Bench Talk

Image Source: Banner Engineering

As packages, parcels, and other products move down a conveyor line, automated sorting systems play a critical role in directing each item to its correct destination. These systems rely on sensors, controls, and mechanical handling equipment to efficiently route products into designated bulk containers such as bins, carts, cages, totes, Gaylord boxes, or basket trucks. Once these containers reach capacity, they must be removed and replaced for the system to continue operating without interruption. Whether retrieval is handled by a human operator or a robotic system, accurately determining when a container is full is essential to maintaining efficiency, safety, and throughput.

Measuring fill levels in bulk containers, however, is far from simple. In material handling and logistics environments, products rarely stack neatly. Packages vary widely in size, shape, weight, and packaging materials, leading to uneven piles with peaks, valleys, voids, and shifting surfaces. Items may land at awkward angles, slide as additional products accumulate, or cluster toward one side of a container rather than distribute evenly. Scrap material exiting a chute may pile up in a single area, leaving large sections of the container empty while still reaching an unacceptable fill height in one corner. These inconsistencies make traditional point-based or mechanical fill-level measurement methods unreliable. Banner Engineering’s multiple sensing solutions address these challenges by accurately monitoring fill levels across entire bulk containers, even in the most demanding applications.

Figure 1: The ZMX sensor detects the volume fill percentage and peak height of packages. (Source: Banner Engineering)

ZMX 3D Measurement Sensor: A Comprehensive Single-Sensor Solution

The ZMX 3D Measurement Sensor from Banner Engineering is an ideal choice for applications that require accurate, full-container fill-level monitoring using a single device. By capturing thousands of laser measurement points, the ZMX provides a highly detailed three-dimensional view of the container’s contents. Rather than simply measuring the tallest point within a bin, the sensor can calculate the overall volume and fill percentage across a defined Region of Interest (ROI). This allows operators to make more informed decisions based on actual container utilisation instead of relying on peak height alone.

Because the ZMX measures across a wide area, one sensor is sufficient to monitor an entire container—whether it is a bin, rolling cage, bag, or Gaylord box. Its dense sensing array, consisting of tens of thousands of pixels, delivers precise measurements and a detailed representation of material distribution throughout the container. This high resolution also allows for accurate ROI configuration, including monitoring right up to the edges of a bin where buildup often goes unnoticed by less sophisticated sensors.

With a sensing range of up to 2.5 meters and a wide 60° × 45° three-dimensional field of view, the ZMX can detect fill height variations regardless of object shape, size, orientation, or color. These capabilities help ensure containers are filled to a consistent volume, prevent overfilling, track fill rates, and optimise conveyor or sorter speeds to improve overall system performance.

Figure 2: Banner’s 3D Configuration Software shows the ZMX viewpoint in real time. (Source: Banner Engineering)

Setup and integration are streamlined using Banner’s 3D Configuration Software. After mounting the sensor above the container and connecting it to power and a PC, operators can view real-time visualisations of what the sensor detects. This live feedback makes it easy to configure ROIs, thresholds, and outputs. Once the configuration is complete, the ZMX operates independently as a self-contained device. Integrated logic eliminates the need for a separate controller or PC during operation, as well as external lighting. Ethernet connectivity and on-the-fly configuration further enhance the sensor’s versatility in modern automated systems.

Figure 3: K50Z detects two different fill levels in a hopper. (Source: Banner Engineering)

K50Z Multipoint Sensor: Cost-Effective and Flexible Measurement

For applications that require effective fill detection at a lower cost, the K50Z Multipoint Sensor provides a powerful alternative. Like the ZMX, the K50Z uses 3D time-of-flight technology to detect objects as they accumulate across a wide area. Instead of thousands of points, it utilises an 8 × 8 pixel array with 64 measurement points, allowing it to measure both the nearest distance and the average distance to objects within its field of view.

