How IoT is transforming bulk solids inventory management

Cloud-based bulk inventory management software pairs with sensors to track liquid or solid levels inside storage vessels and is accessible via PC or mobile app.

Across the globe, industries are demanding continual measurement of stored bulk materials to allow operators to maintain and streamline processes and ensure a seamless workflow. When sensors are paired with Internet-of-Things (IoT) devices, operators can rely on technology to do the heavy lifting of inventory management and shift their focus to other critical tasks.

The benefits of IoT and level sensors

The benefits of employing IoT technology in conjunction with level sensors for managing inventory are wide ranging. For example, a plant manager at a food processing plant is responsible for overseeing the entire process from ingredient procurement through processing. Table 1 outlines what this means for plants using traditional inventory management methods compared to plants using integrated level sensors, devices, and cloud-based software.

Table 1: Traditional inventory management versus integrated IoT inventory management.

How IoT and cloud-based platforms work together

A cloud-based platform is an essential ingredient of every successful IoT ecosystem. Cloud-based platforms bring IoT devices online, enable the management and analysis of sensor data, and automate bulk material management. The following is a look at how cloud-based inventory works in a processor’s IoT environment:

Device management. The platform enables seamless setup, monitoring, and control of level and flow sensors and IoT devices, overseeing inventory, connectivity, communication, data storage, and ongoing maintenance. Device management ensures that each sensor and device operates reliably within the network, while minimizing manual maintenance and intervention.

Bulk inventory management allows processors to enhance operations and stay informed with accurate real-time inventory data backed by precision radar sensors and continuous level transmitters.

Data management. One of the primary roles of a cloud platform is to gather, store, and organize data from connected devices at one or more physical locations. By centralizing data management, the platform streamlines data access for further processing and analysis, unlocking valuable insights for informed decision-making. Data can also be shared with suppliers for the implementation of vendor-managed inventory (VMI).

Integration. To maximize the potential of inventory data, the platform integrates the data with enterprise resource applications, makes application programming interface (API) calls, and shares data with other third-party systems. Integration features allow businesses to create custom workflows and automate responses triggered by IoT events, such as inventory status alerts, to enhance efficiency and scalability.

Analytics. While raw sensor data holds potential, presentation and analytics are what turn that data into actionable insights. A cloud-based platform analyzes patterns, enabling processors to react in real time, learn from past consumption patterns, and forecast future trends. This ability to add context to data allows for smarter, faster decision-making.

Application development. IoT and cloud-based inventory platforms often offer APIs, allowing companies to create custom interfaces with other types of sensors or systems. Integration with enterprise resource planning (ERP) systems for purchasing, finance, and logistics planning is common. Processors can customize their systems, tailoring applications to their specific needs.

Security. Given that company data often includes sensitive information and provides control over critical systems, security is essential. IoT and cloud-based platforms incorporate a range of security features to protect against unauthorized access and potential cyber threats. Encryption, secure communication protocols, and robust authentication measures guard both devices and data.

Cloud-based inventory management gives production managers and supervisors the flexibility to check levels on-the-go.

How to get started

Once a company recognizes the value of an IoT and cloud-based inventory system, they are ready to take the next steps.

Research. Narrow down the type of sensors best suited for the company, industry, location, and specific storage needs. These range from continuous level to point-level sensors.
Identify a device. Various cloud-based inventory systems are available, depending on location, budget, complexity of installation, and more. This is a chance to let technology do what it was designed to do.
Take inventory. Reach out to a professional for a site evaluation. Their job is to recommend sensors and devices needed to maximize efficiency.
Installation. Determine if installation can be done in-house or if this will need to be outsourced. Most devices are configured with the end user in mind, making installation simple with a step-by-step guide.
Tracking. Once sensors and devices are installed, monitoring and tracking can begin. Obtain real-time data from a cloud-based platform. This is accessible via PC or mobile app, available on Google Play or Apple.

In summary, cloud-based inventory with IoT devices is part of a comprehensive solution to facilitate connectivity, data management, analytics, and security, making it the heartbeat of any processors inventory management system.

Jenny Christensen is vice president of marketing at BinMaster, a brand of products manufactured by Garner Industries. BinMaster designs and manufactures reliable, solid-state point and continuous bin level indicators, control systems, and sensors used in the storage of powders and bulk solids.

BinMaster
www.binmaster.com