Seconds Count with Sensors & Silos

BinMaster sensors and software provide significant labor relief by replacing tedious and frequent physical labor. This results in a safer workplace, better inventory accuracy, and strategic ordering and dispatching.

To illustrate the benefits and return on investment, consider Acme Company. Acme stores bulk materials in a 50-foot-tall silo. Acme’s control room sits 100 yards from the silo and an employee measures silo levels twice a shift during seasonal production.

Before a BinMaster system was installed, Acme wasted time, spent excessive labor, and opened the door to error.

Acme`s Time Scenario

• 4 minutes – Employee walks from the control room to the silo and back
• 2 minutes – Employee climbs 50-foot ladder, up and down
• 4 minutes – Employee pulls heavy roof inspection door atop silo and drops a tape measure
• 5 minutes – Employee records measurements, communicates to the manager, fills out a form, or enters data into a spreadsheet
• Total – 15 minutes for one measurement of one silo. How many bins and silos are you measuring?

The United States Workforce Shortage

• 47 million workers quit their jobs during “The Great Resignation” in 2021
• Manufacturing lost 1.4 million jobs at the onset of the pandemic [US Chamber, November 2022]
• 91% of workers desire to work from home, and 3 in 10 workers signaled they would seek new jobs if recalled to the office [Gallup]
• 2.8 million workers are missing in the labor force compared to February 2020 [BLS]
• Labor force participation rate is 62.4%

BinMaster`s Solution

Level sensors and cloud-based software play a leading role. The BinCloud® phone app for remotely monitoring inventory is compatible with a wide range of sensors and measurement technologies.

Level sensors` versatility lends them to use with silos, bins, and tanks of different shapes and sizes, storing all types of solids, powder, and liquids including plastic, cement, grain, feed, ingredients, fuel, and more.

Improved Safety

Is manual bin measurement good exercise or risky? Workforce shortages cannot be completely cured with a bulk material inventory system by BinMaster, but it’s a good step.

Level sensors save time and eliminate ladder climbing. Automated measurements improve processing efficiency, ordering, and delivery scheduling. Improved accuracy eliminates material shortages and reduces carrying costs. Employees can monitor bin levels while on-site or off-premises. High- or low-level alerts via text or email allow for proactive supply chain actions that can add to an operation’s bottom line.

• Ladder injuries account for 136,118 emergency room visits in the US annually
• Falls from ladders account for 20% of fatal falls in the workplace with an average of 113 deaths per year in the US between 2011 and 2016 (CDC)
• A small inspection hatch on a silo could weigh around 20 pounds, while a large steel door could be hundreds of pounds.

Now imagine maneuvering on top of a silo with high winds, a heavy door, and a floppy tape measure... and the hatch slamming shut. Ouch!

Realizing a Return on Investment

• Better Accuracy: Most level sensors are accurate within 0.2” of the distance measured
• Improved Safety: Automated measurements eliminate the need for climbing ladders
• Time Savings: More measurements are done with less manpower, requiring fewer people