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 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.
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.
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.
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.
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.
A major plastics production plant needed to closely monitors bulk inventory to avoid production delays. The plant provides a variety of products fed from plastic pellet storage silos. The facility also uses polyvinyl chloride (S-PVC) which is the world’s third-most widely produced synthetic polymer of plastic. delivers accurate, reliable, and continuous non-contact volume measurements. Enter ResinView.
From bulky cocoa beans to fluffy cocoa powder the chocolate industry counts on massive silos (some more than 1,000 tons) to store raw materials headed to factories across the world. BinMaster 3DLevelScanner can count it all with a point-level measurement that "sees" through powder and reports the level in a silo.
The Baking Industry knows that every pound of ingredient counts towards the bottom line. Changing production lines cannot take long. Cleanups and start-ups all pull production from the bottom line. Product shortages cannot be tolerated and BinMaster 3DLevelScanner can continuously monitor ingredient inventory in silos so managers aren't caught off guard. Inventory levels can be sent to a cloud report to maximize ordering and ingredient reloading practices.