Project Details

On large-scale site development projects, accuracy isn’t optional – it’s essential. For Alan Payne, project lead at The Kearney Companies, based in Riverview, Florida, the difference between guessing and knowing has had a major financial and operational impact. After nearly four decades with the company, Alan has seen plenty of industry change, but few innovations have delivered as much value as Loadscan’s Load Volume Scanner (LVS) system.

A growing need for volume accuracy

Founded by Wes Kearney in 1956 with just a single bulldozer, The Kearney Companies has grown into one of West Central Florida’s leading site development contractors, employing more than 400 people and handling a wide range of subdivision, apartment complex, and commercial developments. With every project, a major part of the operation comes down to one thing: dirt – buying it, selling it, moving it, and measuring it.

Historically, fill material has been purchased by the cubic yard, but without a reliable volumetric measurement system in place, Alan recalls the company being routinely shortchanged.

“Before we were getting ripped off so bad; we were paying for 18 yards, which is just a guess,” he explains. “And we discovered through trial and error, when loads looked light, by levelling them and measuring the truck body to see the volume, we were getting between 12 and 15 yards.” “We figured there had to be a better solution than that because we were getting ripped off big time.”

The turning point came with the introduction of Loadscan’s LVS-3TMM Load Volume Scanners, which provide a precise volumetric measurement of every truckload through its LiDAR laser-based scanners. “So, we found that the Loadscan was what we’re looking for,” Alan says. “We had seen them around and we knew of them and what they did.”

Today, Kearney Companies operates three of these trailer-mounted units across various jobs sites, dirt pits and other locations.

Fair pay and confidence in every load

The LVS system has changed the game by shifting pay-for-load guesswork into data-driven accuracy, which can then be used to avoid difficult conversations with pit owners or other suppliers.

“The critical thing is we’re now paying for what we get, averaging about 16.5 yards per truck, which is pretty close to the legal weight for most trucks,” Alan says.

This clarity in measurement has also eliminated long-standing disputes with suppliers. With ticket-based systems, disputes over truck volumes were common and often difficult to resolve. But with Loadscan, the data is irrefutable.

“Any dispute would be with a supplier of the material, but now there’s no dispute with them because we’re paying them for exactly what we’re getting. “If they don’t have their own volumetric scanner, we have an agreement in place that we’ll send the vendor a report the next morning for the day before, of all the loads that we hauled from their location,” Alan says. “The vendor checks the number of load tickets they provided to our trucks for that day against the number of loads we received on the dump end. “If a load or two didn’t get scanned, we’ll tell them what the average is for the day, and they’ll bill us those extra loads at the daily average.”

The scanner also gets used internally on jobs where material is being moved within a job site. In these cases, it’s not about verifying deliveries, it’s about checking the performance of Kearney’s own loader operators.

“We’ll set the scanner up when we’re moving material on site with dump trucks, just to make sure that our loader operators are loading a full 18 yards”, he says.

“Weight doesn’t matter on a job site with dump trucks, and we want to make sure that our loader operators are loading correctly, so we’ll just have the scanner on site where we’re monitoring our own loader operators.”

Massive return on investment

The financial impact of adopting Loadscan has been undeniable. Alan estimates each scanner has scanned an average of 500,000yd³, and he points out that if the company had continued paying for 18yd³ per load (instead of the measured 16.5yd³), they’d have overpaid by around 50,000yd³ per scanner. “At five dollars per yard, that’s a $250,000 difference,” he says. “So, each scanner has paid for itself at least three times over.”

But the return isn’t just financial – it’s operational. The scanners allow Kearney to optimise haul schedules, eliminate unnecessary loads, and streamline project billing. What once involved levelling truck loads manually or performing rough measurements is now handled automatically, consistently, and accurately.

Strong service and seamless integration

Alan describes the LVS system as straightforward, reliable and simple to use. “We’ve had no real issues but, when we’ve needed support, the local dealer here in Florida has been fantastic.”

He also notes that even Loadscan’s New Zealand-based support team is responsive, despite the time difference. “Even if we have to reach out overseas to New Zealand, their response has been almost immediate.”

Building trust with clients and suppliers

One of the most significant outcomes of adopting LVS technology has been the increased trust and collaboration between The Kearney Companies and its suppliers, and even with its clients. In several cases, project owners have opted to use Kearney’s scan data to validate the quantity of material delivered and placed, knowing it reflects true volumes, not ticket-based estimates.

“One of the interesting things that’s happened, is that some of our clients will now ask us to bill them for the fill material and placement off our daily Load Scanner volumes, because they know that they were not getting what they were paying for before,” Alan says.
“We’ve done jobs where we’ll put the Load Scanner on site, and we’ll give our client a report every day of how many yards were hauled in there, and they will pay us for the material and the placing off that Loadscan quantity.”

Practical, versatile, and proven

The flexibility of the Loadscan system means it’s used in a variety of ways across Kearney’s operations—from verifying third-party deliveries to auditing internal performance. In one example, Alan describes how Kearney’s in-house mulch production, made from chipped trees, is also measured with LVS before resale to manufacturers.

Whether buying, selling, or simply moving material, the scanner ensures that everyone knows exactly what’s in the truck. “It’s not a guessing game anymore,” he says. “You pay for what you get and, if you’re on the selling side, you can show your customer that they’re getting what they’ve paid for.”

A smarter way to do business

Alan says the adoption of Loadscan’s Load Volume Scanners has not only considerably reduced waste and improved billing accuracy, it has fundamentally changed the way The Kearney Companies thinks about material movement. “Before Loadscan, it was always a guessing game,” Alan says. “Now, we’re not guessing. We’re managing. We’re measuring. And we’re making better decisions every day because of it.”

With three scanners in operation and over 1.5 million cubic yards measured to date, The Kearney Companies has no intention of going back to the old ways of doing things. And with results like these, it’s easy to see why.

Project Details

Pro Bark Industries, located in Plaistow, New Hampshire, is a leading producer of mulch, compost, soil, and other organic products.

The operation is just one of the diverse Mayer group of companies and produces around 200,000 yards of material each year, servicing a wide variety of customers, including large garden centres, landscaping companies, and even homeowners who need bulk products.

