A large iron ore operation was unable to achieve nameplate capacity across its secondary and tertiary crushing circuit despite having sufficient installed equipment. The primary instrumentation constraint was a set of legacy single-point (one-dimensional, or 1D) radar and ultrasonic level devices on critical surge bins, which produced erratic or missing readings at low fill levels and under high throughput in dusty operating conditions. One-dimensional sensors return a single distance measurement along the beam axis; two-dimensional (2D) radar scanners sweep a beam across the full bin cross-section to generate a spatial surface profile and calculated volume. This lack of reliable visibility into bin behaviour forced conservative operating set points, increased the frequency of crusher trips and belt protection events, and reduced operator confidence in the control system. The net effect was a highly variable feed to the secondary gyratory and tertiary cone crushers, lower average throughput than design, and elevated unplanned downtime in the crushing area. The operation engaged a technology partner to implement a radar-based instrumentation and control upgrade across the secondary and tertiary crushing circuit. The solution comprised two complementary elements: high-speed 2D radar scanners installed on each critical surge bin to provide continuous fill profiles and calculated volumes, and upgraded high-frequency 1D radar sensors fitted inside the secondary crusher cavity to enable cavity-level-driven speed control. Both measurement streams were integrated into the plant distributed control system (DCS) to drive automated feeder and conveyor set points and sustain choke-fed operation across the circuit. Each scanner provides a true 2D fill profile and calculated volume for bins feeding the secondary gyratory and tertiary cone crushers, as well as for key recirculation and classification bins. This data is used to drive automatic feeder and conveyor set points, stabilising crusher feed conditions and enabling choke-fed operation across the circuit. The approach builds on proven use of radar in harsh bulk materials handling applications, extending that reliability into the comminution control layer. Within the air classification and crushing areas, integration of 2D radar measurements into the supervisory control and data acquisition (SCADA) and control system gave operators a real-time, intuitive view of bin behaviour and material movement inside previously opaque vessels. With trustworthy, high-resolution level and volume data, control set points were progressively lifted from highly conservative values toward the true design envelope of the equipment. This shift from reactive, operator-driven control to stable, instrument-driven control enabled the operation to achieve consistent nameplate throughput across multiple crushing stages while materially reducing downtime events associated with empty bins, overfills, and crusher protection trips. In practical terms, the circuit moved from operating below nameplate capacity under conservative conditions to sustained operation at nameplate with controlled and predictable risk.