When used effectively, radar level sensing can reduce waste, rework and downtime – all before larger investments are required.
Australian food and beverage manufacturers have endured years of volatility. While conditions may be steadier than last year, supply chains remain stretched and costs are still high. Recent analysis shows lead times increasing from 12 to 25 days in the latest quarter, with nearly 80 per cent of companies reporting moderate to large disruptions over the past five years.
At the same time, input costs continue to rise: energy and gas are up more than 50 per cent, sugar up 46 per cent, packaging up 30 per cent, and cocoa up about 200 per cent in less than two years.
In this environment, large capital projects can seem like the obvious solution. However, there is often a faster, lower-risk alternative – improving the accuracy of measurements that guide daily decision-making. Small errors in measurement can quickly scale into costly inefficiencies across operations.
Built for real-world conditions
One of the most effective areas to target is level control in tanks, totes and silos. When readings cannot be trusted because foam, condensation or agitation confuses sensors, the results are familiar: overfills, dry runs, wasted batches and unnecessary cleaning cycles.
Radar level sensing, a non-contact technology, is making a practical difference. Unlike ultrasonic devices or older probes, radar is unaffected by steam, spray, fluctuating temperatures or turbulent surfaces.
It provides stable readings in real-world conditions across dairies, breweries, sauce production and CIP skids. For those investing in food plant automation, the results are clear – fewer manual walk-ups to check levels, less reliance on safety margins, and tighter control of each fill and draw-down.
“When costs are moving targets and lead times are unpredictable, the most valuable upgrades are the ones operators feel immediately,” said Akmal Yang, product sales manager at ifm.
“Reliable, non-contact level makes every shift easier – no foam false alarms, no guessing through steam – and it unlocks small process wins that add up fast. Plants see the benefit long before a major automation project would even break ground.”
To help explain common use cases for radar level sensing, ifm has created a visual guide to its LW Radar solution. The infographic shows where the technology fits and why it works.
In a market still balancing disruption with recovery, stabilising core measurements is a practical first step for food and beverage producers. When used effectively, radar level sensing delivers measurable improvements in waste reduction, rework and uptime – all before larger investments are required.
Explore the LW Radar visual guide.