Using Advanced Monitoring Systems To Manage the Challenges of Large Bin Grain Storage
25 Jul 24

Kelly discusses the challenges and solutions related to managing grain storage in large bins, highlighting a 60-foot grain bin that holds over 100,000 bushels. His primary concern is maintaining grain quality by monitoring moisture levels and preventing spoilage. To address these challenges, He is trialing a new system from OPI.

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00:00 We're standing by a 60 foot grain bin on my operation. It holds just a shade over a hundred thousand bushel, one clear, full, uh, 00:07 our operation is growing like many others across the Midwest. Our grain storage is growing 00:12 and the problem is becoming, keeping the grain in condition, knowing what the moisture is. 00:16 You know, back in the eighties and the nineties when I graduated high school, we had hogs. Uh, you didn't have to worry about the grain so much 00:23 'cause it was a much smaller grain tank. We could grind a load or two out of there for the hogs. We would know the grain is in condition. Mm-Hmm. 00:28 Now with a hundred thousand bushel bin or 150,000 bushel bin or even larger, how do we know the grain is in condition? 00:34 And there's two different sets of expenses that I worry about. Number one, worst case scenario, 00:39 the grain goes outta condition. Mm-Hmm. And all of a sudden we've got some extra cattle feed. 00:42 Yep. Number two, because we don't want it to go outta condition, the other expense, and it's a bit hidden. 00:48 We run that fan more than we need to. There's an added electric expense. Mm-Hmm. And then we dry that corn down below 15. The corn shrinks. 00:55 That's an added expense that isn't something every farmer thinks about because it's not evident on your check. 01:00 But it is a real expense. We're putting in the op blue system here because we're taking the unknown out of the equation. 01:07 Information is power. It's also, uh, a huge added bonus, the safety factor. Mm-Hmm. When, when 01:15 that grain goes outta condition, it bridges up. You've gotta enter that tank. The the grain is standing up on you. Bridging up. 01:20 Like I said, it can be a very unsafe environment. Accidents happen every year and the larger the tanks go, the more the accidents happen. 01:27 Alright. So standing here, uh, we're here next to our, uh, um, fan node control box. 01:33 And as you can see, there is a, uh, piece of hardware there in the middle with a whole pile of wires tied into it. 01:39 Uh, some of the two of the wires are for power and the rest of it is all connected to sensors. So, uh, this top sensor up here 01:46 to the left is tied into the weather station that's right behind you. That tells you the external temperature 01:51 and external relative humidity. Then the next set of wires is a plenum sensor that is in the floor of the transition. 01:58 And, uh, that tells you the temperature and relative humidity under the bin as well as CO2 CO2 is key because that sense is anything 02:07 before the cables will see it. Okay. And we've had that, that's what I was wondering what the CO2 is. 02:12 Yes. That's like a precursor to a Problem. Yes. Okay. Yes. 'cause that's gonna tell you if you got bugs 02:16 or mold or anything else happen, it, it might take because the sensors are four feet apart, it'll just catch it a little bit quicker. 02:23 Yes. Can you tell us exactly how do the cables work inside the bin? Yeah. So, uh, the eve of this bin is less than a hundred foot. 02:29 So we hang these, uh, from the outside that, um, one makes install easier and we can, uh, install when there's, um, corn 02:37 or beans in the bin. Um, we just drop the cable through, we tie it to the door. When you empty it, we drop it down 02:42 and we tie 'em to the floor. That way they don't flail out when you're filling it. So every cable is gonna look really similar to this. 02:49 Um, they're, you know, whether they're a hundred foot long or 125 feet long, there's a, um, strand of cable 02:54 that loops in through here. And then we drop an insert in through the middle of it that has a, a sensing element every four feet. 03:00 So, if I remember right, this bin's about 60 feet tall. So there's 15 sensors between the floor and the roof. And this cable is designed when we measure that up, 03:10 it's measured to be, the bottom of it is about waste high. You have a power sweep in there. 03:13 We don't want these getting caught in the power sweep. And then this communicates with a solar powered node that's on top of the bin. 03:19 Um, and then that communicates with the office. And then, uh, what they see then comes back from that, um, uh, piece of hardware in the office. 03:28 And then this does all the things based on how we set the settings in the, He and you and I are obviously older than 33. 03:34 And you were talking before we got on camera. You know, when you would check bins, if it would sink up to your knees, the grain's good. 03:40 And I, you know, that made me chuckle when you say that. I remember going around with my dad 15 years old way 03:45 before Kyle was born at 33. And, uh, uh, you go and you, you'd go check the bin, you'd climb up. He said, well, how was it? I said, well, 03:52 I sunk into my knees. You know, this is a 10,000 bushel bin, probably a 27 foot diameter. 03:57 He said, well that corn's fine then you didn't worry about it anymore. Mm-Hmm. A 60 foot tank 04:00 or 110 foot tank like we've got here, sinking into your knees doesn't tell you much. Nope. 40 foot down. That's what makes this system. 04:07 Uh, we need this information. That's what makes this system necessary. There's a definite ROI here when we keep the grain 04:13 and condition and we don't dry it too much. Ian, can you talk to us a little bit about what the cost of this system is and what about the, what about if I want 04:21 to add this bin over here behind us, what is that gonna entail? So for the bin that we're talking about here, 04:25 said it's about a hundred thousand bushels. We're looking at that 15 to $20,000 range. And in that we're gonna put a combination of cables 04:33 to read both temperature and moisture. And then some cables are gonna read temperature. Like Kyle said, we're gonna put a sensor in the head space 04:39 and in the plenum that's gonna read temperature, moisture, CO2 and weather station. 04:43 We're also gonna put a gateway on site that's gonna communicate all the information back to the cloud. 04:49 It also means the first bin's gonna be the most expensive. 'cause we don't need a gateway on every one of our bins. 04:54 So if you were to add it to the second bin of an equivalent size, it's gonna be about 2,500, $3,000 less cost. 05:01 Because we're not gonna use the, we're not gonna put in a second gateway on the, We've already got the control system in the 05:07 office and we can keep going. It's Already right there. Okay. So a hundred thousand bushel bin, uh, 17,500 05:13 to do it halfway between 15 and 20. Yep. That's 17 cents a bushel. Yes. Yep. And that's year one. Yes. That's year one. 05:20 Uh, this is gonna pay off rather quickly. So When we've looked at this year over year, uh, and done several case studies, our goal is 05:28 to have this thing be net black in less than three years. And that can be from a combination of things, like you said, 05:34 preventing grain from going bad on the top of the bin. Mm-Hmm. Or preventing, uh, uh, excessive fan runtime and over dry on the bottom. 05:40 Mm-Hmm. But our goal is to have you in the black in less than three years by automating your fan control. 05:46 Uh, I could see that that's a very reasonable statement. You know, a lot of times it's advertised the 05:50 payback is faster than it is. I think three years is incredibly reasonable here based on the, the inexpensiveness of it and what we've done. 05:58 I've had trouble with grain going outta condition in here before. You know, the, we've got the wet bin. 06:02 Grain goes into the dryer, then the dryer dumps in here. That grain, if you're pushing it hard, 06:07 if you're pushing it hard, that grain probably comes in here hotter than it should. And that's what leads to the problems. 06:12 A system like this is gonna keep that fan running and, and again, take that unknown outta the equation. I'm excited to use it. 06:18 I bet we use this the first year or two and then we're talking about the next bin.

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