Worldwide tank monitoring for Merck

Today, intelligent networking can be implemented not only in industrial production, but also across the entire supply chain – from the supplier to the customer. Simple load carriers such as barrels can now become intelligent players in the new Industry 4.0 world. The best example: the iBarrel from Merck, one of Europe's largest pharmaceutical companies. With a newly developed remote monitoring solution, the chemical manufacturer is taking advantage of digitization. Operating data on the location, fill level and removal of its solvent containers used worldwide, for example, can now be recorded automatically, enabling innovative logistics processes and new business models to be realized. The technical 4.0 upgrade of the drums is also certified for use in potentially explosive atmospheres in accordance with ATEX and QPS.

Transparency creates new customer benefits

In the past, load carriers such as drums and containers made of stainless steel were considered rather unsexy and were previously niche products in logistics. Thanks to Industry 4.0 technologies and digital networking, new light is now being shed on these previously relegated liquid carriers. Simple industrial containers can now be equipped with intelligent hardware and software and continue to develop into important players in industrial value chains. For manufacturers and suppliers of chemical products, for example, this opens up completely new possibilities for increasing customer benefits through greater transparency, for example in filling levels, as well as through increased safety in use. But it can also be used to implement innovative logistics processes and new business models.

Worldwide recording of operating states

What has not yet been solved, however, is the intelligent monitoring of all solvent containers worldwide and the recording of current operating conditions. This results in increased benefits both for customers and for Merck as a manufacturer and supplier. Precise knowledge of the location and operating data such as fill level, temperature, internal pressure, possible leakage, incorrect removal or theft of the drums would be tantamount to a quantum leap. Automated collection, evaluation and processing of the equipment data would also allow better control of production and logistics processes. A projection based on the history data makes it possible to plan production volumes in advance and to ensure efficient logistics in line with demand. Automated data collection through the data entering directly into the SAP system enables the right decisions to be made for production orders and delivery dates to be better met – thus increasing customer satisfaction. Remote monitoring of the drums also has clear advantages on the customer side: Users benefit from high transparency of their inventory, pinpoint delivery, high supply security, and safe handling during withdrawal operations.

GPS controlled remote monitoring

RCT developed an overall concept for the transmission unit for monitoring the mobile solvent containers with Merck in 2021. The aim was not only to monitor the fill level and temperature, but also to localize and report the location of the individual containers. Using a simple capacitive and flexible sensor, the individual modules can be adjusted according to the container size. Another important feature is that the unit includes enough memory for wireless transmission of all container data and fill data. This electronic waybill greatly simplifies logistics. There are plans to extend the system to monitor in-plant transport containers and skeleton containers. Here, the entire internal logistics is to be supported.