Smarter Sludge Monitoring with IIoT Radars

Historically, tank levels were monitored manually. This method, while serviceable at times, often lacked consistency and could be prone to error or delay. Missed or poorly timed sludge collections were a common issue, resulting in disrupted thickening schedules and inefficient plant performance. The outcome? More downtime, more reactive work, and less predictability.

Now, Anglian Water uses advanced radar level sensors — specifically, the VEGAPULS Air 41 and Air 42 — to monitor levels in sludge holding tanks. These units are mounted above the tanks and require little to no supporting infrastructure. Designed for distances of 1 to 5 metres, they offer reliable and precise readings even in outdoor settings where ambient and slightly elevated process temperatures are common. The setup is ideal for the often-harsh and exposed conditions encountered across these isolated sites.

The radar-based approach was selected for several compelling reasons. First and foremost, installation was quick and simple, requiring minimal groundwork. Just as crucially, the sensors provided dependable, high-quality data — even under the harshest environmental conditions. Perhaps most valuable, however, was their ability to transmit data directly to a central cloud platform. This enabled real-time insights and visualisations accessible from any location, empowering teams to make decisions faster and with more confidence.

In areas where ATEX certification is required, the VEGAPULS Air 42 stood out as the sensor of choice for the team. Both models are currently installed on brackets above the tanks and are operating successfully in remote, open-air environments. These locations often lack strong mobile signal and on-site infrastructure, yet the sensors have proven capable of delivering accurate data consistently.

After successful pilot trials in 2022 and 2023, Anglian Water began a broader rollout of the technology in April 2024 and continues to do so today. Installation across sites has been smooth, aided by dedicated training sessions for on-site teams. With the support of the VEGA Tools App, teams were guided through the entire setup process, including how to effectively back-up and restore critical sensor data. Feedback from the team described the interface and guidance as intuitive, with the app contributing to a confident and hassle-free deployment.

As these are battery-powered IIoT devices, there was no need to invest in expensive, large-scale infrastructure at each tank site. The utility could instead roll out a reliable monitoring solution quickly and cost-effectively. This approach has not only reduced operational disruption but has significantly improved the planning and execution of sludge thickening and transport schedules.

The adoption of radar level sensors has given Anglian Water greater control and visibility across its network — helping it to reduce inefficiencies, plan smarter, and move closer to its goal of turning waste into something valuable.