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Silo monitoring and

Stored Crop Protection

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Peer Hansen

Biochemist

ph@i-grain.net

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crop-protector.com

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• The iGRAIN^® product portfolio offers technology for post-harvest monitoring of stored grain: temperature, moisture, infestation (CO2) and level measurement. Moreover, we provide automated aeration control, and data solutions ranging from handheld readers, to PC, App and integration with PLC/SCADA.
• Crop-Protector^® represents chiller machines and nitrogen generators for safe storage of crops.
• TOXI-SCRUB^® is a processing line for detoxification of stored crops. This machine is a game changer in the efforts to reduce Mycotoxin contamination, like Aflatoxin and DON in grains and nuts. The machine has capacity to process grain masses up to 40 ton/hour.

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Product portfolio

Innovative individuals developed agriculture over millenniums and created the foundation for our current civilization.

We have the responsibility to

• Secure stored crop quality
• Prevent contamination
• Enhance food safety
• Avoid losses

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The foundation of our civilization

5000 year old milling stones

QUALITY GRAIN MANAGEMENT

Requirements for professional stored grain quality management to detect infestation and preserve grain best possible:

• Sensing - the grain condition must be monitored, including CO₂ (infestation), grain temperature and moisture
• Controlling - the aeration fans, based on EMC (Equilibrium Moisture Content)
• Reporting - all sensor data integrated into an easy read and workable grain management overview
• Managing decisions should based on validated data to preserve the grain best possible and increase value and profits
• Managing should be integrated in a quality control system (HACCP) - this should preferably include risk management … weather formal or not

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GRAIN WEEVIL ATTACK

FUNGUS ATTACK

Grain is obviously a food resource for many organisms, and stored grain will be “attacked” if it is not protected. Infestation will go on until completely spoiled.

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Most dangerous pests are Insects and Fungus

Bacteria, Mites and other biology plays a smaller role in grain storage

In Feed pellets Bacteria is the biggest risk

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What is infestation?

Detecting infestation using a New Technology

Traditionally, infestation has been detected with temperature sensors

The challenge with this technology is that grain is very insulating, so many sensors are required, and it may take a long time to detect a hot-spot

Most scientists recommend monitoring the total metabolism (CO₂) in the grain mass

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Organism + O₂ + Feed (grain C ) Heat + H₂O + CO₂

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Traditional temperature monitoring Advanced monitoring

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Insects Time with increased moisture Fungus & Aflatoxin

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Infestation is biologic activity in the grain

WHAT IS THE TARGET FOR GRAIN MONITORING?

• To detect infestation = Biologic activity (Insects, fungus, etc.)
• Use monitoring data to optimize aeration control
• Use monitoring data for comprehensive quality control
• Data transfer to an App on a cell phone for convenience
• This enables the grain manager to take validated operational decisions e.g.
• Which bin to empty first?
• Chilling?
• Fumigation?

Done in the best way this secures best preservation of grain value

• A HACCP Quality Control system is suggested for all silo applications

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Grain monitoring purpose and target

iGRAIN Produce the following sensors for grain and silo management

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• Radar level sensors for inventory management
• Grain temperature sensor cables
• Grain moisture sensor cables
• Silo headspace humidity monitoring
• Silo plenum pressure sensor for aeration air flow control
• CO2 – Carbon Dioxide monitoring for infestation quantification
• Additional gas sensors for improved infestation control and also to predict safe storage time
• Fire warning sensors based on CO2 or CO gas
• NEW: ALL-IN-ONE Sensor Cable for better and cheaper monitoring

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iGRAIN SENDORS

• BEST INVENTORY MONITORING

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• Total accuracy better than 1%
• Level Sensing Accuracy: +/- 2 cm
• Immune to dust build-up
• Tracking level, volume & weight
• Recording all movements in/out

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iGRAIN Bin-Auditor Radar level sensor, 130 GHz

Suitable for all comodities; wheat, rice, beans, feed

iGRAIN Sensor Solutions

• Digital sensors
• Temperature sensors must be digital to be precise
• Measuring grain moisture at a high and low level in the silo is sufficient
• Rugged mechanical construction
• Grain Moisture Measurement is essential for optimum aeration control
• Measures head-space relative humidity – for roof exhaust control = Fungus prevention
• Alarms before condensation in the silo head space
• Temperature sensors will also do simple inventory management

Moisture & Temperature sensor cables

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CO₂ monitoring and traditional Temp Monitoring

Why is the CO₂ monitoring the most important monitoring sensor?

