Articles by David Zelnio

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Procurement Optimization for Bulk Material Supply Chain

There’s money to be made through smart supply chain strategies like procurement optimization, material aggregation, and strategic sourcing. During the past 30 years, total global material consumption has increased by 80% and is projected to reach 180 billion tons of different materials by 2050.

“We’re engaged with industries using predictive data,” said Conrad Woerner, BinMaster Supply Chain Manager. “If a company can access its bulk material needs and realize just 1 or 2% waste reduction, or create an ordering rhythm to purchase at a lower price point, it could create millions of dollars return on investment.”

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Bulk Density Key to Bulk Material Storage

agriculture concrete bulk density level sensors plastic industry agricultura

What is bulk density? In simple terms, it’s mass per unit volume of powder, liquid, granules--any material-- in a bulk state. When handling solids or powders, a bulk material’s weight is usually stated as lb./ft3 or g/cm3. Veteran processors often have their material weights memorized. While the graphics and easy-to-understand reports on BinCloud seem simple, bulk inventory information results from numerous calculations like vessel size, headspace, and the material's density.

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Improve Carrying Costs with Bulk Measurement System

bulk material supply chain carrying cost material automation

Before COVID and the supply chain crisis, industries relied on savvy just-in-time ordering to minimize carrying costs like warehousing, tied up capital, product spoilage, and waste. According to Investopedia, such carrying costs represent up to 30% of total material value. “We’re navigating the same supply chain waves as our customers,” said Scott Hudson, Executive VP Sales & Marketing, BinMaster. “We’re still hearing from people who can’t get their materials delivered on a consistent schedule, so they’re really using BinMaster for planning orders. They just can’t afford to shut down production because of a bad or outdated measurement.”

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Industry 5.0 Techno Social Revolution

automation bulk material measurement bulk material sensor

As organizations polish Industry 4.0 tools and processes, a new focus has emerged to define ways to benefit employees, sustainability, fairness, and human interactions. Industry 5.0, in some ways, benefits from 4.0 achievements automation and process improvements. Industry 5.0 points to sustainable, human-centric goals and asks, “are we supporting future societal values?”

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Culture & Digital Transformation in Bulk Supply Chains

Digital transformation improves supply chain resilience, automation, accuracy, and efficiency, benefiting people effectively collaborating in a digital system. BinMaster designs systems to pool such technology partners. By bringing bulk material data from sensors atop silos to a secure cloud report, authorized users can access the same information in real time. Decisions and conversations bring decision-makers the same data. It’s all about collaboration, accuracy, and transformation to a more automated process.

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Sensors for bunkers, pie & oh my

grain silo level scanner concrete bunker

Some bulk material applications are straightforward. Others, not so much. BinMaster’s 3D Level Scanner works well in most bins and silo storage. Let’s dive into some more unique applications. Uneven loading can be “seen” with 3D so operators can adjust before major failures. Bulk material tends to pile in uneven ways in a pie-shaped bin. 3DLevelSensors are the best solution for measuring these bins as well. Finally, material stored in bunkers can be measured accounting for the ups and downs of piles.

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International Fuel Ethanol Workshop & Expo | BinMaster

Bioenergy Ethanol fuel omaha few international fuel ethanol expo

Booth #1804

June 12-14, 2023

CHI Health Center

Omaha, Neb.

Visit the show home site

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IoT Key to Cloud Inventory

sensors internet of things bulk material sensor

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A storm of challenges faces organizations including the strain of product demand, limited supply chain resources, and an unprecedented exodus of people leaving the workforce. Industry 4.0 technology and systems provide some relief.

Industry 4.0 is a system that combines informational and operational technology to make manufacturing more aware, predictive, and autonomous. Employees operating in a 4.0 environment are highly connected with a more complete view of their business ecosystem.

“Ultimately, you want to run autonomously in a closed-loop system where humans set parameters, but technology runs itself,” said Chris Hill, Technology Program Director at Iowa State University Center for Industrial Research and Service. “Sensors and software directly feed an Industry 4.0 environment. They replace a physical process and feed information back to people.”

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Bunker, Pies, and Oh my

silo measurement storage bunker

Some bulk material applications are straightforward. Others, not so much. BinMaster’s 3D Level Scanner works well in most bins and silo storage. Let’s dive into some more unique applications. Uneven loading can be “seen” with 3D so operators can adjust before major failures. Bulk material tends to pile in uneven ways in a pie-shaped bin. 3D Level Sensors are the best solution for measuring these bins as well. Finally, material stored in bunkers can be measured accounting for the ups and downs of piles.

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Plugged chutes design and monitor

chutes conveyors flow detect plugged chute

Chutes are used to control the direction of the material, flow stream, spillage, dust and environmental pollution, production degradation, retard or control flow, and surge control.

Cost is a factor for designing a bulk material handling system to accommodate different materials, according to Rich Tavis, BinMaster Representative, Southeast Region.

“I work with a company that purchased an agricultural facility and used it for minerals processing,” Tavis said. “They don’t want to invest in new silos, conveyors, and chutes, so they adapt and utilize sensors to monitor bulk material flow.”

High-tech sensors indicate flow and no-flow material conditions to alert operators before, or shortly after, a plug occurs.

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Articles by David Zelnio