particulate and coating materials
- DD1615 level display local readout at the silo
Grinding mill lubrication
Mill drives are the most expensive things on the site to lose, and their lubrication circuits are where the failure announces itself first.
- WearDetect fine and coarse ferrous debris, water presence, oil temperature
- WearDetect with Display the same sensor with an integrated readout
- LevelPro hydraulic and lubricant level in the circuit
Dust suppression and air quality
Dust suppression is only effective when it runs against the conditions that are actually carrying the dust, which means measuring them on site.
- MaxiMet GMX551 six parameters in one housing on one cable
- MetConnect separable sensors with Pt100 and analogue inputs
- Air quality monitoring the application page for air quality
Quarry face and blasting windows
Blasting is permitted against conditions, and the wind at the face at the time is part of the record that the permission rests on.
- WindObserver 65 precision 2-axis, stainless steel 316, IP66
- WindSonic 75 0 to 75 m/s, no moving parts
- MaxiMet GMX501 multi-parameter station for a permanent installation
Stockpile and radial stacker
A stacker is a moving structure working in dust all day, and both its position and the wind acting on it are measurements worth having.
Stockyard crane and lifting
Lifting and ship loading stop at a wind speed, and the defensible number is the one measured at the jib rather than at the office.
- WindSonic 75 0 to 75 m/s, 0 to 360 degrees with no dead band
- WindObserver 70 precision 2-axis for exposed and extreme sites
- Crane wind monitoring the application page for lifting operations
Haul fleet and haul road
The mobile fleet on a quarry has its own measurement set, and haul road condition drives tyre cost and cycle time more than anything else.
- Off-highway and construction the sector page for mobile plant
- TruMet PW100 0 to 200 mm/hr, 5 per cent accuracy, 0.1 mm resolution
- WearDetect engine and driveline debris monitoring on the fleet
Hazardous area and certified sensing
Where coal, cement or mineral dust classifies the area, an uncertified instrument cannot be installed at all, whatever its specification says.
- WindObserver IS ATEX, IECEx and UKEX, with EN 60945:2002 for EMC, 1.9 kg
- Coal shearing level sensing an intrinsically safe level sensor built for the duty
- Custom level sensing built to the area classification and the liquid
Settlement, discharge and consent
Settlement ponds, sumps and discharge points are kept inside a consent, and the liquid involved is exactly the kind that ruins a conventional sensor.
- LevelSlick FEP coated, for conductive liquids with particles and suspended matter
- LevelPro robust stainless steel level sensing, IP66 and IP68
- Wastewater level monitoring the application page for treatment and discharge
Slurry and process water
Slurry coats, abrades and conducts, which is three reasons at once why most level sensing does not last in it.
- LevelSlick FEP coating with non-stick, low friction properties, operating -40 to +85 degrees C
- Cement and mining level sensing the application page for difficult liquids
- Level sensor range capacitive, no moving parts, factory calibrated
Fixed plant condition monitoring
The plant maintenance plan is better built from a debris trend across the drives than from a schedule that treats every gearbox the same.
- WearDetect CANbus and Modbus RTU into the plant control system
- WearDetect with Display integrated readout for a walk-round check
- Mining sensor solutions the brochure for asset monitoring on site
Calibration and compliance
Where a measurement supports a discharge consent, a blasting permission or a dust boundary condition, it needs traceable calibration behind it.
- Labcal UKAS-accredited, Lab 0625, ISO/IEC 17025:2017
- Air velocity calibration anemometers, Pitot tubes and thermal probes
- Pressure and temperature gauges, transducers, thermometers and data loggers
Find your site application
Explore the measurement challenges across fixed plant and the wider site, from crusher and mill condition to difficult liquids, certified wind measurement, dust and lifting.
Crusher, Mill and Conveyor Drives
The failure you can buy a part for
Crushers, grinding mills and overland conveyor drives are long-lead components on a single production line. Real-time debris monitoring turns an unplanned stop into a planned shutdown.
Engineering: Oil debris sensing on slow-speed drives, CANbus or Modbus RTU into the plant system.
Difficult and Abrasive Liquids
The duty that defeats a float
Slurry, process water and dust-laden liquids are conductive, abrasive and coating. FEP-coated capacitive sensing measures continuously without a float to jam.
Engineering: FEP-coated capacitive sensing, up to 2 m, tank profiling, full and empty alarms.
