Description of the parcel sorting facility
The project was carried out in a parcel sorting plant. The building has an area of about 6600 sqm, which includes an office area and a sorting hall. The facility has been in operation since 2020. At the time of starting the project, it was equipped with classical measurement systems without telemetry functions.
Scope of the project work
The aim of the project was to implement a system of telemetry, smart metering and IoT elements, by communicating existing installations (mainly meters), adding new meters with a wireless communication protocol, supplementing the system with IoT devices – detectors with reading of many climate parameters in the facility, also in wireless technology, with the lowest possible cost and minimal effort and interference with the existing infrastructure.
The scope of our work included:
1. Analysis and design including:
- Verification of technical documentation
- Condition assessment of existing meters and equipment
- Selection of communication interfaces and new meters
- Preparation of quotations and arrangements with the customer
2 Installation and launching:
- Minimal replacement of equipment
- Calibration of meters and start-up of the system
- Installation of LoRaWAN technology to enable wireless communication
3. System integration:
- Connection to customer analytical tools (Power BI)
- Minimal interference with existing facility infrastructure
As a subcontractor in the parcel sorting plant, we have implemented the following systems:
1. Utility monitoring system (smart metering):
- Monitor gas, water and electricity consumption
- Real-time data collection
2. Wireless communication system (LoRaWAN):
- Single antenna providing coverage for the entire facility
- Two-way communication to control devices
3. Integration system with analytical tools:
- Connect to a system for data analysis and reporting
- Leverage the customer’s existing infrastructure
4. Management application demo:
- Real-time preview of system data
- Initial version of tool for future development of facilities management
Most interesting project requirements and solutions applied
The project objectives required the retrofit. In many cases, limited technical availability of existing installations and equipment proved to be a problem.
Solution: a detailed analysis of the available documentation was conducted, and based on this analysis, the new systems were adapted to the existing infrastructure, thereby avoiding the need for equipment replacement.
Minimize cost and interference with infrastructure
The client expected the lowest possible cost and implementation work also in terms of laying additional cabling.
Solution: we used the existing infrastructure, and based the communication in the system on wireless data transmission technology, which allowed us to minimize costs and installation work.
Range of wireless communication in a large facility
The large size of the facility (more than 6,000 sq. m.) would require multiple receiving antennas when using Wi-Fi technology. This would make installation difficult and increase costs.
Solution: the use of LoRaWAN technology, which allowed for efficient two-way wireless communication across the entire sorting hall using just one antenna.
Implementation work at a functioning facility
The sorting plant operated 24/7 without interruption, and the implementation of the project was not to disrupt its standard operations.
Solution: the schedule of activities was adapted to the specific operational requirements of the facility. Assemblies and tests were conducted in a manner that minimized disruption to the sorting plant’s operations.
Long decision-making process
Negotiations and agreements in such a large organization take a lot of time.
Solution: we are prepared for such situations and understand them. We ensured constant contact with the client. Constant communication with the client was maintained, and solutions were flexibly adapted to current needs, accelerating the decision-making process.
The project implementation commenced with a site visit, during which the technical documentation, existing meters, and equipment were thoroughly verified. In the subsequent design phase, communication interfaces and new meters were selected, followed by the preparation of quotes and agreements with the customer.
As part of the installation and commissioning, we replaced the necessary parts of the equipment. We calibrated the system and performed tests. We also created a demo application, and in the next stage we connected the system to the customer’s analytical tools.
Project results and benefits for the Client
The result of our work is a functional monitoring system for the parcel sorting plant. It allows continuous monitoring of gas, water and electricity consumption. The data is collected in real time, allowing a quick response to any anomalies.
The telemetry, smart metering, and IoT system was integrated into the existing infrastructure, minimizing the need for component replacement. LoRaWAN wireless communication was utilized to reduce both costs and installation work. Finally, the system was connected to the client’s application, enabling data analysis and report generation.
The implementation of the project enabled the identification of anomalies and excessive consumption of utilities, so that operating costs can be reduced. The client gained the ability to register the carbon footprint and monitor consumption 24/7, including the ability to quickly diagnose problems (such as errors in the operation of generators). The implementation of the work did not affect the day-to-day operations of the sorting plant, so that the parcel sorting plant remained operationally smooth throughout the implementation.
The telemetry and smart metering system implemented at this facility was a proof of concept as a basis for further upgrades. As part of further cooperation, we expect to implement the following systems based on our project:
- HVAC management systems (heating, ventilation, air conditioning)
- Lighting management system
- Advanced monitoring system (collection and analysis of additional parameters, such as machine performance or precise data on energy consumption in individual zones of the facility)
- Dedicated management application (tool for global management of multiple facilities, report generation, diagnostic alerts and real-time monitoring)
- Automatic report generation and analysis
- Carbon footprint reduction systems (integrated tools for monitoring and reporting CO₂ emissions and implementing measures to reduce negative environmental impact).