• It detects biological activity before temperature monitoring
• The CO₂ concentration can be used to quantify infestation with complex algorithms
• The CO₂ sensor is the best key to calculating the risk of the stored grain
• Steady temperature increase also indicates infestation

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Observe

• High temperature sensor is almost stable (RED)
• CO₂ is moving up from day one of loading the silo (PURPLE)
• Concentration reaches 2400 ppm within 18 days
• For sure unwanted biological activity is progressing in the silo
• A hot-spot is only vaguely indicated by the temperature curve

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Example - iGRAIN CO₂ monitoring

Observe

• High temperature sensor is very stable
• No increasing gap between high and average
• Yet the CO₂ level is increasing steadily!
• Reaching 10.000 ppm = 1% in 40 days! HEAVY INFESTATION
• This is real spoilage, approx. 0,1% per day!
• This shows the power of CO₂ Monitoring

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Example - flour mill date

• SENSORS CONFIGURATION FLEXIBLE:

all sensors are digital

• Grain Moisture
• Head space Humidity
• Temperature every 2 m
• Simple level measurement based on T-sensors
• CO2 concentration = Infestation detection
• VOC – Volatile Organic Gases
• Fire or Smoldering detection (early)
• Other sensors also possible
• Up to 4 AIO Sensors on one cable
• Rugged mechanical construction
• Complete monitoring with iGRAIN Smart APP in cloud-based set-up

ALL-IN-ONE Sensor Cable

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NEW TECH

An example from real life soybean storage silo

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How bad can it get if Monitoring is neglected?

iGRAIN Platform solutions in overview

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iGRAIN PLATFORM SOLUTIONS

• Relay output system for

control of fans

may go via PLC

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iGRAIN fan control at Mandela Mill

iGRAIN solution to PLC/SCADA

• PC or BLACK BOX PC necessary for data processing
• Buffer SQL data-base
• All intelligent processed data can be collected there:
• Weather data
• Grain level – Tonnage
• T-high, T-average T-minimum
• CO2 and moisture
• Main FAN ON/OFF
• Roof Fan ON/OFF

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PLC/SCADA integration

PC solution BLACK BOX PC solution

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Relative humidity in air

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Grain moisture

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GREY background color:

Sensor is NOT active because it is above the grain. It cannot trigger alarms or control action

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NO background color:

sensor is active and shows sensor value

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Dash Board Manager – Matrix view

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Dash Board Manager software

Top View Page – for total overview

TOTAL storage tonnage

Each commodity listed

Weather Station Data

Inventory status – based on temp-sensors or radar

Spinning ikon if main fan or roof fan is ON

RISK FACTOR Overview

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Showing:

% filled

Showing:

TON scale

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Dash Board Manager – Inventory overview

iGRAIN has always focused on the best technology

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More importantly the focus has been on:

Ease Of Application

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Because people working in silos need simple solutions

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That is why our system is based on interpreted data

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This includes full transparency for the top managers

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Interpretation of grain monitoring data is difficult,

and requires skill and experience to be usefull

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Problem:

• So much grain has been lost over time - According to United Nations (FAO), more than 18% of all stored grain is lost every year globally due to infestation with insects and fungus
• Grain managers are busy – always some chain conveyor to fix ☹
• How to detect infestation “automatically”?

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Solution:

• Monitoring must be “INTERPRETED” for grain managers
• Reporting must be part of an easy understandable quality control system
• Aeration control must be automatic
• Management must take an active interest

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How can grain monitoring be made simpler?

The iGRAIN Smart App makes monitoring data simple and easy to evaluate; showing the following data per silo:

• % full and ton
• Grain temperature (max and average)
• Grain moisture concentration – is the grain too wet?
• CO₂ monitoring data– Concentration and increasing trend

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Moreover, based on the sensory input, the system classifies:

• the silos according to risk (listed worst to best)
• Predicts of the maximum storage time
• This tells the grain manager which silo to empty next
• Is the basis of the iGRAIN HACCP reporting systems and possible host QC systems.

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Smart App – Risk factor

Risk factor - HACCP quality control report

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AERATION CONTROL MUST BE CONSIDERED THE SINGLE MOST IMPORTANT TECHNOLOGY IN A GRAIN STORAGE FACILITY:

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• Because it is the only tool to influence the grain after storage
• Temperature can be influenced, and is ONE key to keep the grain SAFE
• Grain Moisture Concentration may be influenced, and is SECOND key to preserve the grain in the best possible way
• Calculating the EMC = Equilibrium Moisture Concentration is the key to preserve the grain, and NOT lose weight and value
• Automatic Aeration is a MUST, because nobody can calculate fast enough with fluctuating ambient conditions

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AREATION CONTROL

AERATION CONTROL �TARGET ILLUSTRATED

• The purpose of aeration control is to bring the grain in the direction of the SAFE CONDITION
• This often means a lower temperature or a drier condition
• This target should be reached without unnecessary loss of grain moisture with EMC control
• Automatic solution to reach safe TARGET without shrinkage

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INSECTS and FUNGUS

FUNGUS

INSECTS

SAFE CONDITION

TARGET

GRAIN CONDITION

TEMPERATURE / MOISTURE

• CO₂ monitoring, this is most important measure to detect emerging infestation!
• Temperature monitoring – Greatly reduced number of sensor cables (longer silo lifetime – and many sensor points also not needed)
• Moisture monitoring: head space sensor to prevent condensation and fungus
• Moisture monitoring for best automatic EMC Aeration Control
• Risk factor management – get the facts from computerized calculations of the real risk – save time … no need to study many complicated tables and curves
• iGRAIN Smart App reporting all sensor data per silo including the risk factor and the predicted safe storage time
• Grain managers can do their job much more efficiently with this technology

