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Articles by David Zelnio

Articles by David Zelnio

One login for multiple sites, bins
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One login for multiple sites, bins

 In the face of soaring inflation, intense competition, and supply chain challenges, industries are turning to technology solutions, particularly Industry 4.0 goals, to stay competitive. McKinsey & Company’s study highlights the cement industry’s need for digitization, sustainability, and resilience to lower operating costs and boost productivity. The World Economic Forum’s 2020 report identified 54 Industry 4.0 leaders in manufacturing, but none were in the cement sector. The study emphasizes the potential of digitization and sustainability efforts to enhance productivity, with technology enabling remote collaboration and quick decision-making.
Addressing the challenges faced by the concrete, manufacturing, and agricultural industries operating across multiple locations, BinMaster introduces SiteView within its CementView platform. This cloud-based software facilitates centralized bulk material inventory management, aiding organizations with better decision-making in purchasing, forecasting, and material movement across sites. The BinMaster system, exemplified by a case serving 58 silos across four states, provides real-time bulk inventory data to dispersed teams, enhancing operational efficiency through custom reports, usage projections, and automated alerts via the BinCloud inventory management software.

Human-centric sensor, software
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Human-centric sensor, software

The year 2023 witnessed a surge in artificial intelligence adoption, with 79% exposed and 22% already integrating it into their work, as per a McKinsey survey. The focus on Industry 5.0 emphasizes collaboration between humans and technology, where AI is considered just another tool. BinMaster, a key player, highlights the importance of human-centric design in sensor and software technology for efficient decision-making. Their BinCloud software, designed with people in mind, organizes and interprets data, making big data actionable. The European Commission defines Industry 5.0 values as human-centric, resilient, and sustainable, aligning with goals for human-centric instrumentation. This approach involves replacing manual tasks with automation, exemplified by level sensors, BinCloud software, and other innovations. The overarching goal is to enhance efficiency, reduce physical work, and empower individuals to make informed decisions in a rapidly evolving automated landscape.

Global supply optimization, material aggregation
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Global supply optimization, material aggregation

The global increase in material consumption, projected to reach 180 billion tons by 2050, emphasizes the need for efficient supply chain strategies. BinMaster contributes to this by offering accurate measurements of bulk materials in various locations. Conrad Woerner, BinMaster Supply Chain Manager, highlights the potential for significant returns on investment through predictive data, waste reduction, and strategic ordering. BinMaster’s sensors and BinCloud software provide real-time inventory views, aiding in predictive ordering and waste reduction.


The importance of procurement optimization, strategic sourcing, and material aggregation in enhancing profits and reducing waste is underscored. BinMaster’s role is pivotal in generating essential data for these strategies. Case studies in agriculture, petrochemicals, and construction demonstrate successful applications of these supply chain strategies. In an era where data-driven decision-making is crucial, BinMaster stands out as a tool transforming bulk material inventory management, facilitating collaboration across managers and departments for strategic supply chain planning. For more information, visit www.binmaster.com.

Flow detect sensor
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Preventing plugs in food processing

Consequences of chute blockages in the food industry include disrupted operations and significant losses in production, labor, and reputation. BinMaster’s Flow Detect, which is a mass flow detector; as well as capacitance probes, rotaries, and vibrating probes, to monitor bulk material flow, or no flow conditions.

German Engineering Federation statistics say that 75% of respondents in the industry faced chute blockages, resulting in a costly average downtime of six hours at $250,000 per incident. EHS Today underscores the link between manufacturing accidents and poorly maintained machinery, urging the food production sector to adopt preventive measures through advanced chute detection technologies and meticulous design strategies.

smart silo and BinCloud
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Master the art of smart silos

Smart silos, equipped with advanced sensors, data analytics, and automation, revolutionize bulk storage conditions and ensure product quality and safety. Intelligent inventory systems leverage IoT and cloud to minimize waste, enhance inventory management, and optimize processing operations. BinCloud BinMaster’s centralized software platform collects and presents data from continuous level sensors. It includes easy-to-understand graphical reports for multiple silos in one, or more, facilities. Intelligent silo systems eliminate the need for risky manual measurements, offering real-time level measurements and allowing administrators to delegate tasks with emailed reports.

Forecasting bulk materials.
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Sensors serve up data for demand forecasting

In the fast-paced world of industrial operations, the efficiency of managing bulk materials plays a pivotal role in determining the success of businesses. This article delves into the crucial aspect of demand forecasting and its impact on inventory costs, resource allocation, and overall profitability. Whether it’s powders, pellets, or solids, the frequency and strategy of replenishing materials can significantly affect the bottom line. The article emphasizes the proactive approach of demand forecasting, citing studies that show potential cost reductions of up to 20% to 30%.

Girl measure pharmacy bulk material.
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Cyber-physical technology for Pharma 4.0

The future of pharmaceuticals liea with Pharma 4.0, where cyber-physical technology secures manufacturing integrity. Embracing automation, autonomy, and decentralized ecosystems, Pharma 4.0 integrates the Internet of Things (IoT), Cyber-Physical Technology (CPT), and Artificial Intelligence (AI). Technologies like BinMaster inventory sensors and IoT software play a pivotal role, proactively safeguarding processing and monitoring systems from potential cyber threats.

Procurement optimization for bulk material supply chain
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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.”

Bulk density key to bulk material storage
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Bulk density key to bulk material storage

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.

Improve carrying costs with bulk measurement system
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Improve carrying costs with bulk measurement system

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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