In recent years, the grain and milling industries have embraced cutting-edge technologies to streamline operations, enhance quality control, increase productivity and ultimately reducing costs. One of the most promising innovations to emerge is LiDAR (light detection and ranging).
Traditionally associated with autonomous vehicles, mapping, and environmental studies, LiDAR technology is now making its way into agriculture and food production industries, including grain handling and milling facilities.
But what exactly is LiDAR, and how is it being used in the grain and milling industries? This article covers the basics of LiDAR and explores its growing applications in grain handling, milling processes, and quality control.
LiDAR Explained
LiDAR is a remote sensing method that uses laser light to measure distances and create detailed, high-resolution maps of objects, surfaces, and environments. The system typically consists of a laser scanner, a sensor to measure the reflected light, and software to process the data. LiDAR works by emitting laser beams that bounce off objects and return to the sensor, providing real-time, three-dimensional (3D) data about the surroundings.
In the grain and milling industries, LiDAR is used to create 3D models of entire structures which then allows users to pull precise measurements for existing roof beams, trusses, openings, and other critical elements to assist structural engineers in the development of detailed design drawings for repairs, equipment upgrades, etc. Traditionally, such information was provided by the contractor by manual field measuring only after construction work has begun, hence impacting design completion and subsequently material lead times, all which could lead to unnecessary cost increases.
LiDAR measurements are also helpful for calculating square footage of damaged areas to help engineers evaluate repair scopes and communicate accurate findings to customers in inspection reports. Additionally, when paired with drone technology, LiDAR eliminates the need for humans to enter dangerous, confined spaces, enhancing safety during structural assessments.
Structural Assessments
LiDAR technology offers a powerful solution for assessing structural integrity and optimizing storage management in industrial settings. It enables the precise identification of damaged areas in spalled concrete, helping to detect deterioration before it leads to critical failures.
While a drone records the details of damage or other points of interest, LiDAR can determine the exact elevation and locations which are then used to communicate the finding as well as efficiently being able to locate the areas for repairs in the future. One such point of interest may be interior damage between silos that may be causing unwanted commodity spillover between bins, which cannot be found with traditional exterior inspections or with traditional interior inspections using a Bosun chair.
Beyond structural assessments, this technology is also invaluable for inventory management, as it can accurately estimate the volume of grain stored in silos and calculate the amount of spoilage that needs to be removed. By providing detailed, real-time data, LiDAR enhances efficiency, reduces manual inspection efforts, and improves overall maintenance strategies.
Thermal Camera Capabilities
In certain cases, clients have requested assessments of silos following an explosion. Leveraging our advanced thermal camera payload, we can precisely detect hot spots and smoldering grain, identifying areas at risk of further combustion. The technology allows us to determine both the exact location of the smoldering material and the remaining volume of grain that could sustain the fire. This critical data enables us to guide the local fire department directly to the affected silo, ensuring a swift and targeted response – all without the need for hazardous human entry.
By enhancing safety and efficiency, this approach minimizes risks while optimizing emergency intervention efforts. Thermal imaging may also help detect water intrusion areas due to cooler temperatures caused by evaporation.
Software Deliverables
Following the completion of a field inspection, we process the collected data using a proprietary modeling software to analyze and annotate high-resolution video, images, and LiDAR data captured by the drone.
This advanced approach allows for the generation a comprehensive, site-specific report, featuring full 4K video, identified points of interest, and a complete LiDAR point cloud for in-depth assessment.
One of the key capabilities of this software is its screen-sharing functionality, which facilitates seamless collaboration during video calls and meetings. This feature allows engineering teams to replay, analyze, and take precise measurements in a live setting, ensuring informed decision-making.
Additionally, the ability to present these findings in board meetings provides stakeholders with a clear, data-driven understanding of the assessment, enabling them to ask informed questions and make well-grounded decisions regarding proposed repairs.
Cheyenne Wohlford is founder and CEO of CCS Group, LLC. The Seward, NE-based concrete contractor provides structural assessments, preventive maintenance, and emergency repairs for terminal and country grain elevators.