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What is a SmartSwitch?

The term "SmartSwitch" has been around since the first stand alone system Masterleo produced that provided the ability to detect and alert operators of the precise time in which their water-to-product and product-to-water transitions were completed. It started rather simply and the system caused a light to flash when good product began flowing down the drain.  This flashing light was the signal for operators to switch from sending product down the drain during this transition.  This concept has evolved and now provides the flexibility to tie into your existing control system or have a fully independent system control your valve switching based on the information our optical sensors are reporting.

When do you know that it is the right time to switch from a floor drain and begin the processing of your product?  We know that some companies use a time delay, while others may have an operator look for "the right" color or consistency of the product before they manually make the switch.

The problem with most methods of water-to-product and product-to-product transitions is that they are not precise.  Different products can vary in time to transition and this only compounds the issue.  When you do not have precision with your transitions, here are the outcomes:

  1. 1.  Diluted product is being processed
  2. 2.  Good, undiluted product is heading down the drain

In most cases, having either one of these outcomes is not optimal for your customers, or your bottom line.  

The Solution

The first thing that we need is a highly accurate, repeatable, and stable optical sensor.  Optek's optical sensors have proved they are up to the challenge and because of their extensive selection, we can help you control what is going down your drain regardless of the type of product you are producing.  The optical sensor communicates with a controller that provides you with a 4-20mA output.  

 Below is an example of the types of products that are commonly used for this application in the food and dairy industries.

AF16-N Single Channel NIR Absorption Sensor

 AF16-N Single Channel NIR Absorption Sensor Brochure

  • Commonly used in food & dairy industries
  • Excellent for sensing product transitions
  • Decrease product loss and BOD charges


C4000 / C8000 Converters Brochure

  C4000 / C8000 Converters Brochure

  • Brochure Includes Detailed Sensor Overview



Once we find the appropriate sensor for your application, we will data log the products and set threshold limits based on your needs.  From there, we are ready to tie this information into your existing controls or create a custom control solution for you.  


Click on the image to the left to see an example of the savings that you could experience.  The Return on Investment (ROI) will be different for every facility but consider how often you have water-to-product transitions or product-to-water transitions.  The amount of product saved could be extensive.  In addition to the product saved you may likely see a dramatic reduction in your BOD charges that the local municipality charges you for dumping of many different products down the drain.  


For more information, please contact us and we will help find the solution that is right for you.

PDF Download

Click on the above link to download a PDF brochure of our SmartSwitch Application.

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