Articles by David Zelnio

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Bulk Density is Key to Bulk Material Storage

What is bulk density? In simple terms, it’s mass per unit volume of powder, liquid, granules, or any material in a bulk state. When handling solids or powders, a bulk material’s weight is usually stated as lb./ft.³ or g/cm³.

Veteran processors often have their material weights memorized. While BinCloud® software's graphics and easy-to-understand reports seem to generate easily, bulk inventory information is calculated using numerous traits, including vessel size, headspace, and bulk density.

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Improve Carrying Costs with Bulk Measurement Systems

Supply Chain Cloud Software Bulk Inventory Automation

Before COVID-19 and the supply chain crisis, industries relied on savvy just-in-time ordering to minimize carrying costs like warehousing, tied-up capital, product spoilage, and waste. According to Investopedia, such carrying costs represent up to 30% of total material value.

“BinMaster is navigating the same supply chain waves as our customers,” said Scott Hudson, President, BinMaster. “We’re hearing from people who can’t get their materials delivered on a consistent schedule, so they’re really using BinMaster for planning orders. They can’t afford to shut down production because of a bad or outdated measurement.”

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Industry 5.0: The Techno-Social Revolution

Cloud Software Bulk Inventory Automation Industry 5.0

As organizations polish Industry 4.0 tools and processes—including level sensors and software for inventory management—a new focus has emerged that helps companies define ways to benefit employees, sustainability, fairness, and human interaction.

Industry 5.0 benefits from 4.0 achievements regarding industrial automation and process improvements. This new phenomenon points to sustainable, human-centric goals, requiring leaders to ask, “Are we supporting future societal values?”

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Culture & Digital Transformation in Bulk Supply Chains

Digital transformation improves supply chain resilience, automation, accuracy, and efficiency, benefiting people effectively collaborating in a digital system.

BinMaster designs systems to pool such technologies. By bringing bulk material data from sensors atop silos to a secure cloud report, authorized users can access the same information in real time. Decisions and conversations bring decision makers the same data.

It’s all about collaboration, accuracy, and transformation to automated processes.

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Sensors for Bunkers, Pie & Oh My

Cement 3D Level Measurement Continuous Level Sensors

Some bulk material applications are straightforward. Others, not so much. BinMaster’s 3DLevelScanner works well in most bins and silo storage.

Operators can "see" uneven loading with 3D technology, allowing them to adjust before major failures. As bulk material tends to pile unevenly in pie-shaped bins, 3DLevelSensors are the best solution for measuring these structures. Material stored in bunkers can be measured accurately, accounting for the ups and downs of piles.

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IoT is Key to Cloud Inventory

Cloud Software IoT Internet of Things Continuous Level Sensors

Organizations face a storm of challenges: the strain of product demand, limited supply chain resources, and an unprecedented exodus of people leaving the workforce. Thankfully, Industry 4.0 technology and systems provide some relief.

Industry 4.0 is a system that combines informational and operational technology to make manufacturing more aware, predictive, and autonomous. Employees operating in a 4.0 environment are highly connected with a more complete view of their business ecosystem. Level sensors and software directly feed the Industry 4.0 atmosphere.

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Plugged Chutes Design and Monitor

Flow Detect Plugged Chutes

Chutes are used to control the direction of material, a flow stream, spillage, dust and environmental pollution, production degradation, and surge control.

Proper chute design can make or break an operation. This construction may include high-tech sensors to indicate flow/no-flow material conditions. Operators can be alerted before or shortly after a plug occurs, allowing immediate action to prevent damage to equipment, bulk material waste, and worker injury.

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Seconds Count with Sensors & Silos

Industry 4.0 Bulk Inventory Continuous Level Sensors Automation

Workforce shortages in the U.S. have sparked great energy toward technology. The urgency to implement automated work processes continues to climb.

BinMaster sensors and software provide significant labor relief by replacing tedious physical labor. These solutions result in a safer workplace, more accurate inventory, and the development of strategies for smarter ordering and dispatching.

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Maintenance, Repair, Operations: Strategic Spending

Bulk Materials Maintenance Repair Operations

According to a study by Markets N Research, maintenance, repair, and operations (MRO) budgets will grow from $701 billion in 2021 to $897 billion by 2028. MRO can cover supply chain management, industrial machine upkeep, technology advancement, artificial intelligence, Internet of Things, and preventative maintenance solutions.

BinMaster sensors and software bring technology improvements with a quick return on investment. Besides replacement parts, companies can budget for future needs—including inventory management systems for new bin, tank, or silo installations.

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Operational Technology & BinMaster

Level sensors and switches have transformed industries that store bulk materials in bins, silos, and tanks. Simply detecting the presence of material opens potential for automation, such as turning conveyors on and off or alerting employees to possible overfills or empty vessels.

Demand for Operational Technology—the practice of using hardware and software to control industrial equipment—continues to grow. Data from level and flow sensors interacts with the physical world through processing equipment, programmable logic controllers, distributed control systems, supervisory control, and data acquisition systems.

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How Industrial Internet of Things (IIoT) Drives Bulk Solids Management

Impact of IIoT Systems on Bulk Solids Management

Now more than ever, manufacturers expect—and must navigate—volatile supply chains and pricing. Effective bulk material management begins with smart systems that make data easily accessible, which ultimately helps strengthen inventory control. Level sensors and software from BinMaster help...

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Benefits of Non-Contact Measurements in Food and Beverage Processing

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CNCR-390 and BinTrac A-Frame Load Cells for Inventory Measurements

Level & Weight Measurement Technologies for Accurate, Automated Operations

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GEAPS Exchange | BinMaster

Booth #3220 February 21-24, 2025 Kansas City Convention Center Kansas City, Missouri Visit the show home site

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Garner Industries is now BinMaster Sensors and Technologies LLC

Garner Industries Announces Corporate Name Change to BinMaster Sensors and Technologies LLC

As of November 10, 2025, Garner Industries LLC will operate under a new name: BinMaster Sensors and Technologies LLC. The new name reflects the company’s continued growth, innovation, and commitment to delivering advanced sensors, software, and technologies that help customers make smarter, safer,...

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Articles by David Zelnio