Pro Bark operations manager, Rory Holmes, says Loadscan’s Load Volume Scanner (LVS) has streamlined their processes, improved accuracy, and significantly increased efficiency to the way the business operates.

The challenge of accurate measurement

At Pro Bark Industries, accuracy in measuring outbound material is critical. With such a high volume of material leaving the yard annually, precise volume measurements are critical to ensure accuracy.

“We normally don’t scan in, because it’s not as important to for us to count the yardage as it comes in because it gets sorted out into different products,” Rory explains. “For us, it’s really important outbound to know what the yardages are,”

Before implementing Loadscan, Pro Bark relied on a manual process for measuring material volume. Loader operators would estimate the amount of material by counting the number of loader bucket scoops and multiplying by the known yardage of the bucket, typically 12 cubic yards. However, this system was far from perfect.

“You’re kind of guesstimating; the loader operators basically just count buckets. They know the yardage of the machine bucket and then they go from there. But it’s definitely not ideal to do it that way because there’s quite a bit of guesswork that that goes into that way of doing it,” Rory admits.

This process was prone to errors. Depending on how the material was scooped or how consistent the loader operator was, the volume could vary – sometimes significantly.

“A loader bucket is built to a certain amount of cubic yards. We usually run 12-yard buckets but, depending on how you dig into a pile or whatever happens if you shake out too much or you don’t shake out enough, you might you might be at 10 yards or you might be at 15 yards,” Rory explains.

Over time, this led to inconsistencies in volume and, ultimately, could affect both customer satisfaction and inventory management.

Enter Loadscan: A revolution for Pro Bark Industries

In the spring of 2024, Pro Bark decided to address this issue by installing the Loadscan LVS. The system immediately transformed how they handled volume measurement.

“We installed it for this previous mulch season, which would be in the spring for us,” says Rory.

Loadscan’s system uses LIDAR laser technology to scan each truckload as it exits the yard, providing precise volume measurements in real time. For Pro Bark, this meant no more reliance on visual estimates or rough calculations. The system provides an instant, accurate reading of the volume in each load, removing much of the guesswork from the process.

“If we have a bigger customer that’s in here a lot, then we’ll have them scan into the Loadscan and that way, when they’re outbound, they can scan out and then they’ll be in our system as a customer,” Rory explains.

“What’s nice about Loadscan is that it’s so easy to use. It’s user-friendly for the truck drivers, so they just come into the office, put in their information and then they’re on their way.”

This method ensures that Pro Bark can track all outgoing shipments, accurately record the volume of each load, and keep a reliable inventory.

Real-time monitoring for better control

One of the most valuable aspects of Loadscan for Pro Bark has been its real-time monitoring capabilities. Rory now has the ability to keep track of the volume of every load that leaves the yard, from his office.

“It’s nice because being able to have the [MyScanner] cloud app that’s on the computer, I can see every load that comes in, and I can keep up with it as the day progresses,” he explains.

“For example, if I notice that there’s something off with the loader operator loading trucks, and if he’s loading light or heavy, then I can make that phone call and let them know to lighten up or to put more on,” Rory says.

“Also, if you have multiple scanners, you can — on your computer in your office — remotely look into your scanners. So it’s just really convenient to use… and it’s also very accurate.”

This enables him to catch any discrepancies as soon as they occur.

This has helped Pro Bark dial in their volumes for each load and fine-tune the process to ensure that they are consistently hitting their targets.

“I think we’ve really been able to get our average yardage on every load. We’ve really been able to dial that in to get it to where we want it to be, so we’re not giving away too much and we’re not shorting people,” Rory continues.

This precision has been critical to maintaining both Pro Bark’s profitability and satisfaction for its customers.

Preventing overloads and underloads

The LVS system has been instrumental in preventing both overloads and underloads. By providing precise volume data, Loadscan ensures that each truck is filled with the correct amount of material, reducing the risk of delivering too much or too little. Rory notes that accurately measuring loads is particularly important for ensuring fairness in customer transactions:

“You obviously don’t want to short people…or give it away for free either,” he says.

In the past, the manual system meant that occasional inconsistencies could lead to situations where material was lost, or customers weren’t receiving the volume they paid for.

“It adds up at the end of the season, for sure,” Rory points out.

Since the installation of the Loadscan LVS, those discrepancies have been virtually eliminated.

Scalability and industry reputation

Although Pro Bark is still relatively new to using Loadscan, Rory is already seeing the benefits in terms of operational efficiency and customer satisfaction. The system has integrated seamlessly into their day-to-day operations, and they are starting to gather useful data that will inform their long-term planning.

“At the end of the year, we’ll take a hard look at the numbers,” says Rory. “It’s also a great way to make sure that you’re matching the hard numbers to what your projections are.

“If you’re purchasing material, and if that’s getting scanned in, then you want to make sure that you’re not getting shorted and that everything’s adding up, so it’s a good way to failsafe your operations as far as taking in material and then sending it out, so it’s a good way to double check things.

The benefits of Loadscan in handling material variability

Another challenge Pro Bark faces is the variation in material moisture content, which can affect the weight of certain products. Materials like soil can be particularly finicky, as excess moisture can result in varying weights, which is where Loadscan’s LVS provides a clear advantage by measuring volume rather than weight, which eliminates the complications that arise from varying moisture content.

The accuracy of Loadscan’s volume measurements, unaffected by moisture content, has made it an ideal solution for Pro Bark’s operations.

Collaborative industry environment

Pro Bark’s relationships with larger local companies in the bark, mulch and compost industries have also been strengthened by the use of the Loadscan LVS. As Rory explains, many of the other industry players, have a strong history with Loadscan, and rely on the system to track their material volumes.

Loadscan’s reputation in the industry, built on success stories around the reliability and accuracy of the Loadscan system, helped influence Pro Bark’s decision to invest in the technology.

“It was a word-of-mouth situation,” Rory says. “The bigger players have several of them at all their locations and, knowing how much these other companies rely on them and use them and don’t have any issues with it.”

This has created an open, collaborative environment where companies can share knowledge, resources and even customers.

“We tend to play nice with everyone because some companies offer products that we don’t offer,” he explains. “Rather than tell a customer ‘we don’t sell that, sorry I can’t help you’, it’s way more beneficial to make a call and say ‘hey, we have a customer that’s looking for this. We’re just going to resell it to them’, and they’re fine with that.”

