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PrecisionFill | Automated Bulk Material Filling | Zadar Labs

PrecisionFill

Automated Bulk Material Filling

Load faster, fill more evenly, and reduce dependence on operator skill.

Radar-guided material placement that measures the surface as it builds, finds the available space, and steers the fill automatically — in the dust and darkness where optical sensors fail completely.

Grain carts & truck loading · Coal, ore and aggregate
Adapts to different materials, receiving containers and equipment

RADAR SPOUT TARGET FILL PROFILE MEASURED SURFACE NEXT FILL LOCATION DUST · SEEN THROUGH MEASURE · FIND SPACE · STEER · RE-MEASURE · CONTINUOUSLY
Measured surface against target profile — the system steers the fill toward where space remains.

How it works

Intelligently fill containers with bulk material in real time.

PrecisionFill combines Zadar's imaging radar technology with radar-based flow and fill level measurement algorithms to monitor the material surface, identify available space, and adjust fill location automatically toward the desired fill profile.

As material accumulates, the system updates its measurements and automatically guides the equipment's loading controls. Radar provides surface information in dusty, dirty, and dark environments where cameras and optical sensors fail completely.

See the sensors behind it
CLOSED-LOOP CONTROL 01 · MEASURE SURFACE & FLOW 02 · FIND SPACE VS TARGET PROFILE 03 · STEER MACHINE CONTROLS 04 · PREDICT SLOW · STOP · CONTAIN CONTINUOUS NO OPERATOR INPUT
The loop runs continuously as material accumulates — no operator input required.

Benefits

Load material faster and reduce loss, without experienced operators.

01

Reduce Operator Workload

Automate the spout-pointing process that otherwise requires high operator attention and skill.

02

Shorten Loading Times

Reduce manual interruptions and load at maximum flow rates without error.

03

Improve Fill Evenness

Direct material toward available space and eliminate uneven surfaces.

04

Use Available Capacity Completely

Fill toward a defined profile while reducing the risk of spillage and overfilling.

05

Reduce Loss

A predictive filling algorithm slows and stops filling, keeping filled material inside target zones.

06

Reliable in Poor Conditions

Radar technology works even in highly dusty or visually obscured environments.

Get started

Bring automated filling to your system.

From grain carts and truck loading to coal, ore, and aggregate handling, PrecisionFill's sensing and control approach can be adapted to different materials, receiving containers, and equipment.

Zadar works with equipment manufacturers and integrators to configure the surface measurement, filling strategy, and connection to machine controls for each application on a customized basis.

 Frequently Asked Questions