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Smart Monitoring for Agriculture & Agritech — Safe, Efficient, and ATEX-Ready

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Quick Overview

Problem

Agricultural operations increasingly rely on mechanised and automated systems, but lack real-time visibility on water, fertiliser, temperature, and safety parameters — especially in dusty or explosive environments such as silos and biogas units.

Solution

Sensa.io provides robust, ATEX-ready wireless sensors for pressure, differential pressure, temperature, vibration, valve position, and acoustic monitoring — improving safety, irrigation efficiency, and equipment uptime.

Value

↑ Resource efficiency • ↓ Maintenance costs (−25–30 %) • ROI < 12 months

ATEX

Zones 20–21 (dust) & Zones 1–2 (biogas) • Ex ia IIIC T135°C Db certified sensors

The Agricultural Technology Challenge

Modern agriculture faces three converging challenges:

1️⃣ Water and fertiliser efficiency under climate and cost pressures.

2️⃣ Safety in dust-prone or methane-emitting environments (grain silos, digesters).

3️⃣ Predictive maintenance of mechanised assets (pumps, conveyors, irrigation).

Manual checks and reactive maintenance lead to resource waste and unexpected downtime.

Sensa.io enables data-driven farming and agro-industry operations by combining rugged, ATEX-compliant sensors with wireless data connectivity and analytics.

Why ATEX and Wireless Monitoring Matter 🔥 ATEX

Many agricultural environments are classified under ATEX Zones 20–21 (dust) or Zone 2 (biogas).

Grain dust or methane accumulation can cause explosions if ignited by non-certified electronics.

Sensa.io’s intrinsically safe sensors allow continuous monitoring without wiring or hot work, protecting both people and assets.

They deliver accurate data on pressure, flow, temperature, and vibration in irrigation, storage, and processing facilities.

Every 1 % improvement in irrigation efficiency saves up to 700,000 litres of water annually per 100 hectares.

Core Use Cases for

Agriculture & Agritech

Use Case
Sensor Type
ATEX
ROI/Value
Poultry House Temperature & Vibration Monitoring (Ventilation Fan Motors)
Temperature
Vibration

Avoids breakdowns, ensures

Feed Line Valve Position Monitoring (Automation, Traceability & Process Reliability)
Valve position

Automation efficiency

Ventilation System Temperature & ΔP Monitoring (Silos & Livestock Buildings)
Temperature
Differential Pressure (ΔP)

Reduces explosion risks

Farm Biogas Digester Pressure & Temperature Monitoring (Safety, Yield & ATEX Compliance)
Pressure
Temperature

Energy production safety

Irrigation Filter ΔP Monitoring (Clogging Prevention & Water Efficiency)
Differential Pressure (ΔP)

Optimizes maintenance cycles

Irrigation Pump Vibration Monitoring (Predictive Maintenance & Water Reliability)
Vibration

Maintenance planning

Grain Silo Acoustic Anomaly Detection (Blockage, Friction & Explosion Risk Prevention) — ATEX
Acoustic

Detects friction / dust ignition risks

Grain Silo Temperature Monitoring (Fire, Spoilage & Loss Prevention)
Temperature

Prevents fermentation & fire

Fertigation Valve & Pressure Monitoring (Precision Irrigation & Input Efficiency)
Valve position
Pressure

Reduces waste, safety around fertilizers

Fertigation Valve & Pressure Monitoring (Precision Irrigation & Input Efficiency)

Grain Silo Temperature Monitoring (Fire, Spoilage & Loss Prevention)

Grain Silo Acoustic Anomaly Detection (Blockage, Friction & Explosion Risk Prevention) — ATEX

Irrigation Pump Vibration Monitoring (Predictive Maintenance & Water Reliability)

Irrigation Filter ΔP Monitoring (Clogging Prevention & Water Efficiency)

Farm Biogas Digester Pressure & Temperature Monitoring (Safety, Yield & ATEX Compliance)

Ventilation System Temperature & ΔP Monitoring (Silos & Livestock Buildings)

Feed Line Valve Position Monitoring (Automation, Traceability & Process Reliability)

Poultry House Temperature & Vibration Monitoring (Ventilation Fan Motors)

Vibration
Acoustic
Differential Pressure (ΔP)
Temperature
Pressure
Valve position
Use Case Sensor Type ATEX ROI/Value

How Sensa.io Technology Works

Open Wireless Architecture

Sensa.io sensors connect to any LoRaWAN, Modbus, or MQTT network and integrate easily into existing farm management systems, SCADA, or irrigation control panels.

They are gateway-agnostic, compatible with Kerlink, Cisco, Milesight, and other industrial gateways.

Sensor Engineering
  • Dust and humidity proof (IP68/IP69K)
  • Intrinsically safe design (Ex ia IIIC T135°C Db) for dust & methane areas
  • 10-year battery life with adaptive sampling
  • Temperature range: −40 °C to +125 °C
  • Resistant to fertiliser corrosion and high vibration

Data Intelligence
  • Pressure & ΔP detect irrigation efficiency and filter health.
  • Temperature ensures grain quality, climate control, and safety.
  • Vibration predicts pump or motor failures.
  • Acoustic identifies leaks or abnormal friction.

Data are transmitted securely (AES-128 encryption) and accessible in real time through dashboards or SCADA systems.