A valuable investment for Pro Bark Industries

Rory believes that Loadscan has had a transformative effect on Pro Bark Industries. By providing precise, real-time volume measurements, Loadscan has eliminated the guesswork that previously led to inconsistencies in outbound shipments. The system has not only improved operational efficiency but also provided Pro Bark with the tools to maintain strong relationships with their customers and ensure that each load is accurate.

As Rory sums up, “For something that’s as sophisticated as it is, it’s really user-friendly. There’s no contact. It’s really easy to set up and use as far as the setup goes and how you adjust it.

“It’s just been a big help, for sure.”

Project Details

The ECON La Cantera quarry in El Salvador is one of the largest aggregate quarries in the country.

The quarry, situated just outside the nation’s capital San Salvador, plays a crucial role in providing aggregates for infrastructure and construction projects across the region. Producing a variety of aggregates essential for development, La Cantera maintains high standards of quality and efficiency. As it has developed and grown, the quarry has continually sought ways to enhance processes and improve production efficiency, in its operations. The introduction of Loadscan’s Conveyor Volume Scanner (CVS) has significantly impacted their operations.

At the La Cantera facility, the quarry extracts approximately 3,000 cubic meters (m³) of rock daily, processing it through a range of separate crusher lines to produce various aggregate products. To manage this large-scale production, the quarry relies on several systems and technologies to maintain smooth operations. A transformative investment made recently was the installation of a number of Loadscan CVS units across all crushers, providing a number of key benefits that have revolutionized operations.

Improved accuracy in production reporting

Before the Loadscan CVS, production tracking was based on counting truck trips, which was neither precise nor efficient. The quarry estimated the production of each aggregate type by truck trips and percentages established over time. However, this method often led to inaccuracies and lacked real-time precision.
With the Loadscan CVS, production reporting has become much more accurate. The system provides precise volume measurements of extracted material, and materials throughout the day. This real-time data has simplified reporting, increased accuracy, and enabled more informed decisions regarding resource allocation.

Tracking downtime and identifying production bottlenecks

Previously, La Cantera struggled to track plant downtime accurately. Estimating idle periods was time-consuming and often imprecise. Understanding the duration of production stops is essential to optimizing efficiency.

Now, with the Loadscan CVS, the quarry can precisely track downtime, enabling investigation into the reasons for the production stops.  The system logs downtime events, offering insights into bottlenecks or issues within the production process. Whether due to maintenance, truck delays, or other factors, the team can immediately identify and address inefficiencies, reducing downtime and boosting overall productivity.

Real-time monitoring of equipment efficiency

Before the Loadscan CVS, equipment efficiency assessments often occurred too late to address performance issues promptly. This delayed response contributed to unnecessary downtime and inefficient resource use.

With the Loadscan CVS, the quarry can now monitor equipment efficiency on a real-time basis. This immediate visibility allows corrective actions for underperforming equipment or deviations in the production process. For example, if a crusher operates below optimal capacity, or if a truck delays its return, the team can adjust operations right away, leading to better equipment usage and reduced downtime.

Managing stock volumes and preventing material shortages

La Cantera produces a broad range of aggregates, receiving around 200 trucks daily that are loaded with materials across 10 different product options. Accurately understanding stock volumes is vital to meeting customer demands.

Before the Loadscan CVS, stock measurements occurred infrequently, with discrepancies sometimes requiring inventory adjustments that could lead to shortages or imbalances.

With the Loadscan CVS, the quarry now monitors stock volumes in real-time. If an aggregate type is running low, the system helps quickly reassign resources—such as trucks and crushers—ensuring a consistent supply of material for each product. This proactive approach has made inventory management more responsive, reducing the risk of material shortages.

Commitment to sustainability and technology

La Cantera is committed not only to delivering high-quality aggregates but also to sustainability and innovation. The quarry operates a solar farm with more than 4,000 solar panels, generating enough energy to power the entire facility. The addition of the Loadscan CVS aligns with the quarry’s broader commitment to using advanced technology for efficiency and sustainability.

By implementing the Loadscan CVS, La Cantera has enhanced operational efficiency, reduced waste, and improved stock and resource management, reinforcing its commitment to quality, environmental responsibility, and technological advancement.

The decision to install Loadscan’s CVS across all crushers at La Cantera has proven to be one of the company’s best investments. The system’s ability to improve production reporting accuracy, track downtime and equipment efficiency, and manage inventory in real-time has transformed operations. This technology has optimized productivity, reduced inefficiencies, and ensured preparedness to meet customer demands. Furthermore, it strengthens the quarry’s commitment to sustainability and technological innovation. The integration of Loadscan has not only enhanced operational performance but also set the stage for continued improvements in the future.

Project Details

Headquartered in central Florida, USA, S&L Materials is a company involved in the construction and materials hauling industry, and has seen significant improvements in operational efficiency and data accuracy through the adoption of Loadscan’s LVS (Load Volume Scanner) technology.

Brian Northway, the company’s Senior Trucking Estimator explains how the company has successfully integrated the Loadscan LVS into its daily operations to enhance logistics, improve load measurement, and streamline data management for back-end reporting.

The challenge: Inconsistent load measurements and operational inefficiencies

Before integrating the Loadscan LVS into its operations, S&L Materials faced significant challenges with inconsistent load measurements and the time-consuming nature of manual tracking. The company operates a fleet of around 150 company and owner-operated trucks, handling large volumes of material, across a varied range of different sites around the state.

However, their traditional methods of estimating the volume of material in each truck created variability and inefficiency.

Brian Northway explains the issues with the previous system:

“We would just take a full dump truck and just, you know, put 18 yards down on the ticket, and that was it. We went by bucket count. We always tried to stay right around 18 to 19 yards in a dump truck.”

This approach relied on estimates made by excavator and loader operators. For instance, with an excavator, it was assumed that three to three-and-a-half buckets would equal 18 to 19 cubic yards but, in reality, these estimates could vary depending on factors such as the type of material, compaction, and truck size. As a result, there was often a gap between actual load volumes and what was reported, leading to inefficiencies and billing inconsistencies.

