Grain Monitoring with Gas Analysis – A new All-In-One technology from iGRAIN

Grain losses of stored grain is a known problem. According to FAO, the Food and Agriculture Organization of the United Nations the post-harvest food loss amounts to a staggering US$400 billion each year. Reducing global post-harvest grain losses in wheat, rice, maize, barley, oats, rye, and millet by 75 percent would be equivalent to approximately three times the cropland area of France. Technology which enables reduction of stored grain losses are badly needed. Such a technological tool must be easy to use for grain managers and give improved information about the actual grain condition in all their silos so they can take the right management decisions; especially which grain to process next!

Traditional monitoring of temperature
Temperature monitoring of stored grain has been regarded adequate for safe storage of grain for more than 70 years. Although temperature monitoring might assist safe storage, it is by far not an ideal way to monitor grain, as grain itself is very heat insulating. Thus, a hot-spot with insects or fungus infestation is not detected until the hot-spot migrates to the temperature sensor. This might mean that losses are already present and possibly growing fast.

Gas analysis is the future of grain monitoring
The superior alternative to temperature monitoring is application of gas analysis in the grain monitoring process. Monitoring carbon dioxide (CO2) levels allows early detection of spoilage and pests in stored grain, as the CO2 level rises with increased presence of respiring microorganism in the grain. Gas analysis has the huge advantage that gasses are flowing freely in the space between the grain kernel, and as a law of nature gasses are migrating fast and evenly in all directions. Therefore, only a few gas sensors are needed to determine the infestation and the quality of the grain in any grain silo. CO2 monitoring is used to determine the infestation level from insects and fungus, and to predict each silo’s grain quality and safe storage time. In-Bin CO2 monitoring was introduced in 2010 by iGRAIN in Denmark.

iGRAIN All-In-One Cable

Gas analysis in stored grain has now been taken even further with the new iGRAIN® All-In-One (AIO) sensor cable, which was introduced in 2022. The AIO sensor cable offers analysis of several gasses: CO2, carbon hydrates, volatile organics, grain ripeness gasses, and moisture for the safest and most efficient grain management. Time tracking of the various gasses in the grain mass, is the key factor to monitor the current grain quality comprehensively and control aeration in the safest and most economical way. The output data support the grain manager to manage the stored grain professionally with minimum effort, time, and grain losses. The AIO cable makes grain management easy and transparent for management and grain owners.

Peer Hansen, R&D manager of iGRAIN, says: “The new gas analysis based technology is what the world has needed for a long time. We are so happy to offer this technology for today and the future! We are confident it will reduce grain losses in all climatic zones around the world.”

Aeration control is the most critical operational process when managing stored grain. Reliable aeration control requires input from about three conditions in the grain: moisture, temperature, and ongoing infestation alias CO2/other gasses. Such information is provided by the AIO sensor and supplemented with data about the outside weather conditions enabling automatic aeration control.

All sensor output is processed in real time, and smart algorithms monitor and control the aeration of the grain. The trend of all the parameters is monitored and processed. This allows prediction of the longest safe storage time in any silo, essential data for any grain manager for best decision making on which grain to process next. The AIO sensor-based aeration system operates automatically, and measurement data are available in real time on a smart phone, iGRAIN Smart App. This makes decision making easy and saves resources especially for farmers and small industries. Since the system is controlling the grain aeration process, it saves energy as the fans will only operate when it is advantageous relative to the current grain condition – the process runs full-automatic 24/7, 365 days a year without human errors. It is scientifically optimized over decades.

The AIO sensor cable may be used as the only monitoring solution in a silo and in any climatic zone. However, in big silos it may be supplemented with additional temperature sensor cables. In any case the number of sensor cables are greatly reduced and thus cheaper than traditional temperature-only monitoring.

Evolution – from temperature to gas monitoring in stored grain

AIO Sensor Cable advantages:

• monitors double amount of grain compared to a conventional temperature cable
• 50% less stress on the silo roof
• 100% effective (HACCP based Risk Factor)
• low price – approx. 67% of conventional temperature sensor cable

The largest benefit of this innovation is enhanced grain monitoring and automatic aeration control resulting in better grain quality and lesser grain losses. This is a big gain for safe and enough food for the world population, the environment, and our resources.

Link to online Article in M&G: Issue 12/2023
Link to Article in pdf format: MAG Article 12/2023 AIO.
Link to product page: All-In-One Sensor Cables