Automated Food Grain Monitoring System Using IOT

Abstract

Post-harvest grain loss due to suboptimal storage conditions remains a significant challenge in agriculture, particularly in developing nations. To address this issue, this paper presents the design and development of a real-time, IoT-enabled food grain warehouse monitoring system utilizing the ESP32 microcontroller. The proposed system leverages multiple environmental and physical sensors to ensure optimal grain storage conditions, minimize spoilage, and improve operational efficiency. The monitoring system incorporates a DHT11 sensor for ambient temperature and humidity detection, an MQ135 gas sensor to detect hazardous gases such as CO? and NH?, and a flame sensor to identify potential fire hazards. A a PIR sensor are used to detect unauthorized access or disturbances within the storage facility. To monitor grain weight, a force-sensitive resistor (FSR) is employed, replacing the traditional load cell. Additionally, a moisture sensor is repurposed to measure the internal moisture content of the stored grains—an essential parameter for preventing fungal growth and spoilage. An ESP32 microcontroller serves as the central processing unit, interfacing with all sensors and actuators. Actuation components include a fan and a water pump controlled via an L293D motor driver to regulate temperature and suppress fires. A servo motor is used for automated door control to manage physical access based on Blynk input. All sensor readings are displayed in real time on an I2C LCD and transmitted wirelessly to the Blynk IoT application, enabling remote monitoring and alerting via smartphone. Control logic is implemented to trigger auto4mated responses based on preset threshold values. For instance, if the temperature exceeds a safe limit, the fan is activated; if smoke or gas is detected, an alert is sent and ventilation begins; if motion is detected during unauthorized times, the door locks automatically and a notification is pushed via Blynk. The system was tested through a prototype model, and real-time data visualization confirmed its capability to monitor critical environmental variables and automate responsive actions. This integrated, low-cost IoT solution offers a scalable and user-friendly approach to enhancing food grain storage practices, reducing spoilage, and improving food security.

Introduction

Problem Addressed:
Post-harvest grain losses due to poor storage conditions are a major issue, especially in developing countries. Traditional monitoring methods are manual, inconsistent, and often ineffective in preventing spoilage from temperature, humidity, pests, gases, and unauthorized access.

Proposed Solution:
A smart, IoT-based real-time monitoring system was developed using the ESP32 microcontroller, integrated with multiple environmental and security sensors. The system ensures optimal grain storage by automating responses and allowing remote monitoring through the Blynk IoT platform.

Key Features:

• Sensors: Temperature & humidity (DHT11), toxic gases (MQ135), fire (flame sensor), unauthorized entry (PIR), grain weight (FSR sensor), and internal moisture.

• Actuators: Fan, water pump, and servo motor (automated door lock), controlled by L293D motor driver.

• Communication & Display: Wi-Fi-enabled ESP32 sends data to Blynk app and displays real-time readings on an I2C LCD.

• Automation: Triggers fan, pump, door lock, and alerts based on sensor thresholds for better grain preservation and security.

Objective Highlights:

• Reduce spoilage via real-time monitoring and automated control.

• Enable remote access and alerts for warehouse managers.

• Provide a cost-effective, scalable system for rural and urban storage.

Literature Insights:
Prior studies lacked full automation, real-time alerts, or cost-efficiency. This system advances the field with low-cost components (e.g., FSR instead of load cells), full automation, and a mobile-friendly interface.

Methodology:
Sensor data is processed by the ESP32, triggering appropriate actuators based on environmental changes. Alerts and data are shared via Blynk for remote monitoring.

Results:
In testing, the system accurately detected environmental changes and responded appropriately, proving effective in automating grain warehouse monitoring and improving storage conditions while reducing labor.

Conclusion

The proposed IoT-based automated food grain monitoring system demonstrates an effective solution for ensuring optimal storage conditions in warehouses. By integrating sensors such as DHT11, MQ135, flame sensor, PIR, moisture sensor, and FSR with the ESP32 microcontroller, the system provides comprehensive real-time monitoring of environmental and physical parameters. The use of Blynk IoT enables remote access and instant notifications, significantly reducing the need for manual supervision. The system not only detects critical issues such as high temperature, gas leaks, fire, moisture, and unauthorized access but also responds automatically through actuators like fans, pumps, and servo-controlled door locks. Prototype testing validated the functionality and responsiveness of the system under various simulated scenarios. The system performed reliably and accurately, proving its potential as a scalable, cost-effective solution for grain preservation. By reducing spoilage and increasing storage safety, this system contributes to improved food security and warehouse management efficiency. In the future, this system can be further enhanced by integrating machine learning algorithms to predict spoilage trends and automate corrective actions more intelligently. Solar-powered modules can be added to make the system energy-efficient and suitable for remote rural warehouses with unreliable power supply. Integration with cloud storage for historical data analysis and visualization dashboards could provide deeper insights into warehouse conditions over time. Real-time SMS could be added as a backup communication method. Additionally, expanding the system to include pest detection sensors, RFID-based inventory tracking, and automated reporting features would further enhance warehouse automation and security. This would make the solution more robust, self-sustaining, and adaptable to diverse agricultural storage environments.

References

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Copyright

Copyright © 2025 Dr. M. Vasu Babu, K. Sreya, J. Rithwik Reddy, G. Satish. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.