Custom sensor solutions developed and manufactured in-house
Binsack Reedtechnik develops and manufactures float switches, suction lances, flow monitors, reed sensors, and reed relays for industrial applications. Our solutions are tailored to your technical requirements—including the medium, installation space, switching point, material, connection, and planned production volume.
We support you from the initial technical consultation through prototyping and approval to reproducible mass production.
Request a Development ProjectWe support you from the initial technical consultation through prototyping and approval to reproducible mass production.
Float switches: Standard projects typically start at 50 units
Suction lances: Production runs typically start at 10 units
Samples and Prototypes Following Technical Review
Since 1993—Development and manufacturing in Mühlheim am Main
Over 17.9 million sensors in use
From sample to series production
Your Benefits in Development and Production
Technical advice
Design based on your actual operating conditions.
Adaptation to the medium and installation space
Material, dimensions, and function tailored to the application.
Samples and Approval
Technical testing prior to the start of mass production.
Reproducible Mass Production
Specified design and documented product features.
In-house manufacturing at the Mühlheim am Main facility
By integrating development and manufacturing, technical requirements can be tailored to cost-effective and repeatable mass production as early as the design phase.
Depending on the product and project, our manufacturing processes include, among other things:
Tool manufacture
Fixtures and tools for custom components and recurring production processes.
Plastics processing
Manufacture and processing of technical plastic parts for float switches, suction lances, and other sensor assemblies.
Cable Assembly
Adapting cable lengths, cable types, connectors, and pin assignments to the specific application.
Ultrasonic welding
Reliable joining of suitable plastic components without additional screw or adhesive fasteners.
Mechanical processing
Machining and modifying components, connections, and geometries in accordance with the technical drawing.
Assembly
Assembly of custom sensors and subassemblies in the approved production version.
By integrating development and manufacturing, we can tailor technical requirements early on to ensure cost-effective and repeatable mass production. Short communication channels between design, manufacturing, and quality assurance enable the efficient implementation of customer-specific solutions.
What products does Binsack develop and manufacture?
Float switches
Custom float switches for monitoring liquid levels. Customizable features include, among others, the design, material, switching point, thread, cable length, and electrical configuration.
Typical Requirements
View Float Switches- vertical or horizontal installation orientation
- Plastic or stainless steel
- one or more switching points
- limited installation space
- special media
- custom connections
Suction pipes
Suction lances for dispensing media from canisters, drums, and IBC containers. Depending on the model, empty detection, backflow prevention, and custom container connections can be integrated.
Typical Requirements
View Suction Lances- Adjustment to container height and container opening
- Empty notification for dosing and conveying systems
- reduced remaining quantity
- materials suitable for the medium
- custom hose and process connections
Flow monitors
Mechanical flow monitors for monitoring a minimum flow rate. The design is based on the medium, flow range, installation orientation, pressure drop, and desired switching point.
Typical Requirements
View Flow Monitors- Monitoring of cooling or process circuits
- Dry-run protection
- Enable signal when the minimum flow rate is reached
- Compact integration into existing lines
Reed Sensors and Reed Relays
Magnetically actuated switching solutions for position, limit, and signal monitoring, as well as for galvanically isolated switching applications.
Typical Requirements
View Reed SensorsView Reed Relays- Defined switching distance
- Compact design
- Compact design
- Custom cables and connectors
- Adaptation to the magnet, mounting orientation, and electrical load
- Use in industrial mass-produced products
Our Development Process
1. Record technical requirements
To begin with, we clarify the actual operating conditions. These include, among other things:
- Product category and desired function
- Medium and concentration
- Temperature and pressure range
- available installation space
- Mounting and process connection
- desired switching point
- electrical load and interface
- Cable or connector specifications
- planned annual and total quantities
The more complete this information is, the faster the technical feasibility can be assessed.
2. Assess feasibility and explore possible solutions
Next, we assess whether an existing product platform can be adapted or whether a more complex custom design is required.
In particular, the following are evaluated:
- mechanical integration
- Material compatibility
- Operating Principle
- electrical load capacity
- manufacturing-friendly design
- Testing and Documentation Requirements
- economic feasibility of the planned series
The goal is not the most technically complex solution, but rather the one that is functionally and economically suitable for the application.
3. Design the product from a technical standpoint
The relevant product features are determined based on the requirements.
These may include:
- Dimensions and Geometry
- Switching point and switching function
- Float or sensor version
- Materials of the parts in contact with the medium
- Mounting and process connection
- Cables, connectors, or connecting wires
- Number of switching points
- Installation orientation
- electrical specifications
Critical characteristics are clearly defined as early as this phase.
4. Create a sample or prototype
Before a product is approved for mass production, it may be advisable to conduct a prototype or sample phase. This phase is used to verify whether the product is mechanically, electrically, and functionally suitable for its intended application.
