Regional Concrete Giant Digitizes Bulk Material Inventory

Nebco, a major player in Midwest construction, recently partnered with BinMaster to modernize bulk inventory management. With 24 plants and a vast network of resources, Nebco faces complex logistical challenges. BinMaster’s bulk material sensors and software align with industry trends, promoting sustainability and resilience. For Nebco, embracing digital solutions signifies a strategic investment in its future. By harnessing technology, the company navigates market challenges while maintaining its position as a construction leader in the Midwest.

Sensors, Software Benefits

With 24 ready-mixed plants, 10 sand pits, four concrete block operations, and two quarries, Nebco built countless buildings and roads in the Midwest for 100 years. The company recently partnered with BinMaster to build a digital inventory system to monitor bulk material.

“I love it,” said Linzy Jones, operations manager for Ready Mixed Concrete, a Nebco company. “We’re learning new ways to use the system but it’s going to be a difference-maker for us. Really, so far, the best part of the process has been the support by BinMaster.”

The company stores massive amounts of cement, sand, water, admixtures, and fly ash, which are moved by 350 trucks every day. Nebco moves large quantities of aggregate and sand on its own railroad, the Big Red Line.

Nebco’s Ready Mix Transit Mixers deliver concrete to construction projects ranging from driveways to miles-long roads and huge construction projects. The company devotes considerable attention to maintaining a clean fleet (BinMaster)

Tracking fly ash and cement in silos, liquids in tanks, and sand and aggregates in piles requires major coordination and high-tech systems that digitally collect material levels and provide data on one cloud-based report.

“We installed sensors on top of silos to measure bulk material levels for multiple locations,” said Nathan Grube, BinMaster regional VP. “Nebco handles massive projects. They coordinate material movements with drivers, plant operators, and construction coordinators on-site. When we showed them BinCloud on a phone and on their PC, they were excited.”

Nebco asked BinMaster for radar level sensors along with BinCloud software.Why Digital Bulk Inventory Boosts Profit

Soaring inflation, heavy competition, and supply chain strain present challenges to the concrete industry. By digitizing bulk material measurements in tanks and silos companies can positively impact safety, planning, and profits.

BinMaster NCR-86 radars sense liquid, powder, and solid materials then continuously feed measurements to IoT BinCloud app for viewing on a PC or phone (BinMaster).

According to a study by McKinsey & Co., the cement industry needs digitization, sustainability, and resilience. The study said cement companies must achieve lower operating costs through higher energy efficiency, yield, and throughput. Digitization and sustainability efforts, it says, should boost productivity at a typical cement operation gaining $4-$9 per ton of cement.

Why Level Sensors Reduce Risk

With technology, the study said, “Fewer workers are required to be on-site continuously, and interactive online dashboards allow managers to remotely collaborate, solve problems, and quickly make informed decisions with the rest of the team.”

Traditionally, measuring silos requires employees to walk on-site, climb ladders, lift heavy access doors atop tall, windy vessels, and drop a tape measure. Every measurement opens risk for three of the top 10 issues listed by OSHA in 2023. In the US, falls represent 7,271 incidents, ladders 2,978, and fall from heights 2,112.

Bulk Material Software Can Optimize Supply

Understanding material use over time is valuable for supply chain optimization. Supplying two massive projects 100 miles apart requires all concrete plants to collaborate. Which plant has enough material? Who has the capacity to take delivery of more sand? How often is resupply at each plant? Could purchasing managers leverage better pricing by knowing history and anticipating larger orders? 

“We’ve been upgrading our BinCloud software to show a history of measurements and we even provide a trendline to help anticipate when materials will run out,” said Scott Hudson, BinMaster executive VP. “These tools help minimize carrying costs.”

Radar for Dust and Continuous Measurement

While workers avoid exposure to concrete dust, radar technology can overcome the challenge of measuring through that dust. Nebco chose to install a series of BinMaster radars atop its silos. The NCR-86 radar is a universal radar sensor for continuous level measurement of liquids and bulk solids.

Radar sensors collect data then move it to BinCloud, which organizes it into real-time monitoring, automated alerts via text, and historical reporting. Software can manage a single site or hundreds of vessels and locations.

“Nebco wanted a uniform system. Something that works on a variety of bulk materials across their properties. They had a variety of storage vessels, so we accounted for that as well,” Grube said. “The NCR-86 radar is very accurate even down to 393 ft. Material can get close to the sensor and still be easily measured.” 

Grube said the radar handles a wide range of temperatures, tested from -196 to +450˚C, and pressures from -1 to 160 bar. NCR-86 are 80GHz frequency sensors and are virtually maintenance-free. They include rugged enclosures with encapsulated electronics to excel in excessive conditions.

Bulk Material Software Pulls Data off the Cloud

Ultimately, sensors feed data to a secure, cloud-based software called BinCloud, which helps with batch control and waste reduction. It sends current tank readings or history to a phone or PC.

BinMaster helps to set up bulk material reports, then operators can add alerts and notifications. Employees can sort measurement data by vessel, location, alert status, or material. Historical data--sorted by date ranges--can be downloaded and help to identify trends and track material by site.

Dave Zelnio is marketing communications manager, BinMaster (Lincoln, NE). For more information, email [email protected], call 402-434-9125, or visit www.binmaster.com.