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From silo to site, VEGA’s radar sensors help eliminate delays and minimise waste – supporting stronger, more reliable supply chains for concrete and other construction materials.

When deliveries miss their window or trucks arrive empty-handed, the issue often starts upstream – not on the construction site, but at the batching plant or bulk material production facility where level data went wrong.

As construction supply chains grow more complex, the pressure to get materials in the right place at the right time has only intensified. Tony Scarborough, VEGA Australia’s NSW business development manager, sees measurement as the element that holds the system together – stable when it works, and costly when it doesn’t.

“Accurate measurement plays a critical role in improving outcomes on construction and infrastructure projects,” says Scarborough. “A good example is concrete batching. You’re dealing with raw materials – cement, sand, aggregate – each stored in separate silos and mixed to precise ratios. If the level measurements in those silos are off, the knock-on effects are immediate.”

One inaccurate reading can derail transport schedules, increase emissions and trigger a chain of disruptions.

“Imagine a truck arrives to collect a load of concrete, but the plant doesn’t have enough material to fill the order because the readings were wrong,” says Scarborough. “That truck’s made the trip, used fuel, added wear to the roads and has to turn around empty. It’s wasted time, energy and resources.”

The same can happen in reverse: a delivery arrives but can’t be unloaded because the receiving silo is already full. Either way, the result is delay, inefficiency and additional cost. And when the project waiting on those materials is running to a compressed timeline, the pressure builds fast.

“If deliveries aren’t arriving on time or the quantities are off, it can seriously impact a construction project,” says Scarborough. “Time is money, and delays like that can push a project back, potentially costing tens or even hundreds of thousands of dollars in lost time.”

Control at the source

While VEGA’s name might be more familiar in process industries, the company’s non-contact radar level sensors are increasingly playing a role in the building materials sector – concrete plants, bulk storage facilities, even wastewater sites that feed into civil construction programs.

“Where VEGA really comes into its own is in the bulk materials space, before anything even reaches the construction or infrastructure site,” says Scarborough. “That’s where accurate measurement makes the biggest difference. It helps make sure everything downstream runs smoothly.”

The sensors are designed to cope with conditions that typically interfere with measurement: dust, noise, internal build-up, foam or condensation. Where older systems like ultrasonic probes can drift or fail under these conditions, radar continues to provide consistent, repeatable data.

“VEGA’s sensors help reduce waste and product loss by delivering accurate, reliable level measurements, especially in tough conditions,” says Scarborough. “We typically use non-contact radar technology, which performs really well in environments that are dusty, noisy or have internal obstructions in the tank or silo.”

The company’s decades of work with radar sensors – more than 35 years – has focused not only on accuracy but on stability. That repeatability matters when readings are driving automated systems or triggering downstream actions.

“Operators can trust that what our sensors are showing is what’s actually there, preventing overfilling, underfilling or unnecessary deliveries – all of which reduce waste across the board,” says Scarborough.

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Fewer overflows, tighter control

While the role of level measurement is critical in materials batching, it’s equally important where containment and compliance are concerned. Tank overflows can result in environmental reports, regulatory penalties and operational downtime.

“We often get calls from customers after they’ve had a tank overflow, usually because they didn’t have proper level measurement in place,” says Scarborough.

“One customer of mine was recycling oil, and every time there was a spill, they were required to report it to the EPA. That meant not just operational disruption, but fines and a direct impact on their bottom line.”

The solution combined radar level sensors with remote monitoring. The team gained real-time visibility into tank status from off site, with alerts triggered as capacity neared. The same systems are now standard in sewage pumping stations.

“If that station overflows, you’re not just dealing with operational failure, you’ve got a serious environmental and public health issue,” he says. “That’s why our sensors are classified as critical in these applications.”

Clean data, leaner systems

Reliable level data also contributes to more efficient energy use by giving control systems stable inputs. Unstable readings create fluctuation, forcing pumps and systems to cycle unnecessarily.

“When it comes to energy efficiency, it really comes down to accuracy, and just as importantly, repeatability. Some processes don’t need ultra-fine accuracy to the decimal point. In certain applications, a 5 or 10 per cent margin is acceptable. What matters most is that the measurement is consistent,” says Scarborough.

“When the data is dependable, the control system can operate more efficiently. There’s no second-guessing, no overcorrection and no wasted energy adjusting for bad data.”

Connecting plant and process

To support tighter coordination across plant and site operations, VEGA’s sensors are built for full integration into modern control infrastructure. That includes conventional signal protocols as well as newer industrial Ethernet standards such as Advanced Physical Layer (APL).

“We’re expanding the range of outputs we offer,” says Scarborough. “It’s about making sure our products are compatible with as many platforms as possible, so customers can use the data where it matters most.”

The company’s flagship radar device, the VEGAPULS 6X, released in 2022, reflects that philosophy: simplified configuration, robust signal processing and certification for use in safety-critical environments.

Sustainability in practice

While much of VEGA’s contribution to sustainability comes from improving customer processes, the company is also aligning its own operations with long-term environmental targets.

“There’s a global sustainability campaign underway across the company right now,” says Scarborough. “Each regional office is actively tracking and reporting efforts to reduce environmental impact.”

That includes warehouse and office practices, freight considerations and product design decisions.

“We’re designing for reliability and longevity,” he says. “That’s part of the sustainability equation too.”

Why early adopters win

Scarborough points to early adoption as a key advantage. He compares it to the industry’s past shift from contact probes to ultrasonic systems, now playing out again as operators move to radar.

“Customers who adopt radar early often see results overnight,” he says. “In some applications, the improvement in measurement stability and reliability is dramatic. And again, those benefits – less waste, more uptime, fewer manual checks – feed directly into sustainability, even if it’s not labelled as such.”

For construction teams, that means fewer hold-ups, smarter supply chains and materials that show up when they should.

On show at Converge Expo 2025

Visitors to this year’s Converge Expo will be able to see the VEGAPULS 6X up close, alongside VEGA’s full radar range and integration options for building materials, wastewater and cement industries.

“It will be one of our largest displays yet. Interactive zones, giveaways, and a range of engaging features to create a dynamic experience for attendees,” says Scarborough. “We look forward to connecting with industry and highlighting how accurate measurement supports strong, sustainable outcomes.”