Modern radar level measurement for greater certainty in the silo park

Level measurement as the foundation of modern bulk material logistics – greater efficiency and safety at Zwijndrecht silo park

Greater efficiency and safety thanks to modern level measurement at the Zwijndrecht silo park

In the building materials industry, reliable inventory data is what determines profitability, delivery capability and certain outcomes. Companies that store and handle large quantities of cement, fly ash or limestone flour need precise level measurement that provides reliable information at all times – regardless of dust, temperature fluctuations or mechanical stresses.

This was precisely the challenge facing Cementbouw BV in Zwijndrecht, the Netherlands. The company, a part of the international CRH Group, operates a silo park there with thirteen large silos for various mineral raw materials. The goal was to replace the existing combination of traditional inventory management and conventional level gauges with a modern radar level measuring system.

The result: Significantly higher process reliability, better utilisation of silos and a new level of remote monitoring – achieved with VEGAPULS 6X radar level stransmitters and the VEGA PLICSMOBILE T81 mobile communication unit.

Why conventional level measurement technology is now reaching its limits

Many plants still rely on mechanical or simple electronic level gauges, supplemented by manual calculations in spreadsheets or ERP systems. While this approach is traditional, it has its weaknesses:

No current level data is immediately available
Safety reserves must still be maintained
High level of manual work required
Increased risk of overfilling or material shortages

Cementbouw used such a system for a long time. VEGA level sensors reliably prevented overfilling, while inventory levels were tracked in Excel files. However, with increasing demands for efficiency and transparency, there was a growing desire to use digital, non-contact level measurement, which delivers up to date, precise information at all times.

VEGAPULS 6X: State-of-the-art radar level measurement for smart processes

Thanks to the VEGAPULS 6X radar transmitters, the levels in the silos are measured contactlessly, precisely, independently of dust or bulk material movements and with a high update rate, eliminating the need for manual checks – for greater efficiency and process certainty.

VEGAPULS 6X is a universal radar level transmitter for liquids and bulk solids. In Zwijndrecht, it was mounted on a swivel flange, allowing the radar beam to be optimally directed to the silo outlet. Installation and commissioning are remarkably simple. Rob Smulders, Business Development Manager at VEGA, reports:

“Our technician installed all the instruments on the silos and commissioned them in a single day. All you have to do is align the sensor with the silo outlet, enter the silo’s linearisation data into the sensor – and you’re done.”

Key advantages of radar level measurement:

Non-contact measurement without cable wear
High measurement accuracy even in dusty conditions
Level data update in real time
Independent of material properties
Maintenance free operation

For Cementbouw, this means: Exact level data – even during ship loading and unloading.
Arjan van de Rest, senior staff member, explains:

“Radar level measurement is significantly more precise, delivers level updates at very short intervals during unloading, and allows readout at any remote location.”

More efficient inventory management and logistics thanks to precise, real-time level data

The raw materials are stored in large silos in Zwijndrecht – now precisely monitored by VEGAPULS 6X sensors.

With new level measurement technology, it means the planning department, can continuosly monitor how much material is actually available in each silo and track how the inventory is evolving.

This brings multiple benefits:

Optimised planning of deliveries by ship and lorry
Improved coordination with freight forwarders and captains
Maximum utilisation of existing silo capacity
Reduced safety reserves

Instead of ”leaving space” as a precautionary measure, Cementbouw can now say exactly how much material can still be loaded into the silos. This allows storage and transport capacities to be optimally utilised – a clear competitive advantage.

“In the past, we had no data transparency and were constantly forced to plan in safety reserves. Now we can tell the captain: ‘Go ahead and unload another 50 tonnes, because, thanks to the radar sensor, we know that we’re only 80 per cent full.’ This allows us to make much better use of our actual capacity.”

Rolf Rutten, manager of the silo park, describes the advantages of the new level measurement technology:

Greater security thanks to state-of-the-art level sensors

Besides efficiency, the CRH Group focuses on one thing above all else: Safety for people, equipment and the environment. Overfilling silos can lead to material spillage, dust pollution, structural damage and risk to personnel. Precise level measurement with radar significantly reduces this risk. The sensors deliver current measured values continuously, enabling early detection of critical conditions.

VEGA PLICSMOBILE T81: Level data directly to the cloud

With VEGA Inventory System (VIS), captains are able to read out the silo level practically live during unloading.

Since there is no central control network in the silo complex, Cementbouw is using the compact VEGA PLICSMOBILE T81 radio unit. The level data is transmitted to the radio unit, via the HART multidrop protocol, and then sent directly to the cloud via wireless network. VEGA Inventory System (VIS) makes clear and concise data readily available – also via app. Captains can monitor the level virtually in real-time during unloading and immediately see how much material has already been transferred.

Scalable solution for Cementbouw customers

Raw materials are usually delivered by ship. The modern level instrumentation from VEGA used at Cementbouw makes it easier to plan deliveries and optimise ship loading and unloading.

The combination of VEGAPULS 6X and PLICSMOBILE T81 is so impressive that Cementbouw plans to offer this concept to its customers as well. Especially large customers with high turnover benefit from:

Independent level measurement
Transparent inventory overview
Optimised deliveries
Additional service by Cementbouw

This creates a digital ecosystem based on level measuring instruments, making supply chains more efficient and stable.

Conclusion: Radar level measurement: the key to the future

The project in Zwijndrecht impressively demonstrates how modern radar level measurement is replacing traditional methods and setting new standards. With precise level measurements, smart cloud connectivity and high operational reliability, Cementbouw is laying the foundation for future-proof bulk material logistics.
Investing in reliable level measurement technology today pays off in terms of:

Transparency
Security
Efficiency
Planning certainty

And results in a decisive competitive advantage.

Related industries

Building materials

Robust instruments for use in the harsh environments typical of the building materials and aggregates sector.

To the industry

Cement

Reliable instrumentation for all processes: from the quarry to the cement storage facility.

To the industry

Products

VEGAPULS 6X

PLICSMOBILE T81

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Radar level measurement in the silo park: How Cementbouw is revolutionising processes with VEGAPULS 6X and PLICSMOBILE T81