For the composting process to be effective, precise control of the temperature in the piles and the water level in the irrigation tanks is essential. A compost company approached us to implement an automation solution that would provide remote control of these parameters, without the need for constant operator involvement. In this case study, we present the technical details of a solution based on a PLC, hydrostatic measurement probes, wireless temperature sensors and a SCADA system. Keep reading for implementation details!
The company that approached us for support deals with compost production and storage on a daily basis. Its main goal was to streamline parts of the production process - especially in terms of controlling the temperature and water level of the compost. The client wanted to reduce the amount of work done by operators, so it was looking for an automated solution to control the irrigation and aeration of the material. He also wanted to ensure stable and optimal production conditions, which would increase the efficiency of the entire plant. The company already had the right technical conditions in place, including modern building infrastructure. All it needed was a reliable automation system that would easily integrate into the existing plant.
We automated the entire compost production process using a JUMO variTRON 500 Touch PLC as the central unit. This unit continuously collects data on compost temperature and water levels at two locations: directly in the irrigation tank and in the storage water tank.
JUMO MAERA S26 hydrostatic level probes - made of acid-resistant steel - constantly measure the amount of water in both tanks. This lets the controller know when to automatically open the irrigation system's valves to provide the compost with optimal moisture. At the same time, special JUMO Wtrans B wireless sensors continuously measure the temperature in the compost piles. If the temperature of the compost deviates from the optimal values, the variTRON automatically activates the aeration fans, restoring the correct process conditions.
The entire process is managed by JUMO smartWARE SCADA process monitoring and control software, which allows operators to easily control the entire process and access detailed historical data. Thanks to such a solution, composting parameters always remain optimal and the process runs stably, without the need for manual intervention by operators.
The JUMO variTRON 500 Touch PLC (705004) works with JUMO Wtrans B temperature sensors (707060), MAERA S26 level sensors (402090) and the smartWARE SCADA system (701820) to ensure ideal composting process conditions.
After implementing the automatic control system, the company immediately noticed an improvement in the efficiency of the entire composting process. Thanks to continuous and accurate monitoring of temperature and water levels, it was possible to maintain stable conditions, which directly translated into the quality of the compost obtained. Operators gained more time, as many routine tasks - such as manual control of parameters - were taken over by the system for them. In addition, access to historical data now allows the technical team to analyze production results in real time and easily make optimizations, further increasing the efficiency of the entire plant.
My name is Ewelina Szmit and I have been involved in content marketing for several years, combining my professional skills with my passion for writing. I am convinced that even the most technical topics can be presented in an interesting and accessible way for everyone. Outside of work, I express my creativity by creating collages from newspaper clippings. I like to spend my free time actively, walking my dog or running.
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