Smart Grain Storage System

As the Lead Engineer of this project, I designed a modular, tech-enabled grain storage unit capable of minimizing post-harvest loss in India’s rural agricultural communities. This solution integrates renewable energy, embedded systems, ultrasonic pest deterrence, and passive bamboo insulation into a unified architecture—targeting three key problems in grain storage: high moisture, pest infestation, and grid power dependency.

Our objective was to move beyond isolated interventions and instead develop an end-to-end system that is sustainable, sensor-driven, and robust enough to perform across India’s diverse agrarian climates.

​

​

Structural Innovation: Bio-Composite Architecture

​

The storage unit’s core is a cylindrical silo fabricated from treated bamboo slats reinforced with polypropylene resin. This approach allowed us to combine the environmental resilience of bamboo with the weatherproof strength of modern polymers, resulting in an enclosure that was breathable, insulating, and structurally rigid.

The design includes:

• A dual-wall system with air gaps for thermal buffering

• External surface coated with natural water-repellent sealant

• Elevated base to prevent water seepage during monsoon

This structure was selected over metal silos and mud godowns due to its superior thermal inertia, pest resistance, and local material availability.

​

​

​

​

​

​

​

​

​

​

​

​

​

​

​

​

​

​

​

Environmental Sensing and Automated Control

​

At the heart of the system lies an IoT-based monitoring network powered by an ESP32 microcontroller. This MCU was selected over alternatives like Arduino UNO, Raspberry Pi, and ESP8266 due to its:

• 16 PWM channels (ideal for ultrasonic transducers)

• Low-voltage operation

• Built-in Wi-Fi and Bluetooth

• High cost-efficiency for rural scalability

The embedded system manages real-time environmental data collection using the following sensors:

• DHT22 for temperature and humidity monitoring

• Soil moisture probes (optional) for extension into field storage

• Gas sensors for CO₂ monitoring (to detect spoilage onset)

• IR sensor to detect rodent movement at access points

Sensor inputs are parsed by the ESP32, which triggers a relay-controlled heating system (such as incandescent bulbs or PTC heat beds) when humidity exceeds set thresholds.

​​

​

​

​

​

​

​

​

​

​

​

​

​

​

​

​

​

​

​

​

​

​​​

​

Ultrasonic Pest Repellent Technology

​

To reduce dependency on toxic chemical pesticides, we integrated an ultrasonic repellent circuit operating at 40 kHz—a frequency range shown to disrupt auditory and neural patterns in common grain pests and rodents.

The setup includes:

• 40 kHz ultrasonic transducer with 100W sound pressure output

• Ultrasonic generator circuit connected to a relay and ESP32

• Directional emitter design embedded in silo wall

This frequency-driven deterrent is particularly effective against insects like weevils and moths, as well as small rodents, with no environmental toxicity or residue left on grains.

Visit Ultrasonic Pest Repellent Page(give hyperlink) for more information.

​

​

Renewable Power System

​

The system is entirely solar-powered, using:

• 20W photovoltaic panel mounted atop the unit

• 12V lead-acid battery for night storage

• MPPT charge controller for optimized energy management

In remote villages with unreliable electricity access, this off-grid solution allows for uninterrupted operation of both sensors and heating mechanisms—without adding financial burden to farmers.

Solar integration was chosen over direct grid reliance to ensure:

• Continuous uptime during monsoon season

• Operational cost reduction

• Portability of unit to off-network farms

​

​

Assembly and Modular Deployment

​

All components—sensors, circuit modules, heating elements, and structural parts—are housed in a weatherproof compartment designed via CAD and prototyped in HDPE. The assembly process follows a bolt-on model, allowing quick construction with basic tools.

The entire unit can be disassembled into modular panels for transport and relocation, making it viable for seasonal deployment across varying crops and locations.

​

​

Field Implementation and Future Scope

​

The design has been deployed on 200 farms through collaboration with a rice sheller network in Punjab and Haryana. Farmers report major improvements in grain quality retention and near elimination of rodent damage within 2 months of use.

Planned upgrades include:

• GSM module for SMS-based remote alerts

• BLE mesh networking to create farm-level storage networks

• Machine learning algorithm for predictive spoilage detection

​

​

Conclusion

​

This Smart Grain Storage Solution stands as a functional example of engineering-driven sustainability—melding material science, embedded automation, renewable energy, and agricultural insights into one cohesive intervention. In bridging the gap between traditional storage systems and advanced IoT-enabled units, the project aims to empower rural economies with scalable, cost-effective, and ecologically sound technologies.