07 October 2024

Gareth Mitchell, UK partner manager, Heliot Europe discusses how sensors, IoT and LPWAN technology can minimise waste within manufacturing, and improve the refuse collection process

Manufacturers are increasingly burdened with rising energy and labour costs, regulatory demands, and growing environmental responsibilities. Among the common issues they share is inefficient waste management. Traditionally, industrial waste bins, particularly in vast setups like automotive production lines, are emptied on a fixed schedule, often before they are full, resulting in wasted resources. Internet of Things (IoT) technology presents a solution by equipping bins with sensors that are able to monitor fill levels. This enables real-time data collection to optimise waste collection processes, reduce unnecessary trips, and for the reallocation of human resources to more critical tasks. Gareth Mitchell, UK partner manager, Heliot Europe discusses how sensors, IoT and LPWAN technology can minimise waste within manufacturing, and improve the refuse collection process.

The hidden inefficiency in waste collection
To grasp the magnitude of the waste management problem in manufacturing, consider a typical example from the automotive manufacturing industry. In this industry, production lines can span to more than a kilometre in length, with individual disposal bins at each stage for different types of waste - standard, specialised, or recyclable. In an ideal situation, these bins should be emptied when they are full, but this is often not the case.

In many scenarios, subcontractors are used to collect waste from bins. When bins are not completely full, these trips are wasted. As well as this, the manual method of monitoring the fill level of a bin is often wasteful. In manufacturing environments, employees are generally pulled away from their typical work locations to manually inspect bins, depending on the manufacturer’s process and type of waste, which reduces potential productivity and output for these workers. Moreover, in the absence of specific monitoring data or insights, the frequency and timing of collection often becomes incorrect and poorly coordinated. Is it truly efficient for staff to spend time inspecting fill levels of rubbish bins when they could be engaged in more productive activities?

As a result, the whole waste collection process can be inefficient for many manufacturers, both in terms of how the bins are filled and how resources and productivity are squandered in managing or collecting them. Should manufacturers really be paying subcontractors to collect bins when they aren’t full? All these inefficiencies highlight the need for tracking of waste within bins and improved communication when bins need to be collected and replaced.

Automating waste management
A more effective alternative to collecting partially full bins or manually checking a waste disposal status is to utilise IoT technology. This can significantly enhance human productivity and efficiency, while streamlining the tracking and collection of bins. By equipping bins with IoT sensors connected to back-office IT systems, they can provide real-time or as near to ‘real-time’ data on waste levels. This kind of information could digitise the management of waste more effectively.
The sensors can measure the bin’s volume or mass, providing data about how full the bin is. This information can be shared with manufacturers and third-party waste collection firms to determine the optimal time or day to collect waste. With sensors indicating fill level (e.g., by weight or fill level), manufacturers can reassign employees to other tasks within the organisation too, thus recovering this lost productivity.

Connecting bins to the internet via the sensors also allows manufacturers and sub-contractors to accurately track bin locations and assess any replacement needs at the same time too. Questions like whether the collection schedule with the subcontractor needs to change, or if there is a more sensible route within the factory itself to collect the waste can be addressed, for example. This data could significantly improve the waste management strategy for manufacturers.
In some scenarios, manufacturers use reusable packaging for storing or transporting goods. For instance, in glass production, where car windscreens are produced, the windscreen might be produced and loaded onto A-Frame Stillages (trolleys or racks) and transported to automotive manufacturers, who then return the racks to the glass manufacturer. In this example, IoT sensors can help to track and trace the location of these racks and other reusable packaging, ensuring they are returned and re-used effectively. And this approach is not unique to this example either - it also has applications and uses within other reusable packaging scenarios.

Connectivity and sensors
A major advantage of this technology is that these sensors can be retrofitted onto existing bins within manufacturing warehouses and locations. These sensors are also designed to be able to connect to various data networks in several ways too. In environments where WiFi and 4G struggle (cellular) to penetrate metal and large machinery, the most cost effective and reliable method of data connectivity comprises using a selection of appropriate forms of low powered wide area network (LPWAN) connectivity.

LPWAN connectivity is preferable in this scenario because LPWAN networks comprise wireless wide area network technologies that interconnect low-bandwidth, battery-powered devices with low bit rates over long ranges. This is key because it helps to bring down the cost of transmitting the data. Furthermore, because the transmission of more data often results in increased costs and power usage in sensors and IoT devices, it is important, where possible, to maximise their battery life. This is especially important because, once a device is in the field, frequent battery changes are expensive and challenging. LPWAN devices typically last around five or so years in these scenarios.

Another reason that many organisations opt for LPWAN connectivity over cellular is because LPWAN connectivity gateways can be easily set up across manufacturing sites or production facilities with ease. This capability allows for the connection of devices in challenging environments with limited signal, and even allows for installations underground. Moreover, it is also relatively straightforward and faster for an LPWAN provider to set up additional network connectivity than it is for a mobile phone company to expand their existing network. Moreover, LPWAN providers typically offer more robust service level agreements compared to cellular providers. These benefits make LPWAN technology an excellent choice for connectivity in smart waste management services, offering cost and time efficiencies in installation, operation and maintenance.

Conclusion

In manufacturing, efficient waste management is paramount, not just for cost saving reasons but also for enhancing productivity and sustainability. The integration of IoT and LPWAN technologies provides a robust solution for manufacturers, addressing inefficiencies inherent in traditional waste management processes. Moreover, the adoption of LPWAN connectivity ensures robust and reliable data transmission, even in challenging environments, further streamlining the waste management process. This connectivity promotes an effective use of resources, making the entire operation more efficient and sustainable.

As the manufacturing sector continues to grapple with rising energy costs, labour shortages, and increased regulatory pressures, embracing these technologies is an attractive solution for manufacturers across a broad range of industries. IoT enabled smart bins and LPWAN connectivity represent a way forward in waste management techniques, offering both economic and environmental benefits.