For example, a sample is used to check:
- Installation Space and Assembly
- Connection compatibility
- switching point
- Freedom of movement
- Cable installation
- Media Contact
- Function within the overall system
The specific nature and scope of sampling are determined on a project-by-project basis.
5. Review and Approval
The agreed-upon product characteristics are tested prior to mass production. The type and scope of the testing depend on the product, its application, and customer requirements.
Possible inspection characteristics include:
- Switching function
- switching point
- electrical parameters
- Dimensions
- Leak-tightness
- Cable length and pin assignment
- mechanical function
- unique product assignment
Once technical approval has been granted, the production version is finalized.
6. Mass Production and Long-Term Supply
Once approved, the product is manufactured according to the agreed-upon specifications. The goal is to ensure consistent quality across recurring shipments.
Changes to materials, geometry, connections, or function are not considered in isolation, but are evaluated in terms of their impact on the entire application.
If necessary, the following may also be agreed upon:
- custom labeling,
- defined packaging units,
- technical documentation,
- Test reports,
- on-demand or volume-based delivery models.
Example: Float switch for limited installation space
Background:
A equipment manufacturer needed a level-limit monitoring system for a compact tank. A standard float switch interfered with the tank's internal geometry.
Requirements:
- maximum outer diameter
Requirements:
- maximum outer diameter
- specified installation length
- fixed switching point
- Medium and Temperature
- existing threaded connection
- Desired cable length
- Planned annual volume
Solution:
Solution:
An existing product platform was modified in terms of float diameter, installation length, connection, and cable configuration.
Result:
- Integration without an additional adapter
- defined switching point
- approved sample
- Reproducible mass-production version
Quality begins with development
Product quality isn't just the result of final inspection. It begins with clear technical specifications and a design optimized for manufacturing.
For each project, the following should therefore be determined early on:
- which product features are critical to functionality
- what tolerances are required
- how the function is tested
- what data must be documented
- which changes require approval
This approach helps reduce misunderstandings between development, purchasing, manufacturing, and subsequent use.
Development for Production Customers
Binsack focuses its custom solutions primarily on industrial mass-production applications.
Collaboration is particularly suitable when:
- a standard product does not fit mechanically
- a particular medium requires specific materials
- a custom switching point is required
- Cables, plugs, or connectors need to be adjusted
- a solution should be provided that is sustainable and reproducible
- technical coordination and sample submission are required
A custom design is less suitable when the goal is simply to find a single, readily available standard part at the lowest possible unit price.
Typical Project Sizes
- custom float switches: typically in quantities of 50 or more,
- Custom suction lances: typically 10 units or more
- Samples and prototypes following technical and economic evaluation.
The actual minimum order quantity depends on the scope of customization and any necessary tooling or development costs.
- Samples and prototypes following technical and economic evaluation.
The actual minimum order quantity depends on the scope of customization and any necessary tooling or development costs.
Do you need a sensor that's right for your application?
Please send us any available technical data, drawings, or a brief description of your application. We will determine whether an existing product platform can be adapted and what information is needed for further design.
Direct Contact with Technical Support
Don't have all the technical specifications yet?
No problem. Send us a sketch, photo, drawing, or the key specifications. Our technicians will determine which design is technically feasible.
FAQ on Development and Manufacturing
Can Binsack customize existing products to meet customer specifications?
Yes. It is often more cost-effective and faster to modify an existing product platform than to develop a completely new one. Depending on the product, possible modifications include changes to dimensions, materials, switching points, threads, cables, and connectors.
Does Binsack also develop completely new sensor solutions?
That depends on the technical requirements, the planned production volume, and the development effort required. The first step is to determine whether an existing design can be used or adapted. A completely new design makes sense, particularly for long-term production projects.
What are the minimum order quantities?
For custom float switches, the minimum order quantity is typically 50 units. For suction lances, it is typically 10 units. The actual minimum order quantity depends on the cost of customization, tooling, and testing.
Are samples or prototypes available?
Samples and prototypes can be produced following technical and economic evaluation. They are used to verify installation space, assembly, function, switching point, and connections prior to series production approval.
How is media resistance tested?
To make a reliable assessment, the exact name of the medium, its concentration, temperature, and exposure time are required. In addition, potential cleaning media and varying operating conditions must be taken into account. A general material approval without this information is not sufficient.
What data helps speed up the technical review?
A dimensioned drawing, a 3D model, or an installation sketch—along with details regarding the medium, temperature, switching point, electrical load, connection, and planned production quantity—are particularly helpful.
Can existing drawings or sample parts be reviewed?
Existing drawings, specifications, and sample parts can serve as the basis for the technical evaluation. This process involves determining which features can be adopted and where adjustments are necessary.
Does Binsack also make one-of-a-kind items?
The focus is on customer-specific mass-production applications. Individual prototypes may be possible as part of a planned mass-production development project. Purely one-off production without the prospect of subsequent mass production is generally not the focus.