Cocoa beans and cocoa powder are stored in silos and warehouses. Sometimes beans are stored in their original sacks before they are processed; beans are even sorted according to type. Eventually, cocoa beans are stored in huge silos, many of which hold more than 1,000 tons.
For one BinMaster customer, cocoa powder and bean storage needed to be isolated from production to ensure adequate air circulation, cool temperatures, and regulated humidity.
Challenge #1: Storing Pods
Cocoa bean storage silos are usually quite large. Beans are prone to generating dust, making it difficult for sensors to measure the beans reliably and accurately. They may pile unevenly inside the silo, which can be a challenge when accurate volume measurements are needed.
Challenge #2: Shell Storage
Shell byproducts are stored in silos before being shipped for use in other products, like mulch or fertilizer. Shells have a coarse texture and, when combined with humidity and temperature, can build up or create irregular topography in the silo.
Buildup can potentially damage the silo and diminish product quality. Additionally, internal temperatures rise over time, which may cause beans to mold and clump. Detecting buildup as it occurs and knowing the overall material volume is crucial to the end user.
Challenge #3: Storing Cocoa Nibs
Cocoa nibs are stored in silos prior to entering the cocoa production process. End users must accurately monitor inventory levels to ensure continuous supply of nibs into the entire cocoa production process, helping avoid unexpected interruptions and losses in reduced profitability and time.
Challenge #4: Powder Storage
Prior to being bagged or shipped in bulk, cocoa powder is stored in silos. As powder is conveyed into a silo, it can pile unevenly and be extremely dusty. The powder is prone to bridging and buildup within cocoa storage units and cocoa powder storage containers.
The Solution?
Accurate inventory measurement is necessary to provide an adequate supply of beans for production. BinMaster’s 3DLevelScanner technology, featuring multiple-point mapping, overcomes these problems and enables accurate assessment of volume remaining in the silo at any given time.
