IBC Tank Monitoring Systems

IBC Tank Monitoring Systems

An IBC tank is an industrial-grade, pallet-mounted container used to store and transport powders and liquid bulk. These tanks are commonly referred to as a tote capable of stacking and can be moved by a forklift or a pallet jack. Today, the most common types of IBC tanks are categorized under flexible, folding, and rigid. The term intermediate is derived from the volume these containers carry, which is between drums and tanks. This article will discuss everything about intermediate bulk containers; read on to learn more.

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Technologies Applied in Measuring IBC Tank Levels

There are different technologies used in IBC tank monitoring systems. When faced with a situation to choose one, you will have a wide range of options to consider. However, given the high number of these technologies, some are only better suited for specific tasks. Discussed below are some of the standard technologies used in measuring IBC tank levels.

Differential Pressure

This is one of the oldest and most trusted IBC tank monitoring technology. The differential pressure technology is commonly used on liquids and liquefied gases, both in the open and closed IBC tanks. This technology can also be applied to pressurized tanks. In the differential pressure technology, there is a meter that includes a diaphragm mounted with a sensor. There is also a stable body that is used to measure the levels of pressure in the container. Upon the exertion of pressure, the diaphragm will deflect, changing the direction of the sensor. This will create a reflective electrical signal. It is important to note that the sensor in this technology is susceptible to pressure movement.


This is another technology used to measure levels in IBC tanks. It relies on emitted sound waves to accurately determine the level of the content. The ultrasonic technology gauges the distance between the tank’s surface and the top; then, it uses it to calculate the level. This improved technology is effective on both liquid and solid content. It starts its operations when the transducer releases ultrasonic impulses that represent the mechanical energy. When this is done, the waves rise up the material like an echo, promoting level measurements. Consequently, the transducer will calculate the time it takes to travel the tank’s height and content. This helps it to accurately calculate the level of the content and other crucial details.


This is one of the most recent technologies in measuring IBC tank levels. It is also one of the latest and most advanced technologies that can provide highly accurate readings. Over the last five years, this technology has improved significantly to become reliable and efficient. The laser technology works when a laser is mounted at the top of each vessel pointing downwards. To give accurate readings, the laser emits a beam of light. It is reflected from the material’s surface to the other end the material has been detected. Note that calculating the levels in this technology is based on the laser’s time to reach the surface of the content.

Role of IoT in Tank Monitoring

IoT plays an essential role in IBC tank monitoring. Storage facilities depend on these systems to accurately and effectively monitor the stock levels. In most cases, companies only rely on employees to physically monitor the tank levels. This can quickly turn out to be risky, ineffective, and time-consuming. Consequently, these storage facilities will run out of stock due to improper monitoring. To stop this from happening, they need IoT level sensors to monitor the content levels in IBC tanks remotely. IoT level sensors do an excellent job in monitoring the content under storage.

Using manual methods to monitor tank levels can be very dangerous. Chances of experiencing overfills and spillage are high when monitoring these tanks manually. Besides, there could be catastrophic blasts when explosive material spills over due to improper monitoring. Furthermore, manual monitoring could give inaccurate results. This can make the business run out of stock due to lack of timely refills and restocking. IoT level sensors are highly accurate and can stop this from happening. A company will be able to restock the refill on time, ensuring a steady flow of goods.

IBC Tank Monitoring Systems and Cloud-Based Solutions

Tank monitoring systems and cloud-based solutions have one primary purpose: keeping track of the tank’s content level. The system also monitors other vital metrics like temperature and pressure. IBC tank monitoring systems are highly sophisticated communication technology tools that help determine the content levels. Storage facilities rely on these systems to keep track of the tank’s content. They are highly advanced that you can monitor tank content from anywhere you are. These systems are effective on any content, be it water, chemicals, lubricants, or fertilizer. Combined with cloud-based solutions, these systems are highly effective.

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Data That Can Be Monitored and Displayed on a Connected IBC

There are different types of data that can be monitored and displayed on a connected IBC. Here are some of them.

Qualitative Data

Also known as qualitative or categorical analysis, this type of data describes the tank’s content using a finite set of classes. In simpler terms, this kind of data can be measured or counted easily using numbers. Qualitative data can also be divided into several categories. When used in IBC tanks, this data often involves solids. For instance, if the tank contains bags of fertilizer, it can only be measured by numbers. This means that the dashboard’s information indicates the total number of bags in the IBC tank.

Qualitative Data

This is another kind of data that IBC systems can monitor. Qualitative data is one of the most common types of data monitored by IBC systems. It tries to quantify things by evaluating their different numerical values. Just like qualitative data, quantitative data is often applied to solid tank contents. Quantitative data is helpful because it helps you monitor your stock, knowing when you need to restock. This type of data can also be obtained from gases and liquids.

How Can IoT Level Sensors for IBCs Help Your Business?

Thanks to the internet of things, so many processes are now optimized. IoT is a growing infrastructure of internet-connected devices ranging from light bulbs to vacuums. This technology is aimed to increase automation, control, and data collection. There are several ways IoT level sensors for IBCs can help your business; discussed below are some of them.

Improves Communication

The amount of information provided by IoT level sensors monitoring systems is crucial for effective management of the content. When the intelligent sensors deployed in various IBC tanks relay information simultaneously, the acquired bandwidth can be very detailed. Furthermore, IoT level sensors ensure that information is pre-processed on-site, cutting down on the size of data that has to be sent remotely. With fewer data to process, the system reduces bandwidth and latency. This ensures that crucial information like leakages is shipped immediately, preventing accidents and other possible explosions.

It Makes It Easy to Access the Tank

With IoT level sensors, it is easy to access the tank’s content. They help streamline the process of monitoring IBC tanks and their content. Furthermore, IoT level sensors play an essential role in inspecting the content’s temperature and humidity. They also relay information on crucial aspects of the content, like its pressure. This is done remotely, preventing the need for physical inspections. By doing so, IoT level sensors avoid the chances of accidents to employees. They also ensure that business is running smoothly by alerting you whenever the content is almost running out. This prevents products from running out of stock due to untimely refiling.

It Saves Money

IoT level sensors are cost-effective compared to traditional tank monitoring systems. They require low maintenance costs and provide more accurate information. In a business setup, this system saves time and money because it does not need monitoring. Given that it can handle several tasks at a go, you can reassign human resources to other duties. This will increase productivity, helping your business improve.

Monitoring IBC Tanks Increase Logistical Conversions

IBC tank monitoring systems play an essential role in the production process. Some different components and aspects are involved in an IBC tank monitoring system’s operations, and this article has discussed all of them.

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