Case Study: Reliance FG900 Flat‑Glass Boiler Level Gages and DuraStar® LED Illumination for the Food & Dairy Industry
Background
Accurate boiler water‑level monitoring is critical in dairy plants and food factories. Steam is used to heat water, pasteurise products and clean equipment, yet a traditional sight glass can be hard to read when operators are rushed or when the lighting is poor. In the food industry, visibility and safety standards are strict because an incorrect water level can lead to production losses or even a boiler shutdown.
A cheese manufacturer in the Midwestern United States recently faced this problem. The plant’s ageing boiler level gages had poor contrast and were difficult to see, particularly when steam made the glass opaque. Operators struggled to confirm the actual water level, which increased the risk of running the boiler below safe levels, potentially damaging the boiler or compromising product quality. To solve this challenge they replaced their old sight glasses with Reliance FG900 flat‑glass gages equipped with DuraStar® LED illumination. This case study shows how the upgrade improved visibility and reliability and why it is relevant for food and dairy producers in Canada.
Why Reliance FG900 Gages?
Clark‑Reliance’s FG series flat‑glass gages are designed specifically for the demanding conditions found in high‑pressure steam service.
Key design features include:
- Wide‑body construction that provides extra strength and rigidity
- The robust body helps the gage withstand high steam pressures and mechanical stress.
- Premium tempered borosilicate glass for the FG400/FG900/FG1500 models that resists thermal shock. Each glass pane is tested for surface trueness and is protected by a high‑quality mica shield, extending service life in hot, corrosive environments.
- Uniform finger‑clamp design that distributes the sealing pressure evenly across the glass. This design ensures gasket tightness and makes the gage easy to dismantle for cleaning and maintenance.
- Compatibility with DuraStar LED illumination, the recommended illuminator for flat‑glass gages
In addition to their robust construction, FG Series gages can be configured to suit different boiler‑drum heights. Clark‑Reliance notes that you can choose single, double or triple windows for ultimate visibility. The 5/8 inch (15.9 mm) wide window slot provides a high‑visibility reading and makes it easy to see the water level at a glance. Models are available for both ordinary and hazardous locations, including ATEX‑compliant versions
Westech Industrial’s FG Series product page echoes these advantages: the gages use a wide‑body construction and tempered flat glass to resist thermal shock, and every glass pane is checked for surface trueness. When combined with the DuraStar LED illuminator, these gages provide a dependable solution for steam boilers in food plants.
How DuraStar® LED Illumination Improves Visibility
The DuraStar LED illuminator attaches directly to the FG900 gage and dramatically improves level visibility. According to the product literature, the illuminator uses three columns of directed amber LEDs to create a bright, star‑like image at the water line. This design gives operators a sharp contrast between water and steam, even when ambient lighting is poor. Additional benefits include:
- Superior visibility day or night and high contrast. Amber LEDs focus light on the meniscus (water–steam interface), so the water line stands out clearly.
- Long life—the LEDs are rated for approximately 100 000 hours of continuous service, reducing replacement costs.
- Maintenance‑free operation and no heat generation. Unlike incandescent lamps, the LED strip does not heat the gage or nearby piping.
- Field‑upgradeable design that attaches to new or existing Reliance gages without tools.
- Approved for hazardous areas. DuraStar is suitable for Class 1 Division 1 Groups B, C & D and Class 2 Division 1 Groups E, F & G environments, meeting the requirements of many food‑processing boilers.
These features make the FG900 / DuraStar combination ideal for food and dairy facilities where operators must see the water level at a glance during shift changes, CIP (clean‑in‑place) cycles, or emergency blow‑downs.
Case Study Results
The cheese manufacturer’s experience illustrates the impact of the upgrade:
- Superior visibility – operators reported that the amber LEDs created a brilliant star‑like image that was easy to see from a distance, even through steam or condensate. This reduced the time spent verifying boiler water levels, allowing staff to focus on production.
- Improved safety and compliance – by providing a clear, continuous view of the steam‑to‑water interface, the FG900 gage helped ensure the boiler operated within safe limits. The rugged design and Class 1 Division 1 approvals gave the facility confidence that the equipment met stringent safety standards.
- Greater durability – the wide‑body construction and tempered glass resisted thermal shock and reduced the likelihood of glass breakage.
Unlike the plant’s previous tubular gages, the FG900 offered longer service life and easier maintenance. - Efficiency gains – because the LEDs are rated for 100 000 hours, the plant expects many years of uninterrupted service without lamp replacements. The high‑visibility display also reduces the risk of human error that can lead to costly downtime.
Although this case comes from the U.S., the challenges and benefits apply directly to Canadian food and dairy manufacturers. Facilities in Canada often operate under strict CFIA (Canadian Food Inspection Agency) and provincial boiler codes that demand reliable level indication. The FG900 gage with DuraStar illumination helps satisfy these requirements by giving operators a dependable and easy‑to‑read indication of boiler water level.
Why Food and Dairy Producers in Canada Should Consider This Solution
Canadian dairy plants, cheese makers and other food‑processing facilities rely heavily on steam boilers for pasteurisation, cleaning and process heating. When water‑level gages are hard to read, operators may inadvertently run boilers at unsafe levels or over‑fill them, wasting energy. Upgrading to an FG900 flat‑glass gage with DuraStar illumination provides:
- Compliance with boiler codes – FG series gages are suitable for steam pressures from 450 to 2 000 psi
and meet ASME recommendations for direct reading. DuraStar is approved for use in hazardous locations. - Enhanced hygiene – the gasket design allows sections to be dismantled easily for cleaning, an important consideration in food plants where contamination must be avoided.
- Reduced downtime – high visibility reduces the risk of low‑water conditions that could trip the boiler and halt production. The long‑life LED illuminator minimizes maintenance.
Learn More and Contact Westech
Westech Industrial Ltd. distributes Clark‑Reliance products across Canada, including the FG400, FG900 and FG1500 flat‑glass gages and the DuraStar LED illuminator. For more technical details or to request a quote, visit our Reliance Flat‑Glass Water Gages & DuraStar Illumination page. You can also explore our Documents section for brochures and operating manuals.
Ready to upgrade your boiler level indication?
If you operate a dairy, beverage or food‑processing plant in Canada and struggle with visibility on traditional sight glasses, consider upgrading to the Reliance FG900 with DuraStar LED illumination. Contact Westech Industrial today to discuss your application:
Phone: 1‑800‑912‑9262
Email: sales@westech‑ind.com
Our level‑instrumentation experts can help you select the right configuration for your boiler and ensure your facility meets safety and regulatory standards.