Brian elaborates on the challenges with the old system:

“You had drivers that would pop the tailgate, you know, they’d lose some of the material; trucks weren’t coming in [with] full loads and stuff.”

These discrepancies were problematic, especially as drivers were often paid based on the volume of material they hauled. Without accurate load measurements, it was difficult for the company to ensure fairness and transparency in compensation. In addition, the manual process of tracking loads and generating reports for billing was labour-intensive and prone to error.

The solution: Loadscan LVS technology

To solve these issues, S&L Materials turned to Loadscan, who provided a technology-based solution through its Load Volume Scanner.

The Loadscan LVS uses laser scanning technology to measure the exact volume of material in each truck as it passes through a scanner, providing precise and consistent data. The solution ensures that each load is accurately recorded in real time, which significantly reduces human error and makes the overall hauling process more efficient.

Brian explains the decision to adopt the Loadscan system:

“We decided to go with the Loadscan. That way, there was no ifs, ands or buts about it. We knew what was in the truck and, not only that,  you can put the truck number down, where they were going. It just made it a lot easier with being able to calculate and keep track of loads and how many yards are moving in and out of a job.”

The integration of the Loadscan LVS meant that S&L Materials could eliminate any guesswork from their operations. With each truck’s exact load volume automatically measured and recorded, the company could now rely on hard data to improve logistics and billing accuracy.

Improved efficiency in operations

The Loadscan LVS system has significantly improved operational efficiency at S&L Materials. The company now knows the exact volume of material being moved by each truck, which has helped reduce unnecessary trips and optimize the loading process. Before Loadscan, trucks would sometimes be underfilled or overfilled, based on rough estimates, but now every truck is loaded as efficiently as possible.

Brian shares how the technology improved speed and accuracy:

“Even the truckers like it because most of the truckers get paid by the yard. So when they come in and they’re hauling and it’s 18, 18, 18 [cubic yards] when we were generating tickets, they looked at it and would go ‘I know I’ve got more than 18 in there’, so now, with the Loadscan, there’s no guesstimating. They know exactly what it is.”

This level of precision means that the trucks are loaded more consistently, reducing downtime and improving efficiency, as trucks no longer need to return to the site to correct underfills or overfills.

Streamlined billing and data management

In addition to improving operational efficiency, the Loadscan LVS has greatly enhanced S&L Materials’ back-end data management. The system automatically generates daily reports detailing the number of trucks that have passed through the scanner and the exact volume of material that was hauled. These reports provide invaluable data for the company’s billing department.

Brian explains the impact of the system on the company’s billing process:

“We pull a report every day off MyScanner, so we know exactly what happened here. How many trucks, how many yards went out. And then we, you know, build off of that for our billing department.”

By automating the data collection and reporting process, the Loadscan LVS reduces the risk of errors that could occur with manual data entry. This has streamlined the invoicing process, ensuring that clients are billed accurately based on the actual volume of material moved rather than relying on estimates.

Additionally, the Loadscan LVS system allows for remote monitoring. If there are any issues or discrepancies in the load measurement, the team can remotely access the system to investigate and resolve any problems.

“The scanner is also really nice when you can remote in and actually see what’s going on. If there’s an issue, it definitely helps out a lot,” Brian says, highlighting the benefit of remote access.

This ability to monitor operations remotely has improved oversight, allowing S&L Materials to act quickly to address any issues that arise without needing to be on-site in person.

Enhancing client relationships with accurate data

The Loadscan LVS has not only improved internal processes but also enhanced the company’s relationships with clients. Clients can now be confident that the volume of material they are being billed for is accurate and verifiable. In contrast to the old system of estimating, the LVS provides concrete data that clients can rely on.

“When we would go set them [Load Volume Scanners] up at different mines where we were hauling out of, they’d look at it and be like, ‘what does this do?’, and when we started telling them that it takes the volume inside the truck and tells you how many you have, instead of just guessing 18 on every ticket, now you know whether you’re running 20/21 or if you’re at 17, so it definitely helps out a lot better.”

This transparency not only strengthens trust but also gives S&L Materials a competitive edge in the market. Clients appreciate the clarity provided by the LVS, knowing they are being billed based on precise measurements rather than estimates.

The future with Loadscan

The impact of Loadscan LVS on S&L Materials has been overwhelmingly positive, improving operational efficiency, data accuracy, and client relationships. With the technology in place, S&L Materials can now track every load in real-time, generate accurate billing reports, and ensure that their trucks are loaded to optimal capacity.

“It definitely makes it a lot easier. You’re not just guessing at an 18-yard bed and they’ve actually got 20. So you know, we can better keep count of what we got exported,” Brian says as he reflects on the improvements the system has brought.

Project Details

PR Russell, a leading producer of bark, mulch, and compost products based in New Hampshire, has solidified its position as a dominant player in the bulk supply market in the region.

As one of the first companies in the USA to implement the Loadscan Load Volume Scanner (LVS), PR Russell has revolutionised its operations, significantly enhancing efficiency and accuracy in product measurement and loading processes.

Background on PR Russell

Established with a commitment to quality and reliability, PR Russell has become a cornerstone of the bark and mulch industry in the USA’s North-East.

The company is known for its dedication to providing high-quality products while ensuring customer satisfaction. However, like many businesses in the bulk material industry, PR Russell faced challenges in measuring and loading products efficiently. Traditional methods often led to discrepancies, customer complaints, and wasted time.

Challenges prior to Loadscan implementation

Before adopting the Loadscan LVS, PR Russell relied on manual measurements to determine the volume of material loaded onto trucks.

Marco explains the limitations of this approach: “We would physically measure the trailer and put lines in the trailer every ten-yard increments. So that was a guideline for the loader operator, but not efficient.”

This system was prone to human error, leading to inconsistencies in the loading process. Additionally, the company faced significant challenges with customer complaints regarding perceived short loads.

“There was a lot of complaining in the past of, ‘Well, we think this is three yards short,’” Carrier recalls. “There was always room for discrepancies.

“That’s how we did it in the past. And, like I said, not very efficient.”

This uncertainty created friction between the company and its customers, undermining trust and satisfaction.

The shift to Loadscan LVS

Recognising the need for improvement, PR Russell decided to invest in the Loadscan LVS, a transition Marco describes as a game-changer.