Proven ROI and Field Results

Operators who deployed Sensa.io in upstream fields typically achieved:

15–25 %
water and fertiliser savings
30 %
fewer pump breakdowns
Reduced
fire/explosion risk in silos
Case Example

Acoustic & Vibration Detection of Rockfall or Structural Movement (Early Warning & Worker Protection)

Early warning to protect workers underground

Case Example

Gas Vent Line Acoustic & Pressure Anomaly Detection (Methane Hazard Early Warning)

Early detection of dangerous methane releases

Payback: typically < 12 months depending on scope.
Get the ROI Calculator for Upstream Operations

ATEX Compliance and Safety

All Sensa.io sensors for upstream operations comply with:

  • Ex II 2 D Ex ia IIIC T135 °C Db (Dust Zones 20–21)
  • Ex II 2 G Ex ia IIC T4 Gb (Gas Zones 0–1 for biogas)
  • IECEx and ATEX Directive 2014/34/EU

Each sensor is supplied with Declaration of Conformity, calibration certificate, and maintenance guide.

This ensures safe operation in dusty, humid, or methane-rich environments — fully compliant with EU and international standards.

FAQ - Common Questions

Are Sensa.io sensors compatible with any gateway or network?

Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.

What ATEX certifications apply to Sensa.io devices?

All hazardous-area models are certified Ex II 2 G Ex ia IIC T4 Gb and IECEx approved for Zones 0–2.

What is the typical battery life?

Up to 10 years at 15-minute intervals, depending on signal strength and environment.

How are the sensors integrated into existing systems?

Through standard protocols — LoRaWAN, Modbus, MQTT, REST API — no proprietary middleware needed.

How does predictive maintenance reduce OPEX?

Early anomaly detection reduces emergency interventions by 30–40 %, extends equipment life and lowers energy costs.

General & Functionality

What is the typical ROI when deploying sensors in upstream production?

Depending on asset criticality and scope, operators generally achieve payback within 6 to 12 months, driven by reduced downtime, lower maintenance overhead, and improved safety compliance.

How are calibration and maintenance handled in ATEX zones?

Sensors are factory-calibrated and include internal digital calibration tables. No field recalibration is required for 5–10 years; visual inspection every 3 years is sufficient.

How are data transmissions secured in remote fields?

All data packets are encrypted end-to-end with AES-128, and communication can run over private LoRaWAN or VPN-secured 4G networks. This guarantees industrial-grade cybersecurity and compliance with IT/OT segmentation policies.

Can Sensa.io sensors monitor hydrate or wax formation in flowlines?

Yes. Temperature sensors placed along the flowline detect critical cooling patterns leading to hydrate or wax build-up. Real-time data allows proactive heating or chemical injection, avoiding costly blockages.

How does acoustic leak detection work in upstream applications?

Acoustic sensors detect high-frequency sound anomalies generated by gas or fluid leaks. When combined with pressure readings, they localise the leak within ±10 m, reducing detection time from hours to minutes.

Can sensors remain active during well interventions or shutdowns?

Yes. Thanks to intrinsically safe (Ex ia) design, sensors can operate continuously in Zone 0 even during interventions, without hot-work permits or risk of ignition.

How do pressure sensors resist sand abrasion and high vibration in wellheads?

Each pressure module uses 316L stainless-steel diaphragms and vibration-proof electronics (rated up to 20 g RMS) with conformal coating. This ensures long-term stability in abrasive and high-shock environments typical of wellhead zones.

How does predictive maintenance with Sensa.io actually reduce OPEX?

By analysing vibration, pressure, or ΔP trends, the system detects anomalies before they escalate. This reduces emergency interventions by 30–40 %, extends equipment lifetime, and lowers energy consumption by 10–15 %.

How can Sensa.io sensors be integrated into our SCADA or DCS system?

Integration is immediate through standard industrial protocols: LoRaWAN, Modbus RTU/TCP, MQTT, or REST API. Data can feed directly into Honeywell, Emerson, Schneider, or ABB SCADA platforms without middleware.

How long do the batteries last in upstream operations?

Up to 10 years depending on the transmission interval and signal quality. The adaptive power management system automatically adjusts the sending frequency according to the measured parameter’s variability.

What ATEX certifications cover Sensa.io sensors?

All hazardous-area models are certified Ex II 2 G Ex ia IIC T4 Gb (Gas Zones 0–2) and Ex ia IIIC T135°C Db (Dust Zones 20–21). They are also IECEx approved and comply with the European Directive 2014/34/EU.

Are Sensa.io sensors compatible with any LoRaWAN gateway or network?

Yes. Sensa.io sensors are fully gateway-agnostic and connect seamlessly to any LoRaWAN or MQTT-compatible infrastructure — including Kerlink, Cisco, Milesight, MultiTech, or private industrial networks. This ensures flexible integration with existing SCADA or IoT systems.

Specific Technical Questions/

Agriculture & Agritech

What ROI can be expected for farms or cooperatives?

Typically within 6–12 months, depending on size and automation level. Savings come from lower input use and reduced losses.

Do sensors comply with smart agriculture standards (ISO 11783)?

Yes, Modbus and API integration allow compatibility with ISO 11783 and precision-farming software.

What is the maintenance requirement?

No calibration for 5–10 years; periodic visual inspection is sufficient.

Can they help optimise irrigation cycles automatically?

Yes, pressure and valve data feed into irrigation control systems to adjust flow rates in real time.

Are they suitable for fertiliser or slurry tanks?

Yes, all wetted parts are resistant to ammonia and chemical corrosion.

Can sensors detect methane leaks from digesters?

Yes, pressure and acoustic sensors detect micro-leaks and pressure drifts before safety limits are reached.

How do sensors prevent silo explosions?

By continuously monitoring temperature and acoustic anomalies; early detection prevents spontaneous ignition or overheating.

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