Ok I think I got to the bottom of this. Sometimes i drive on the motorway in high revs and the dpf only reaches a temp of 200c which is not enough for passive regen. Other times, the temp inside the dpf gets to around 300c in which case the fill level is normal.
The temp sensor upstream of turbo also plays up i.e under load on the motorway it is 170c and when driving slow it can reach over 300c in which case again, the dpf fill level becomes normal
The temp sensor upstream of turbo also plays up i.e under load on the motorway it is 170c and when driving slow it can reach over 300c in which case again, the dpf fill level becomes normal