“Now loading is just loading. Come to the ramp, we’re going to load you up and you move on, so we saved a lot of time.”

The LVS technology makes the measurement process much more efficient, allowing for precise volume calculations without the need for manual intervention.

Efficiency gains

With the implementation of Loadscan, PR Russell experienced substantial time savings during the loading process. Carrier highlights that the need for the truck driver to monitor the loader operator has been eliminated.

“The loading was a process where now it’s just streamlined,” he explains.

This newfound efficiency has allowed the company to serve more customers in less time, ultimately leading to increased productivity.

In addition, the accuracy of the Loadscan system has transformed how PR Russell manages its operations.

“Every time we did testing, it was on the money,” Carrier states, pointing out that the consistency has virtually eliminated customer complaints about short loads.

“Once we had that system [Loadscan LVS], that went quiet. We don’t talk about that anymore.

“It’s a big deal…and it’s accurate,” he adds.

Improved measurement and training

The Loadscan LVS has not only enhanced operational efficiency but has also improved the way the loader operators operate.

Carrier emphasises the importance of measurement in the improvement process: “In order to improve it, you have to measure it. If you can’t measure it, you can’t improve it.”

“If you can’t measure it, you can’t improve it” – Marco Carrier, PR Russell

The Loadscan system provides precise data, allowing operators to understand their performance better.

“It was really a great deal for us. It saved a lot of time; it’s a good training tool for our loader operators.” Carrier explains.

This training aspect has been crucial, as operators can now receive immediate feedback on their performance. For instance, if a customer requests 80 yards of product but an operator mistakenly loads 81 yards, the system flags the discrepancy, enabling corrective action.

Navigating volume and weight challenges

The bark and mulch industry often deals with a wide range of different products, and Marco points out that the weight and volume of the materials handled at PR Russell can vary significantly.

“We deal with both extremes. When we deal with cedar bark, you can put 100, 110 yards onto a trailer and be at legal weight. If we deal with our aged material, once we get to 72 yards, we’re at weight capacity, so it’s a huge variation in that case.”

This presents challenges in accurately converting between weight-based purchases and volume-based sales.

Before using a Loadscan volume scanner, PR Russell struggled with this conversion.

“So this is where we would scratch our head a lot of time if we didn’t have a good way to measure the yardage.

“We did not really know how to do our conversion between everything we buy by weight to everything we’re selling by volume,” he says.

With the Loadscan system, however, they have developed a better understanding of their operations.

“There’s always variation obviously, but we have a way better understanding of where we’re going,” he asserts.

The bottom line: A valuable investment

Reflecting on the impact of the Loadscan LVS, Carrier declares,

“Looking back, it’s the best investment we’ve ever done for the industry.”

“…it’s the best investment we’ve ever done for the industry” – Marco Carrier, PR Russell

This statement underscores the profound changes the system has brought to PR Russell’s operations, highlighting the benefits of increased efficiency, improved accuracy, and enhanced operator performance.

Conclusion

PR Russell’s adoption of the Loadscan LVS has transformed its operational efficiency and customer satisfaction levels. By moving away from outdated measurement techniques, the company has streamlined its loading processes, reduced complaints, and fostered a culture of continuous improvement through precise measurement.

As Marco aptly summarises, the investment in Loadscan has not only optimised their operations but has also set a new standard in the bark and mulch industry, highlighting the significant advantages that technology can bring to traditional industries.

Project Details

When it comes to supply and delivery of aggregates and bulk products, precision and honesty are paramount. For Taylor Bros Transport Ltd in Tauranga, the integration of Loadscan’s LVS-3BMF load volume scanner (LVS) has been a game-changer.

Managing Director, Andrew Taylor, has been in his role for about two decades after taking over from twin brothers Garry and Kevin Taylor — his father and uncle — who started the business in 1965. During his tenure, he says the company has significantly changed the way it does business, with Loadscan’s innovative technology playing a key role in how the company’s operations have been transformed.

Transition from weight to volume

“We’ve always been a tipper operation and we concentrate fully in bulk material; bulk cartage, tipper trucks,” he says.

Originally, Taylor Bros Transport relied on selling products solely by weight, using loaders fitted with scales. However, as market demands shifted towards volume-centric transactions, they encountered challenges by using that as the sole system of measuring product. Andrew highlights how the paradigm shifted when customers increasingly sought loads measured by volume rather than weight.

“People wanted volume; they weren’t buying weight, they wanted volume and the only way we could see we could do this properly was to get a Loadscan,” he says.

“We knew there was no argument. When you sell by a Loadscan, you just can’t argue; they’re proven to be accurate and, to us, it’s all about honesty and integrity, and that’s something we were missing because we couldn’t guarantee what loads we were putting out there.”

The implementation of Loadscan’s LVS addressed the critical need for accuracy and accountability in their transactions. Andrew emphasises the highly precise nature of Loadscan measurements has eliminated disputes. The technology proved itself accurate, providing the foundation for a commitment to honesty and integrity in their business dealings.

Cubic metres as the currency

In a market where customers measure everything in cubic metres, the Loadscan LVS became indispensable. Taylor Bros Transport adopted a cubic metre-based system, aligning seamlessly with customer expectations.

“We sell by the cubic metre, our customers measure everything in cubic metres, they want to know they’re getting cubic metres. Out of this yard, everything is by cubic metres and, again, there’s no other way than by using that Loadscan.”

This move not only streamlined their processes but also ensured that customers received precisely what they paid for.

“Some people will do it and think they’re going to make more money, but for us it came back to that honesty thing; we wanted to know our customers were getting what they paid for.”

It’s a benefit of the Loadscan system that’s reinforced by Taylors’ Transport Manager Brent Smythe.

“We’re looking after the customer,” he says. “Because we’re charging by volume so we’re measuring in volume — it just makes it nice and simple.”

Customer satisfaction and transparency

The transition to Loadscan brought about improved customer satisfaction and, with the integration of vehicle tracking in their trucks, it further reinforces transparency. The technology allowed them to detail, with precision, the journey of each load through the scanner.

“Our customers are happy and we don’t have any problems at all. We never ask for proof of purchase or anything like that.

“We also run GPS in our trucks so we can show what went through the scanner and where that load went to, and that technology has been good for us to show our customers that we are honest and do have integrity.”

