Agrochemical Plant Transforms Tank Inventory

Measurements Needed to Be More Frequent

Tracking tank levels was done one tank at a time. They climbed each one, took a manual measurement, and wrote it down.

Others were measured using a battery-powered laser and a mesh network that took readings once or twice a day. Some tank levels were tracked on a whiteboard with a Sharpie. The previous system provided a limited number of tank readings, so the level of a tank may have changed before the measurement was recorded.

Climbing Was Dangerous

Their slippery, stainless-steel tanks didn`t have attached ladders, creating a safety hazard and a risk of falling. On top of that, some stored chemicals emitted dangerous fumes when tanks were opened to retrieve level measurements.

Inventory Turns Rapidly

Each day included several incoming and outbound chemical deliveries. Plant personnel hustled to meet the demands of local farmers. Purchasers scrambled to keep up with orders. Blending operations needed real-time inventory to ensure they had chemicals in stock.

Inventory turnover was very high—especially seasonally, when chemicals moved in and out rapidly.

Sensors Automated Measurement

Designed for measuring corrosive, harsh, and aggressive liquids, compact non-contact radar level sensors were installed to automate tank level measurement. Their level readings provided accuracy within 0.2” and updated continuously without manpower. Employees recieved continuous data, no longer flying blind between manual measurements.

The system started with 36 sensors installed on their most critical tanks, and was easily scalable to all 150 tanks—plus further expansion dependent on the plant`s future plans.

Current Inventory, Always on the Network

Instead of writing down measurements, purchasing and production personnel accessed data via Binventory® software, installed on on-site PCs. Six computers were networked within the operation, meaning everyone viewed the same inventory at the same time.

Benefits of Inventory Transformation

• Workers could stop manually measuring inventory
• Occupational safety risks were reduced by eliminating climbing and exposure to fumes
• Tanks were sorted by chemical in the software, helping workers know how much of each was on hand
• Inventory was accessed on any networked computers; everyone viewed the same current data
• Personnel ran reports as needed to know what tanks were getting low
• Blending could rely on having the chemicals they needed
• Purchasing and suppliers experienced less stress, with fewer last-minute orders
• Ordering got easier, knowing how much to order and when it was needed.
• Time-taking inventory was cut by 75%
• Shorter lead times and fewer out-of-stocks improved customer satisfaction

Alternatives for the Future

Instead of Binventory on a local network, the plant could move to BinView®, built on the BinCloud® platform.

This would put inventory in the cloud making multi-site access much more simple. BinView can be accessed from a phone, tablet, or PC, making it portable and accessible when off-site. 

BinCloud also lends convenience to co-ops with many different types of grains, feeds, ingredients, chemicals, and fuels that need to be monitored.

Improved Scheduling & Product Management

Production teams blending chemicals were assured they had all the different ingredients they need for each blend in stock. Purchasing found ordering easier thanks to current inventory.

Inventory was transformed across several sites thanks to reliable radar sensors and smart inventory management software.