Reliable monitoring of fill levels in Intermediate Bulk Containers (IBCs)

Intermediate Bulk Containers (IBCs) are standardized, mobile transport and storage units with a volume of 1000 liters. They consist of a tank bladder in a metal cage and are mounted on stackable pallets. IBCs are used across all industries, both indoors and outdoors, to supply, collect or store liquid or free-flowing media. Examples include the supply of adhesives in the packaging industry, the collection of condensate, the provision of process materials or the storage of extinguishing agents.

In order to be able to initiate the timely replacement of an IBC, accurate, automated fill level detection in the IBC is crucial. The technology used for this must be able to withstand harsh weather conditions and should not require a wired power or network connection. To avoid time-consuming configuration changes, the typical measuring range must already be preset in the sensor. The connection of further inflow or outflow lines to the IBC lid must not be obstructed. If required, the solution should also enable geolocalization (localization) of individual IBCs.

The battery-operated ultrasonic wireless sensor WILSEN.sonic in the IBC version measures the fill level with millimeter precision and transmits this as a percentage value via LoRaWAN. The device can be quickly, easily and safely screwed into any IBC lid with a standard 2" thread without a cable. For lids with two screw-in openings, the unused one remains free for supply lines or other attachments. The measuring range of the sensor is preset, parameterization is not required. When changing the IBC, the sensor remains in the cover and can simply be reused - there is no need to re-register in the LoRaWAN network. This means that only one device is required per measuring point, regardless of the number of IBCs used. The sensor is also retained when an IBC is disposed of. The WILSEN.node wireless sensor node can also be used to detect leaks and maximum fill levels in drip pans below the IBCs. It enables the wireless connection of capacitive sensors or vibration limit switches, which are particularly suitable for this detection task.

Thanks to the robust ultrasonic technology, the WILSEN.sonic always reliably detects the fill level, regardless of the color or composition of the medium. The message transmitted via LoRaWAN also contains data such as ambient temperature and battery status. Additional measurement data (e.g. sensor location via GPS) can be added if required. A replaceable high-performance battery enables a maintenance-free operating time of up to 10 years. The housing of the sensor is very robust (protection class IP66/67) and designed for outdoor use. With the WILSEN app (Android and iOS), the device can be easily registered and parameterized via Bluetooth in the energy-efficient, encrypted LoRaWAN wireless network. The LoRaWAN downlink channel also enables parameterization or querying of parameter values via remote access.

At a glance

• Reliable monitoring of fill levels in IBCs
• Quick and easy installation via 2" thread and preset measuring range
• Energy-efficient communication via LoRaWAN®
• Secure data transmission with end-to-end encryption
• Battery life of up to 10 years
• Additional leakage monitoring via wireless sensor node WILSEN.node possible