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Case Studies

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.

Industry 4.0, Safety and Worker Shortage
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Industry 4.0, Safety and Worker Shortage

While manufacturing managers were implementing the Industry 4.0 philosophy, COVID-19 hit. The pandemic brought worker and supply chain shortages and accelerated the effort to boost technology in manufacturing. BinMastersensors and software fit perfectly into Industry 4.0 goals.

 Eny, Meeny, Miny, Mo Sensors
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Eny, Meeny, Miny, Mo Sensors

Point-level sensors are inexpensive, easy to use, and durable, but you gotta choose the right one for the right situation. Proper level measurements, alarms, and inventory control should involve more than eny, meeny, miny, mo, and BinMaster representatives can help.

Poultry Plant and Sensor Measurement
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Poultry Plant and Sensor Measurement

Poultry operations require a variety of bulk materials with everything from liquified fat to lime and grains. A Midwest-based poultry feed mill faced a very tedious and manual inventory process before BinMaster brought solutions. Raising livestock requires tight control of what materials are ordered, how long feed is stored, and when feed is running out and needs to be restocked. 

Ethanol Plant Gets 3DLevelScanner for Reliable Measurement
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Ethanol Plant Gets 3DLevelScanner for Reliable Measurement

Ethanol operations face plenty of challenges including bulk inventory measurement. Dust, accuracy, and reliability all must be considered with raw material storage. Our case study looks at extreme amounts of dust - especially during fill rates of up to 580 tons per hour - which made it extremely difficult to track the filling and emptying processes. Using just a single measurement did not account for the topography of material in bins. Multiple points created an average-level measurement.

Municipal Water Measured with Radar
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Municipal Water Measured with Radar

Islands in the Caribbean endure plenty of weather events, but Hurricane Maria in 2017 was particularly damaging to Puerto Rico. According to their government, the water system, with 114 municipal water treatment plants, was severely damaged, leaving about half of the residents without water. Extra funding and attention to long-term solutions include water level storage sensors and software by BinMaster.

Municipal Water Measured with Radar Puerto Rico

3D and Radar-Can't Touch This
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3D and Radar-Can't Touch This

See through silo walls without touching product

Food manufacturers find non-contact level sensors attractive for a number of reasons. Of course, since nothing comes into contact with the material, there’s no risk of equipment interfering with the process or rogue parts breaking off and getting stuck in equipment or contaminating ingredients intended for human consumption. Plus, they provide continuous level measurement for optimizing inventory and preventing silos from running empty. No food manufacturer wants to risk tagging a bad batch due to a missing ingredient. Today’s most popular non-contact technologies are laser, radar, and 3D scanners.

3D Radar, Radar Can't Touch This

Concrete Colossus and CementView
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Concrete Colossus and CementView

Sometimes stories illustrate solutions. A major concrete company reduced material shortages and simplified life for drivers and dispatchers using sensors and cloud software called CementView®. Read the story of how a company with 10 ready-mix plant locations automated monitoring of 58 silos containing cement powder, IPF, and fly ash. CementView® keeps dispatchers informed. Using a PC, tablet, or phone dispatchers can monitor inventory for each silo and plant location by material. Text and email messages automatically alert to low levels.

Concrete Colossus

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