ELECTRONIC SENSORS Streamlining Waste Management in Manufacturing
with IoT Technologies Manufacturers today face escalating energy and labour costs, stringent regulatory pressures and growing environmental responsibilities, with waste management also emerging as a key challenge.
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raditionally, industrial waste bins, especially in expansive setups like automotive production, are emptied on fixed schedules. Often, they are emptied before they reach full capacity, resulting in wasted time, resources and missed productivity. By leveraging Internet of Things (IoT) technology, manufacturers can implement real time bin monitoring to optimise collection schedules, redirect human resources to more critical tasks and reduce unnecessary trips, as Gareth Mitchell, UK partner manager, Heliot Europe explains.
The ‘waste’ in waste collection To appreciate the impact of waste management inefficiencies, consider the automotive manufacturing industry, where production lines can exceed a kilometre in length. At various stages of production, bins for different types of waste, standard, specialised and recyclable, are generally placed strategically along the line. Ideally, these bins should be emptied only when they are full; however, in practice, they are often collected prematurely. This results in wasted trips and increased costs, especially for manufacturers outsourcing waste collection to third-party providers. Moreover, the manual task of checking bin levels consumes employees’ time, further diverting them from core responsibilities. Consequently, the waste collection process can be inefficient and costly for many manufacturers, leading to wasted resources and misaligned collection schedules. Improving the tracking of waste in bins and establishing better communication about when bins need to be emptied is essential for enhancing this operational process.
Automating waste management with IoT
IoT offers manufacturers a powerful solution to optimise waste management processes. By equipping bins with sensors connected
to back-office systems, manufacturers can gain real time insights into fill levels, enabling data-informed, automated collection schedules to be produced. This kind of information helps to reduce unnecessary collections, but also frees employees from having to perform routine checks, allowing them to focus on more productive tasks. Furthermore, automated waste monitoring can enhance collaboration with waste collection providers. With real time data, manufacturers can align schedules with actual needs rather than assumptions, optimising subcontracted services and reducing costs. For manufacturers that use reusable packaging, such as reusable racks (A-Frame Stillages) for automotive glass windshield production and transportation, IoT sensors can be fitted to these transport racks and data connectivity can then be used to enable the effective location tracking of racks to support with return logistics. With this data, manufacturers can ensure reusable items are efficiently returned for repeated use, reducing material costs and supporting circular practices.
The Role of Connectivity and Sensors
One of the main benefits of IoT in waste management is the ability to retrofit sensors to existing bins without significant infrastructure overhauls. In industrial settings, low power wide area network (LPWAN) connectivity options enable reliable, cost effective data transmission compared to alternatives such as cellular and WiFi. LPWAN networks are particularly suited for manufacturing environments, where metal structures and large machinery can often obstruct WiFi and cellular signals. The low-bandwidth requirements of LPWAN also ensure longer battery life for sensors and IoT devices, minimising the need for frequent maintenance, a critical factor in large facilities where downtime is costly.
24 NOVEMBER 2024 | ELECTRONICS FOR ENGINEERS
This connectivity model allows manufacturers to place IoT-enabled bins throughout their warehouses and facilities, knowing they can rely on stable, low-cost communication even in hard to reach areas. LPWAN connectivity gateways can also be set up quickly and scaled easily, providing flexibility for expanding or reconfiguring, factory floors without extensive infrastructure investment.
Conclusion
In manufacturing, waste management inefficiencies can cost more than just wasted material. They also consume time, divert resources and drive up operational costs. By implementing IoT and
LPWAN-enabled sensors, manufacturers can reinvent traditional waste management processes, optimise bin usage, cut down on unnecessary collection trips and free up workers for higher priority tasks. This modern approach highlights how real-time data collection and smart connectivity can streamline waste management, improve productivity and contribute to broader sustainability goals. As IoT technology advances, the potential for a more efficient and environmentally responsible manufacturing sector continues to grow.
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