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Recommandations for best silo monitoring

�Online Service Centre support

iGRAIN

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iGRAIN Denmark, USA, Uganda, Thailand

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We can support via our network in many countries

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We have local partners everywhere

CROP-PROTECTOR® PRPDUCTS

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GRAIN CHILLERS

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NITROGEN GENERATORS

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OZONATION TECHNOLOGY

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Main Advantages of CHILLING Machines

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• If there is a problem … puts insects / mites / bacteria to sleep

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• Extends the possible storage time

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• Caution:

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• Costs some money

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• Does not stop Fungus and Mycotoxin growth

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• Always dries the grain with approx. 0,4 – 1,0 % moisture

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Grain Chillers

HIGH QUALITY CHILLING MACHINES

• 25 - 120 HP compressors
• Applicable for any climate
• Both air- and water-cooled condenser technology
• Higher air volumes than any other supplier in the market

Main Advantages of NITROGEN generators

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• Nitrogen fumigation is considered natural fumigation because Nitrogen is not a pesticide and can be applied on organic products

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• If there is an infestation problem … Nitrogen puts insects / mites / bacteria and Fungus to sleep and over time kills most species

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• May kill most insects if applied for 5 - 10 days (depending on species and remaining Oxygen concentration)

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• Extends the possible storage time a lot

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• Caution:

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• Costs are in the range $ 3 – 10 per ton depending on set-up and quantity

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• Normally dries the commodity a little, like 0,1 – 0,4 % absolute moisture

Nitrogen Generators

HIGH EFFICIENCY NITROGEN GENERATORS

• PSA generator with up to 99,9% Nitrogen purity
• Capacities available 10 - 500 m₃/Hour
• Online gas analysis monitoring included
• Integrates with iGRAIN silo monitoring systems
• Displays the Nitrogen percentage in the silo with iGRAIN O₂ Sniffer

Distribution manifolds and rugged hoses

NITROGEN GENERATORS

Layout example With Distribution manifolds and rugged hoses

Sideview of Nitrogen generator

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NITROGEN GENERATORS

HIGH EFFICIENCY NITROGEN GENERATION

• Purity PSA generator up to 99,9% Nitrogen
• 30 – 500 m3/Hour
• Online gas analysis monitoring
• Integrates with iGRAIN Monitoring Systems
• Displays the Nitrogen percentage in the silo with iGRAIN Oxygen Sniffer

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Mycotoxin detoxification with the TOXI-SCRUB®

The Ozonation Proces and the Machinery

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Biochemist Peer Hansen

ph@i-grain.net

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TOXI-SCRUB® treatment of grain, beans and nuts:

• Terminates all types of fungus including Aspergillus, Penicillium and Fusarium
• Eliminates all spores (Conidia)
• Kills all insects, mites, bacteria and other unwanted biology
• Reduces Mycotoxin significantly – scientifically validated
• Reduction of Aflatoxin in corn and DON in wheat and rice are important applications
• Application for nuts and beans also available
• Reduction rate of 80%+ is possible and scientifically validated

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Removal of Aflatoxin and other Mycotoxins

What creates Mycotoxins like Aflatoxin?

• Starts in the field

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• Grows after harvest if rice not dried properly

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• May continue to grow if sanitation is poor in the silos

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• Aeration and Moisture control is the keys to SAFE rice

Contamination of Corn / Maize��Corn/maize has most likely the biggest problem with Mycotoxins, because it has a very high moisture content on its own. Safe storage is only possible if it is dried fast and properly.

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Creation of Mycotoxins: first you have fungus��Nature is incredible! Some funguses are very aesthetic. �They multiply abundantly via the spores that’s why grains are already “contaminated” with spores on the surface in the field.

Cross-section view of the TOXI-SCRUB® processing�line and the associated material handling�����Control container with Ozone generator

Top view of the TOXI-SCRUB® processing line

TOXI-SCRUB^®

Aflatoxin Scrubber

TOXI-SCRUB Reactor.

Where the

main

decontamination

takes place

with use

of Ozone

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Pre Reactor

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Ozone generator

in 40’ container

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Design - 24 ton/hour plant

TOXI-SCRUB^® Processing line Soroti, Uganda

Main Advantages of TOXI-SCRUB®

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• Removes AFLATOXIN and other MYCOTOXINS

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• Kills ALL insects + Mites + Fungus + Bacteria

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• Makes GOOD GRAIN out of CONTAMINATED GRAIN

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• SAFE storage for 1 year after treatment

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Treatment Cost:

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• Costs about $ 3 - 6 per ton – depending on commodity and other factors

Thank you for listening!

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Why not work with the most knowledge based company in the industry