Hazardous Area Wind Measurement
Certified for the classified part of the site
Coal, cement and mineral dust can create areas where an uncertified instrument cannot be installed. WindObserver IS is designed for those positions.
Engineering: ATEX, IECEx and UKEX certification, EN 60945:2002 for EMC, stainless steel 316, IP66.
Dust, Blasting and Air Quality
The condition, and the record of it
Blasting windows, dust suppression and boundary monitoring are wind and weather decisions. The record of conditions at the time can form part of the permission to work.
Engineering: Multi-parameter weather stations, precision 2-axis wind, optical rainfall.
Silo, Tank and Pond Level
Continuous level, not a dip reading
Cement silos, fuel and lubricant tanks, process water and settlement ponds all need continuous level rather than a reading taken when someone remembers.
Engineering: Capacitive level sensing, stainless steel and FEP options, IP66 and IP68.
Lifting and Stockyard Cranes
The limit judged where the load is
Stockyard cranes, ship loaders and mobile lifting can all operate within defined wind limits. Measuring wind at the jib rather than at the weighbridge keeps the decision tied to the operating point.
Engineering: 2-axis ultrasonic wind measurement, no moving parts, heated options.
insight
Why slow-speed drives are the hardest thing on site to monitor, and the best thing to measure
Vibration analysis works well on machines that turn quickly. On the slow, heavily loaded drives found in quarries and cement works, a developing fault can produce little vibration energy and be difficult to separate from the background of the crushing circuit.
Oil debris measurement takes a different approach. WearDetect captures ferrous wear particles with a magnet and reports fine and coarse debris, so the signal is the wear itself rather than a symptom of it.
Fitted as a smart sump-plug replacement or in a bypass circuit, it can provide 0-10 V, 4-20 mA, CANbus or Modbus RTU output into the plant system.
It also reports water presence and oil temperature, giving visibility of water ingress alongside mechanical wear.
Mining, quarrying and cement technologies
Products engineered for fixed plant and the sites around it, spanning oil debris monitoring, capacitive level sensing for difficult liquids, certified and precision wind measurement, site weather and independent calibration across Gill.
Plant and process
WearDetect
Oil debris sensor
On slow, heavily loaded drives, WearDetect monitors ferrous debris to provide an indication of developing wear.
LevelSlick
FEP-coated capacitive level sensor
For slurry, process water and conductive, abrasive or coating liquids found across quarrying and cement operations.
WindObserver
Precision 2-axis ultrasonic anemometer
The stainless-steel open-head range includes WindObserver IS for classified areas where an uncertified instrument cannot be installed.
Blade position sensors
Non-contact inductive position sensing
Gate, chute, diverter and stacker slew feedback from a sealed sensor measuring across a gap to a passive activator.
Site measurement
MaxiMet
All-in-one weather station, no moving parts
One unit, one cable and one output string for blasting windows, dust suppression and the record behind a working restriction.
WindSonic
Lightweight 2-axis ultrasonic anemometer
For jib, stacker and boundary mounting where lifting is governed by a wind limit and the sensor has to keep reporting through dust.
TruMet PW100
Infrared optical rain gauge
A solid-state alternative to the tipping bucket, with no mechanical tipping mechanism to block in dust-heavy environments.
UKAS-accredited calibration for six measurement parameters
Labcal is an independent UKAS-accredited calibration laboratory, Lab 0625, operating to ISO/IEC 17025:2017.
It provides calibration across gas and air flow, air velocity, liquid flow, pressure, temperature and humidity, supporting equipment from Gill and other manufacturers.
That matters on a site where instruments may come from different suppliers, plant and contractors.
01 · Gas and air flow
Gas meters · Mass flow controllers · Dispensing systems · Low-flow laboratory to higher-flow industrial
02 · Air velocity
Anemometers · Pitot tubes · Thermal probes
03 · Liquid flow
Flow meters and sensors · Process control equipment · Water used for the accredited capability
04 · Pressure
Gauges · Transducers · Manometers · Transmitters
05 · Temperature
Thermometers · Probes · Thermocouples · Data loggers
06 · Humidity
Hygrometers · Probes · Transmitters
The measurement has to reach the control room and the maintenance plan
A sensor on a crusher is only useful if its output reaches the system that plans the shutdown, whether that is the plant control system, SCADA layer or maintenance record.
