In boiler manufacturing, every millimeter, component, and production step matters. A level gauge may appear to be a small part of the overall system, but its design has a direct impact on installation effort, delivery time, maintenance access, and total cost.
With the new KRP25 reflex level gauge, KLINGER introduces an improved product solution developed for very-low-pressure boiler applications up to 20 bar. Designed by KLINGER Italy, the KRP25 responds to a clear market requirement: a reliable, cost-efficient, and easy-to-integrate level gauge for OEM customers operating in a highly competitive environment.
Fact box
KRP25 at a Glance: Key Benefits
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Lower overall cost through a simplified design and reduced component complexity
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Innovative half-cover concept with a stronger construction and fewer parts in the cover assembly
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No hinge-related issues thanks to the new zinc-plated half-cover design
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Easier installation due to a more practical and streamlined construction
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Reduced delivery time through the use of semi-finished body stock for faster final customization
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Smaller minimum center-to-center distance, helping avoid special constructions and easing integration
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Improved user access to documentation via a new nameplate with QR code linking directly to the online IOM manual
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The valve connection is not rotatable, unlike the previous design. For the intended target application, however, this compromise supports cost efficiency and standardization.
Engineered for OEM Requirements in Boiler Manufacturing
Andrea Piazzolla, Technical Office and R&D Manager at KLINGER Italy, says, “The KRP25 project was developed with a specific target application in mind: steam service in very-low-pressure boiler systems. The product is designed in carbon steel and can be connected to the boiler via flange, or threaded tube connection, depending on the application requirement.”
For OEMs, this focus is important. It means the KRP25 is not a generic redesign, but a targeted engineering solution created around practical customer needs: competitive cost, reliable function, simplified assembly, and improved availability.
Contacts mentioned in the article:
Andrea Piazzolla, Technical Office and R&D Manager at KLINGER Italy
Peppino Sampietro, Managing Director of KLINGER Italy
A New Half-Cover Design with Fewer Components
At the heart of the KRP25 is its newly developed half-cover concept. “Traditional designs often rely on several components, such aswelded hinge elements and additional plates on R25/MR25 . KLINGER’s new design simplifies this structure,” emphasizes Peppino Sampietro, Managing Director of KLINGER Italy.
The KRP25 half-cover is made of laser-cut zinc-plated sheet metal. The two cover elements fit together through a small relative rotation and incorporate threads for the push screws. This solution removes the need for a welded hinge and eliminates the additional bottom plate used in previous designs.
The result is a more streamlined construction with fewer parts, easier handling, and improved robustness. By reducing the number of components, the KRP25 also supports more efficient manufacturing and installation.
| Feature | Existing R25 / MR25 Design | New KRP25 Design | Customer Benefit |
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| Overall concept | More complex design with additional components | Simplified design optimized for OEM applications | Lower cost and easier production |
| Cover design | External cover with welded hinge and additional bottom plate | New zinc-plated half-cover concept with simplified assembly | Stronger, cleaner, and more practical design |
| Number of parts | More components in the cover assembly | Fewer parts due to hinge and bottom plate elimination | Reduced complexity and easier handling |
| Installation | Functional, but more component-intensive | Easier to install thanks to the simplified structure | Reduced assembly effort |
| Valve connection | 360° rotatable connection | Side connection with rear, right or left connection from the body; not rotatable | Lower cost, with one technical limitation |
| Valve type / connection concept | D-DG type with integrated flange solution | AB12 valve with threaded blind flange and union connection | More cost-efficient configuration |
| Minimum CC distance | Given a visibility, larger minimum center-to-center distance | Given a visibility, reduced minimum CC distance | Easier integration, less need for special construction |
| Section IX example | Visibility: 318 mm Minimum CC: 415 mm | Visibility: 318 mm Minimum CC: 380 mm | More compact installation envelope |
| Delivery model | Less flexible body preparation | Semi-finished bodies can be stocked and finalized later | Shorter delivery times |
| Documentation access | Conventional nameplate | New nameplate with QR code to online IOM manual | Faster and easier access to product information |
The main disadvantage of the KRP25 compared with the previous design is the non-rotatable valve connection. However, this design choice is a key enabler of the product’s cost reduction and manufacturing efficiency.
Stronger Sealing Through Improved Bolt Force Distribution
The new half-cover is not only simpler. It also improves the way mechanical force is applied to the sealing area. Compared with the previous MR25 design, the bolt force works in a more efficient area for hydraulic sealing. Instead of acting primarily in the middle section, the force is applied more effectively at the side of the sealing area. This contributes to stable sealing performance and supports the reliability required in boiler applications.
Initial hydraulic testing of the first half-cover samples delivered excellent results, confirming the technical potential of the new design.
Reduced Cost Without Losing Focus on Reliability
Cost reduction was one of the key objectives of the KRP25 development. Several design decisions contribute to this goal. The simplified half-cover reduces part complexity. The removal of the hinge and bottom plate lowers manufacturing effort. The revised valve connection concept also supports a more cost-efficient instrument design.
For the KRP25, the valve connection is made by a side-side connection from the instrument body. This means the connection is not rotatable, unlike the MR25 solution with its 360° rotatable valve connection. This is the main limitation of the new design. However, for the intended OEM boiler applications, the simplified non-rotatable configuration offers a strong balance between cost efficiency, functionality, and production standardization.
Shorter Delivery Times Through Smarter Body Production
The KRP25 also supports reduced delivery times. The new body concept allows KLINGER Italy to work with semi-finished bodies held in stock at fixed lengths. These bodies can later be finished according to the customer-specific center-to-center distance.
This approach creates more flexibility in production. Instead of manufacturing each body completely from the beginning after receiving final customer dimensions, KLINGER can prepare standardized semi-finished components and complete the final machining at a later stage.
For OEM customers, this can mean faster response times, improved planning reliability, and better availability.
Smaller Center-to-Center Distances for Easier Integration
Another technical advantage of the KRP25 is the reduced minimum center-to-center distance. By removing the connection piece, the design allows smaller CC dimensions for each section.
For example, in section IX, the minimum center-to-center distance can be reduced from 415 mm in the R25/DG design to 380 mm with the KRP25. This reduction can help avoid special constructions, lower additional engineering effort, and simplify integration into boiler systems with limited installation space.
Digital Documentation via QR Code Nameplate
The new KRP25 nameplate includes a QR code that links directly to the online IOM manual. This gives users faster access to installation, operation, and maintenance documentation. For customers, this means less time searching for manuals and easier access to relevant product information at the point of use. For KLINGER, it supports a more digital, efficient, and service-oriented product experience.
KRP25: Practical Innovation for Competitive Boiler Applications
The KRP25 reflex level gauge demonstrates how focused engineering can create measurable value. By simplifying the cover design, reducing component complexity, shortening delivery potential, and improving installation flexibility, KLINGER provides OEM customers with a product designed for the realities of modern boiler manufacturing.
Technically sound, application-driven, and focused on customer value: The KRP25 is a clear example of KLINGER’s approach to innovation.