Return on investment and eliminating guesswork

While the primary motivation for adopting Loadscan was not about seeking a direct return on investment, Andrew acknowledges that the machine quickly paid for itself.

“We didn’t buy it with getting a return on investment in mind – we bought it around knowing what we were selling and making sure our customers were getting what they were being charged for.

“We’re more than confident we’ve paid for it, more than once I’m sure, because nothing goes out the gate that’s unaccounted for now.”

The elimination of ‘estimation’ regarding product quantities significantly impacted their bottom line. The company was no longer giving away or unintentionally losing product, ensuring that every load was accounted for.

“Before, it was all guesswork. Who knows what we gave away; we’re sure it was considerable, but now we’re sure we’re not, and that’s the key to it for us.”

The ease of use and accessibility

Taylor Bros Transport attests to the user-friendly nature of Loadscan’s LVS, with the majority of vehicles passing through the scanner trouble-free.

“Most of the vehicles through our yard now will scan, and everyone finds it easy to use,” he says.

Brent also reinforces the Loadscan system’s efficiency as far as reporting and paperwork are concerned.

“Before we had the scanner, we worked off the certified scales in the loader – the product was put in the back of the truck per tonne, and was then worked out in the office per metre. Then a manual docket was having to be filled out for every truck that was filled up, every time it came into the yard.

“Now, the scanner scans their load in volume in metres and then it’s up to the driver to come in and enter his rego. It’s a real simple process. They only have to enter four things into the display unit that controls all that, and then it prints him out a ticket.

“It’s got rid of all the paper. Some days we’d be filling out 150 dockets. Every time they came in, they’d have to come in and fill out a docket – it’s got rid of that totally, so it’s just made it so easy.”

The system’s ease of use also extends to generating real-time reports, facilitating quick and efficient decision-making.

Accounting integration and future prospects

From an accounting standpoint, the company charges off the data generated through the scanner, showcasing a commitment to leveraging technology for operational efficiency. Andrew Taylor expresses excitement about ongoing improvements in technology and the prospect of seamless integration with their accounting systems. This evolving synergy between Loadscan and accounting systems promises further enhancements in data management and financial tracking.

“It’s easy to do tallies because we’re often asked for up-to-date information. It’s easy to go to the computer and download the reports, and that’s something we do on a weekly basis, or a daily basis if required.”

For Taylor Bros Transport Ltd, Loadscan’s LVS-3BMF is more than just innovative technology; it has become an assurance of accuracy, transparency, and integrity in their operations. This illustrates how the adoption of Loadscan technology not only met the evolving market demands but also exceeded expectations in terms of operational efficiency, customer satisfaction, and financial accountability.

As the partnership between Taylor Bros Transport and Loadscan has continued to evolve, it reinforces the value of Loadscan’s innovative payload management solution in an industry where accuracy, accountability and ease-of-use are paramount.

Project Details

When significant floods hit New South Wales in mid-2022, parts of the region were devastated, washing away homes, displacing families and ruining livelihoods.

It was the third major flood some parts of the region had suffered in 2022, and the Hawkesbury River – one of the main tributaries in the Sydney area – peaked at 14m, a level not seen for decades. Meanwhile, the Warragamba Dam, which serves as the primary reservoir for the water supply for Sydney, overflowed, flooding areas downstream with more than 500 gigalitres of water – around 20% of the massive lake’s total capacity.

Once the water had receded, the huge level of damage was apparent, causing major issues for councils, utilities companies and service providers as they swung into action to get the region back on its feet.

One of the larger projects fell to the Hawkesbury City Council, which was tasked with clearing a major landslip on the banks of the Hawkesbury River near the settlement of Wiseman’s Ferry, around 75km northwest of Sydney. There, almost 30,000m² of earth had come down, blocking a road and causing major issues for those in the area.

Solving problems

Sadat Rahman, the Project Manager Infrastructure Recovery for the council, confirmed the size and nature of the job posed some problems for the council.

“The council has never done a job with this level of excavation – it was a huge landslip area,” he says.

After engaging a surveyor and contractor to undertake the job, Sadat’s next challenge was to ensure the accuracy of the data coming out of the site, and to match that with payments that were being made to the relevant parties.

“One of the challenges was how and what we’d use to measure this, how we make an informed decision for the claims,” Sadat explains.

After initial discussions, the Loadscan LVS-3TMM was suggested as the solution to the unique challenges posed by the difficult job.

Accurate to within +/-1%, the Loadscan system was selected as the best solution for the role and was quickly installed on-site in order to capture the information that was necessary to meet the level of detail required under the contract Sadat was managing.

“On a normal scale job, we wouldn’t need a Loadscan, but when we’re talking about 29,000m² of loadout material, that’s huge, and that’s why we thought we needed to check what we were taking out…and to double check with the surveyor information.”

Keeping track of vehicle movements

Trucks were fitted with Radio Frequency Identification (RFID) tags to ensure loads were tracked accurately, making for more efficient truck movements into and out of the challenging site. Once each truck had completed a reference scan and had their details loaded into the system, every subsequent load by that truck was then automatically picked up by the RFID receiver, with all the relevant details uploaded in real time to the Loadscan LVS.

In addition to using the Loadscan to measure what was coming out of the site, the surveyor also used a drone on a monthly basis to estimate the amount of material in the body of the landslip.

“Before they started any work, they do a scan [with the drone], and at the end of the month they do another scan; that difference gives the volume of material that we removed.

“That information is then double checked by the Loadscan.”

As part of that process, Sadat discovered that drone-generated figures were considerably different to those provided by the more accurate Loadscan LVS due to the compaction of the material on the site that was being measured prior to being loaded out.

Ensuring accuracy of data

The information delivered by the LVS also assisted Sadat with reconciling financial requirements with the contract company, especially when the scans made it easy to differentiate the type of material being hauled from the site.

As part of the contract, there was a different cartage rate for spoil and rock, which initially proved difficult to manage until raw data was made available to Sadat, where the 3D scans confirmed exactly what was being hauled from the site.

“In our contract, there was a rate for spoil and a separate rate for rock,” he explains. “The drone survey does not differentiate what is rock and what is spoil.