Gill supports environmental monitoring, industrial sensing, embedded electronics and systems integration, allowing measurement to connect with existing control, SCADA and asset management systems.
Whether the requirement is Modbus RTU into fixed plant, 4-20 mA into an existing controller, CAN on mobile equipment or a configurable sensor embedded into an OEM build, engineers can support integration from specification through commissioning.
Outputs and options
- Modbus RTU : Plant control and SCADA
- 4-20 mA & 0-10 V : Analogue channels on existing controllers
- CAN & RS232 : Mobile plant and vehicle networks
- Certified installation : WindObserver IS for classified areas
Why mines, quarries and cement plants specify Gill
WindObserver IS carries ATEX, IECEx and UKEX certification for classified areas, and WearDetect counts ferrous wear debris in gearbox oil, so wear shows up before failure. Designed and manufactured in Lymington, Gill technology is specified in 150+ countries.
The signal is the wear, not a symptom
WearDetect captures ferrous debris and reports fine and coarse counts, providing an indication of developing wear on slow-speed drives.
Built for liquids that coat and abrade
LevelSlick is FEP coated for conductive liquids carrying particles and suspended matter, operating from -40 to +85°C.
Certified where the site is classified
WindObserver IS carries ATEX, IECEx and UKEX, with EN 60945:2002 for EMC, enabling wind measurement in classified areas.
Nothing to seize in dust
Ultrasonic wind measurement and non-contact position sensing have no moving parts, reducing mechanical exposure in dusty environments.
Designed to integrate
Modbus RTU, CANbus, 4-20 mA, 0-10 V, RS232 and RS485 are available across the range, allowing measurements to reach the plant system.
Evidence when it is asked for
Independent UKAS-accredited calibration across six parameters supports traceability for equipment from any manufacturer.
Mining, quarrying and cement application notes
Explore application-specific guidance covering difficult liquids, conveyor drive condition monitoring, bearing wear and wind measurement in stevedore operations.
Site measurement questions, from the crusher to the consent
Gill supplies sensing technologies for fixed plant and the wider site, including oil debris monitoring, capacitive level sensing, non-contact position sensing, ultrasonic wind measurement, weather stations and optical rainfall measurement. The range covers applications from crusher and conveyor condition monitoring to difficult liquids, lifting, blasting and site weather.
This sector focuses on fixed plant and the wider mining, quarrying and cement site, including crushers, mills, conveyors, silos, ponds, classified areas and site weather. Off-highway applications focus on mobile machinery and the sensing requirements associated with vehicles and equipment that move between locations.
Vibration analysis can be effective on high-speed machinery. Slow, heavily loaded drives can produce lower vibration energy, making developing faults harder to distinguish from the background vibration of the plant. Oil debris monitoring takes a different approach by detecting ferrous wear particles directly in the lubricant.
The application depends on the properties of the liquid and the installation. Gill’s LevelSlick uses FEP coating and is designed for conductive, abrasive and coating liquids. It provides continuous level measurement without a mechanical float.
The appropriate level technology depends on the liquid, vessel geometry, temperature, installation and required output. Gill provides capacitive level sensors in stainless steel and FEP-coated configurations, with options for different environments and applications.
Our team can assess the liquid characteristics, tank geometry, measurement range, temperature, mounting and required output before recommending the appropriate configuration.
Equipment for classified areas must meet the certification requirements of the specific installation. Gill’s WindObserver IS carries ATEX, IECEx and UKEX certification and is available in stainless steel 316 with IP66 protection.
Wind measurement for lifting depends on the required range, mounting position, environmental conditions and integration requirements. Gill provides ultrasonic 2-axis wind sensors including WindSonic and WindObserver, with ranges extending to 90 m/s on the WindObserver range.
A tipping bucket uses a mechanical tipping mechanism, which can be vulnerable to contamination in dust-heavy environments. The TruMet PW100 uses infrared optical measurement instead, with no mechanical tipping mechanism. It measures liquid precipitation from 0 to 200 mm/hr, with 5% accuracy and 0.1 mm resolution.
Yes. Labcal, Gill Group’s independent UKAS-accredited calibration laboratory (Lab 0625), operates to ISO/IEC 17025:2017 and supports equipment from Gill and other manufacturers across six accredited measurement parameters.
Speak to our team
Tell us what you need to measure, where and under what conditions. We’ll help you work out the appropriate approach.
We aim to respond in one working day.