Unlocking Efficiency in Grain Processing with IIoT

Creating efficiency by merging digital technology with physical systems

The Industrial Internet of Things (IIoT) is revolutionizing the grain and processing industries by merging digital technology with physical systems to create smarter, more efficient operations. By leveraging IIoT, facilities can address critical challenges such as labor shortages, high downtime costs, and the growing demand for productivity improvements.

Artur Rdzanek, IIoT director at Dodge Industrial, explains how IIoT transforms grain processing by enabling real-time monitoring, predictive maintenance, and centralized data management. This integration not only enhances operational efficiency but also ensures facilities stay future-ready in an increasingly competitive industry.

The IIoT Advantage: Addressing Labor Shortages and Safety

With baby boomers retiring at a rate of 10,000 per day through 2030, the grain industry faces a significant labor shortage. This shift leaves facilities struggling to
maintain critical operations with a reduced workforce. IIoT provides a solution through automated monitoring systems that reduce the need for constant manual oversight.

Wireless sensors play a crucial role, measuring parameters like temperature, vibration, and lubrication levels. Alerts are generated when metrics approach
thresholds, allowing maintenance teams to address potential issues before they escalate. For instance, by identifying early signs of wear on a gearbox, teams can prevent catastrophic failures and avoid costly downtimes.

Big Data in Action:Transforming Insights into Results
IIoT generates massive amounts of data, often referred to as “big data,” which can overwhelm facilities that lack the tools to process it. However, IIoT platforms are designed to filter, analyze, and visualize this data to produce actionable insights. For example, a grain elevator equipped with IIoT sensors collects 480 data points
per device daily. When scaled to a facility wide level, this data enables managers to identify trends, predict failures, and optimize operations. Advanced analytics
turn these raw numbers into meaningful patterns, helping facilities move from reactive to proactive maintenance strategies.

Real-World Results: Preventing Costly Downtime

The financial impact of unplanned downtime is a pressing concern for grain facilities. According to Rdzanek, a typical plant loses $6,870 per hour of downtime, or $54,960 per eight-hour shift. In one example, a grain elevator equipped with IIoT condition monitoring detected rising vibration levels on its primary offload conveyor. By addressing the issue proactively, the facility avoided 40 hours of unplanned downtime, saving approximately $320,000 in lost productivity.

IIoT in Practice: Centralized Dashboards and Alerts
IIoT’s centralized dashboards provide an intuitive way for managers to oversee facility operations. By consolidating data from all sensors into a single interface, dashboards allow teams to monitor multiple locations, compare benchmarks, and track performance metrics in real time. This functionality is further enhanced by mobile notifications.  Alerts for metrics like temperature and vibration ensure immediate action can be taken when critical thresholds are reached. This instant feedback loop minimizes risks, supports timely decision-making, and keeps facilities running smoothly.

Building a Future-Ready Industry
IIoT is more than a technological upgrade – it’s a strategic investment in the future of grain processing. With ongoing advancements in machine learning, artificial intelligence, and cybersecurity, IIoT platforms are continuously evolving to meet the needs of the industry.