“When it’s spoil, you cannot say it’s rock. Rock is a higher price and, once I got the raw data, I declined lots of payments.

“The scanner helped me a lot. It helped to solve that problem.”

The Loadscan difference

As well as solving a problem for the HCC on this project, Sadat says the process of implementing Loadscan’s LVS on the site was made far easier with the assistance of Loadscan’s staff.

“Whatever we requested, you were there to help us, to give us training, which helped us a lot to get familiar with the system.

“You were there to help us.”

Project Details

On large-scale site development projects, accuracy isn’t optional – it’s essential. For Alan Payne, project lead at The Kearney Companies, based in Riverview, Florida, the difference between guessing and knowing has had a major financial and operational impact. After nearly four decades with the company, Alan has seen plenty of industry change, but few innovations have delivered as much value as Loadscan’s Load Volume Scanner (LVS) system.

At Queenstown Hardfill, the business revolves around efficiently managing materials for a range of projects in the challenging terrains of Queenstown and Southern Lakes.

Company owner Steve Rout explains that the company faced significant challenges with accurate volume measurements before incorporating a Loadscan load volume scanner into their operations.

Before the addition of the Loadscan scanner, disagreements led to disputes with engineers and surveyors, and often delayed payments and strained business relationships. The tipping point came following a completed project where they had to spend a year proving their work to receive rightful payment.

“We used to keep quite a good paper record of everything, so eventually, after 12 months, we were able to prove we’d done it, and we got fully paid,” Steve says.  “But by then, we were bloody sick of having these arguments and discussions and negotiations that go backwards and forwards while your cash flow is tied up….and it becomes quite adversarial, when you’re dealing with a big chunk of dough.

“After that, we got the first trailer-mounted [Loadscan] unit, and it just ceased the problems.”

As an early adopter of the load volume scanner, Steve put the machine to work and it quickly became an invaluable asset to their operations. The unit’s mobility and efficiency addressed the absence of weighbridges in remote sites, allowing them to accurately measure and record materials without relying on subjective weight estimates.

“When you’re out on sites, you don’t have weighbridges, and we were a long way from the nearest town — 50km at least — so you just don’t have that availability,” he says.

“We operate off a lot of remote sites and we can measure accurately what we’re doing, because our projects are always priced by volume.”

While the company’s original scanner is still in operation at Queenstown Hardfill’s Glenorchy gravel pit, a second, newer Loadscan LVS-3BMF model is employed at the company’s Queenstown headquarters where it continues to deliver accuracy and reliability of volume measurements into and out of the site.

“On this site, we use it for material out; we put out quite a significant volume each year, and we also run a transfer area here where small trucks and trailers and smaller contractors bring material and we take it by truck and trailer to larger sites, which we manage as part of our operation.

“So, once again, it’s time and accuracy. There’s no doubt of what came in or what went out…and there’s no argument with it.”

The key advantage of the Loadscan LVS is its ability to measure volume directly, eliminating the need for conversion to weight. Steve says they’ve resisted the industry trend of converting everything to tonnage because it introduces uncertainties and risks.

“We’ve got materials in this district that run from about 1.2 tonne a cube up to about 2.3 tonne a cube. So, your guys are always trying to estimate, is this hard, is it loose, is it soft, is it really heavy and dense, how much airspace is in the load?

“So these are all the things that drove us to thinking we have to find a better way that can be scanned quickly, and then there’s no argument; no argument about what we deliver to our client, no argument about what we take out of a site.”

Initially implementing Loadscan’s volume scanner took some time for widespread acceptance, as sceptics questioned its accuracy. However, they swiftly validated its precision by cross-referencing scans with on-ground measurements, earning the trust of engineers and contractors alike.

“Once we bought the first scanner, it took about six months to get acceptance.

“A lot of people didn’t think it was accurate, but we were able to prove very quickly it was. We surveyed truck loads — we’d tip it out on the ground and survey it and verify it.

“After that, most of the engineers accepted it.”

Contract clarity

Loadscan has also become integral to Queenstown Hardfill’s pricing system, serving as the basis for volume measurements in their contracts.

“We changed our quoting system to be based by volume measure through the scanner, and we basically had that in the contract as if that’s the volume it had, that’s what we got paid for. It was part of the contract documentation and it just stopped all our arguments.

“End of story.”

This shift has brought clarity, putting an end to disputes and streamlining operations. It has proven particularly beneficial for remote sites lacking weighbridge infrastructure, where traditional measurement methods would be impractical.

The system guarantees accuracy and ensures dealings with clients have become smoother, as they appreciate the transparency and reliability Loadscan brings to their operations.

“It guarantees our QA, and we can back it up with facts,” Steve says. “So once again, it helps with your dealings with clients because they know there’s not going to be any hassle.

“If we tell them we’re bringing them 500 cubes, they get 500 cubes or, vice versa, if we’re carting 500 cubes out of their site, they know that’s what’s happening.

“It allows you to work remotely without having any issue about trust or misunderstandings.”

That trust has translated into improved cash flow, a critical aspect of their business.

“As we all know, cash flow is king now.  If you haven’t got your cash flow because you’re having an argument, it affects your business.”

Beyond the financial benefits, Loadscan has helped them maintain their commitment to delivering what they promise. It has prevented potential discrepancies caused by human error or subjective judgments, creating a more efficient and trustworthy operation.

“We love the thing. We just love it. We don’t have arguments with clients anymore.”

Project Details

Russell Pratley, the Regional Environmental Supervisor for Dunedin infrastructure management company Delta, is pretty clear when asked why the company installed a Loadscan Load Volume Scanner (LVS) at a Dunedin City Council quarry in rural northern Taieri on the outskirts of the southern city; cost, installation location, and accuracy and relevance of load measurement.

A cost-effective solution for a flexible location

Russell explains that a traditional weighbridge posed both a logistical challenges and financial barriers, especially as there was the prospect of needing to relocate the weighbridge should the quarry expand in future years.

“The first thing was the cost of the weighbridge was going to be a lot more tricky for us, especially where we’ve got this scanner positioned,” he explains. “If we were going to mine this area then we’d have to shift the weighbridge…and so a lot of it was the cost.

“We’ve had a lot of experience with weighbridges in the past, and this causes a lot of headaches with load cells breaking and stuff like that,” he adds.

