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

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.

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 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.”

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.

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.

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.

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.

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.