The K50Z features a 45° × 45° beam angle and a two-meter sensing range, making it well-suited for monitoring the entire target area of a basket truck or a similar container. One of its most valuable features is the ability to configure two independent outputs. These outputs can be assigned to separate zones within the same container or used to monitor two different containers simultaneously, reducing the need for additional sensors in automated sorting systems.

Figure 4: Banner Measurement Software shows the K50Z with two independently configured outputs monitoring two separate areas. (Source: Banner Engineering)

The configuration is handled through Banner’s Measurement Sensor Software, which provides a real-time visual representation of the sensor’s detection area. This intuitive interface allows operators to quickly make both coarse adjustments and fine-tuned changes, ensuring reliable detection without complex programming.

Figure 5: The Q20-2 detects the fill level of packages in a cart. (Source: Banner Engineering)

Q20-2 Series Laser Sensors: Versatile and Economical Point Measurement

The Q20-2 Series Laser Measurement Sensors offer a more traditional yet highly versatile approach to fill-level detection. These sensors use an infrared laser with a larger spot size than typical single-point laser sensors, allowing them to better handle uneven surfaces with peaks and valleys. Like Banner’s 3D sensors, the Q20-2 can reliably detect targets of varying colors and materials, including dark, shiny, or clear objects.

However, unlike the 3D time-of-flight sensors, the Q20-2 measures a single point rather than an entire area. As a result, multiple sensors may be required to monitor different sections of a container. However, for applications where monitoring one critical point is sufficient, the Q20-2 delivers high performance at a lower overall cost, making it an excellent option for simpler or budget-conscious installations.

Figure 6: ZMX measures bin fill level with visible status using a WLS15 strip light (Source: Banner Engineering)

Visual Indication: Turning Data into Action

Accurately measuring fill levels is only part of the solution. Clearly communicating these measurements to operators is equally important in automated sorting environments. Visual indication bridges the gap between sensor data and actionable insight.

Banner offers a wide range of visual indication solutions, from compact single-color indicators to large multicolor and segmented displays, with the lights easily programmed via Banner’s Pro Editor software. Tower lights, such as the TL70 Pro Series, can be configured to display container status using different colors and animations, clearly signaling when bins require attention or need to be emptied.

For the most detailed visualisation, programmable multicolor strip lights such as the WLS15 and WLS27 Pro Series provide a clear, intuitive representation of fill levels in real time. These lights translate sensor data into color gradients that reflect container status. For example, an empty basket truck might display a solid blue. As boxes accumulate, a green light rises from the bottom, transitioning to yellow as the container passes the halfway point. When the container nears full capacity, the light turns red and can flash to warn of potential overfill. This dynamic, easy-to-understand feedback allows operators to respond quickly and keep systems running smoothly.

Conclusion

Automated fill-level monitoring solutions bring clarity and control to one of the most unpredictable parts of material handling and logistics operations: how products actually accumulate inside bulk containers. Because parcels, packages, and scrap materials rarely stack evenly, relying on simple height detection or manual checks often leads to overfilled containers, wasted capacity, system interruptions, and safety risks. Advanced sensing solutions that can interpret uneven surfaces, shifting loads, and mixed materials can provide a far more accurate understanding of true container utilisation.

The ability to measure fill levels reliably across all or part of a container allows systems to operate closer to their optimal limits without crossing them. Containers can be filled more consistently, sorter speeds can be better controlled, and changeover timing becomes predictable rather than reactive. This directly improves throughput while reducing downtime caused by jams, spills, or premature container swaps. Just as importantly, the flexibility of the sensing approaches ensures that both simple and highly complex applications can be addressed efficiently, without overengineering or unnecessary cost.

When combined with a clear visual indication, fill-level data becomes immediate, actionable information. Operators no longer need to interpret raw measurements or guess container status; instead, they can see at a glance when attention is required. This reduces cognitive load, minimises errors, and supports safer, better organised work environments. Overall, accurate fill-level monitoring enables smoother workflows, higher system reliability, improved safety, and better use of available space—key advantages for any operation focused on maintaining high performance in fast-paced, automated logistics environments.