That cost factor, coupled with potential reliability issues of a weighbridge, led them to explore alternatives. Enter Loadscan, where an LVS-3BMF load scanner provided a solution tailored to their needs, offering not only cost-effectiveness but also a seamless integration into their operational framework.

“The volume scanner was the better option for us because we sell our metal by the cubic metre.”

“We’ve got weight scales on our loader and we’ll estimate how many cubic metres, as the loader weighs by tonne, but we never have sold it by the tonne.

“We’ve always measured by the cubic metre of gravel coming out — or any product coming out — by the cubic metre,” Russell states.

“It’s very hard to estimate cubic metres if you’re selling by the tonne.”

Embracing precision with volume scanner technology

As well as accurately measuring every truck load of material leaving the site, the data generated by the LVS also provides real-time updates which allows Russell to manage the annual totals being removed from the 14-hectare site.

“We pay a royalty to the City Council for every cubic metre that we sell that comes out of this quarry,” Russell says.

“It was like 30,000 cubes a year, and then the last 2 or 3 years it was down to 22,000. And now we’re at 18,000 cubes,” Russell says.

The quarry also sits on top of an aquifer, which is protected and, consequently, means the limit of the amount of gravel that can be extracted from the site is reducing as part of meeting environmental targets.

Waste Disposal Levy information

Perhaps more immediately relevant to the overall operation of the Delta quarry is the amount of cleanfill coming into the site, which then allows the land to be restored as the quarry is mined.

Trucks entering the site to dump cleanfill are scanned in through the LVS, with totals tallied and the companies then billed according to Ministry for the Environment’s (MFE) waste disposal levy scheme. This precision extends to different categories of clean fill, including class three, four, and even class five material entering the site.

“With the clean fill, we convert the MFE factor of 1.5 tonnes per cubic metre, and then we pay the levy back to the government for $10 a tonne,” Russell says.

“We load different categories of clean fill.

“We generally have class three and four clean fill.

“If we have a contractor doing subdivisions and they’ve got virgin material coming in here, then I can put a category into that machine saying class five, virgin material, so we’re capturing everything that comes in and out now.”

Navigating operational challenges with Loadscan

While acknowledging the reliance on truck drivers for correct data input, Russell emphasises the streamlined process Loadscan brings to their invoicing and administrative tasks through the cloud-based MyScanner web portal, which ties into the Delta billing and administrative system. The real-time access to information allows them to address concerns promptly and ensure accurate invoicing.

“That information is accessed by our administrator in town, and we have a guy in an office that that takes all that information and does the invoicing directly off that,” he says.

Accurate operation with Loadscan

Russell provides insights into the unique challenges posed by the Delta site, where Loadscan not only ensures compliance with the city council’s limits but also aids in responsible practices. The accurate measurement of various materials, including gravel, soil, and bark products they sell, reflects the precision and reliability of Loadscan’s technology.

“It works very, very accurately.”

Awesome technology

“I really think this system is awesome. It’s awesome technology. It works really, really well for what we’re trying to achieve.

Since being installed in December 2022, Russell says the scanner has proven its worth with accurate measurements and increased operational efficiency.

He says the technology and seamless integration into the Delta administrative system provide a serious contrast to the potential challenges a weighbridge would likely have brought, while delivering an accurate measurement tool that increases efficiencies.

Project Details

In the heart of OceanaGold’s Macraes Operation goldmine in Otago, every ounce of efficiency counts, and Senior Geologist, Graham Gibson, says the Loadscan Mine Payload Scanner (MPS) has emerged as a game-changer in truck load measurement.

He says the MPS volume scanner has revolutionised operations, offering a seamless and continuous workflow, as well as identifying issues such as carryback, which can quickly have a negative impact on profitability.

Tackling carryback head-on

It’s when the trucks return from dropping their load at the waste pad or ROM pad that carryback — a perennial concern in mining — is often detected.

By using data from the scans provided by the MPS, carryback becomes a quickly identified issue and a very manageable task which can be quickly rectified.

“They come back through the scanner, and they’ll obviously see if they’ve got any carryback,” he says. “It’s significantly reduced the carry back because we can get on top of that straight away.

“If we’ve got more than half a cubic metre of carryback on, then the truck will go up to the ROM pad and get the carryback scraped out, so the next load has got a clean tub again.

“And I think that’s one of the main benefits for the Loadscan system is just any truck with carryback in it, it’s just getting it out straight away,” he says, before reinforcing the carryback issue with another strong endorsement.

“Less carryback, more tons out of the hole, the less fuel, less CO₂. It’s better for everyone,” he states.

Beyond the surface: Utilising data for efficiency

Graham reveals a hidden treasure in the Loadscan MPS capabilities — the utilisation of the data that’s generated by the system.

Beyond mere load measurements, the MPS offers detailed 3D scans, which give an insight into truck loading, weight distribution and chassis balance. Graham envisions leveraging this data for enhanced truck efficiency, a big step towards optimising fleet utilisation.

“As in checking that trucks are loaded properly because there’s so much, rather than just the truck’s not loaded properly.

“It puts weight on the chassis where it shouldn’t, forward or back, side to side and, quite often, if it’s loaded heavy on one side, there’s actually room for dirt on the other side.

So, using a lot more of that data as well potentially will help us out with truck efficiencies and effectiveness.”

Loader education also becomes a key focus, with the ability to visualise load distribution in 3D and pass this on to the bogger operator who is working at the face.

This contributes to maximising truck efficiency and reducing environmental impact as well as addressing carryback when required.

“That’s it’s one thing that we can use it more in the future is for loader education — if there’s carryback in the front left of the tub, or how that load’s sitting left and right and forward, back.

“There’s a lot of advantage in there as well.”

Pursuing operational excellence

In the tireless quest for peak performance, the Loadscan MPS at Macraes Goldmine emphasises the successful lateral thinking that can be employed in the drive to improve day-to-day mining operations.

Graham underscores the far-reaching impact of minimising carryback, leading to increased material extraction, lowered fuel consumption, and a diminished carbon footprint. The Loadscan MPS goes beyond being a mere instrument; it acts as a driving force for a mining future that is not only more efficient and sustainable but also more profitable.