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Safeguarding Genetic Assets – Precision Cold Chain Monitoring for Grandparent Stock Transportation
The global poultry industry relies heavily on the health and genetic integrity of Grandparent Stock (GPS) – the foundational breeding birds that produce all subsequent generations of broiler and layer chickens. Transporting these high-value live animals is arguably the most critical segment of the poultry cold chain. Unlike inanimate perishable goods, GPS are extremely sensitive to environmental fluctuations. Even minor deviations in temperature, humidity, or ventilation during transit can cause severe stress, compromised health, reduced fertility, and even mortality, leading to devastating genetic and economic losses for poultry breeders. Traditional monitoring methods, often involving manual checks or basic data loggers, are simply inadequate for the precision and real-time responsiveness required.
Our customer, a specialized transport provider for the poultry breeding sector, faced immense pressure to guarantee optimal conditions for its GPS shipments. Their existing challenges included:
- High-Value, High-Risk Cargo: Each GPS bird represents significant genetic investment; losses directly impact future production cycles and profitability.
- Extreme Environmental Sensitivity: GPS require a narrow band of temperature (20−24∘C) and humidity (50−70%) with precise ventilation. Deviations cause irreversible damage.
- Lack of Real-time Visibility: Manual checks provided only historical data, making it impossible to intervene if conditions deteriorated during transit.
- Reactive Problem Solving: Issues like refrigeration unit malfunctions or ventilation failures were often discovered too late, resulting in compromised or lost shipments.
- Compliance and Biosecurity: Demonstrating consistent environmental control for animal welfare regulations and maintaining biosecurity protocols was challenging without automated, verifiable data.
- Disputed Claims: Proving optimal transport conditions in case of a dispute was difficult without continuous, tamper-proof records.
Our customer recognized that to uphold its reputation and protect its clients’ invaluable genetic assets, it needed a robust, real-time precision cold chain monitoring solution tailored for live animal transport.
The Solution: An Integrated Precisol’s Ecosystem for Live Animal Logistics
To meet these stringent requirements, customer implemented a comprehensive Industrial Internet of Things (IIoT) solution, leveraging an integrated ecosystem of Precisol’s technologies. This system provided granular, real-time environmental control and traceability throughout the GPS transportation journey.
The core components of the solution included:
- Precisol’s CAN Telematics Gateway with GNSS: This rugged, industrial-grade gateway was installed in every transport vehicle. Its integrated GNSS (Global Navigation Satellite System) module provided precise, real-time location tracking, enabling customer to monitor routes, geofence critical zones (e.g., biosecurity checkpoints), and provide accurate ETAs. The gateway’s robust cellular (LTE) modem ensured continuous, secure data transmission to the cloud, even when vehicles traversed remote areas.
- Precisols RS485 Modbus Gateway (Integrated/Companion): This component served as the critical interface for environmental sensors and control systems. It collected data from various Modbus RTU devices within the refrigerated compartments.
- High-Precision Temperature Controllers and Humidity Sensors: Multiple high-accuracy temperature controllers and humidity sensors were strategically placed throughout the GPS transport compartments. These devices provided continuous, granular readings of the internal environment. Crucially, these sensors communicated their data via Modbus RTU over RS485, ensuring seamless integration with the Precisol’s gateway.
- PLCs for Environmental Control: The sophisticated ventilation, cooling, and heating systems within the transport vehicles were managed by on-board PLCs (Programmable Logic Controllers). These PLCs controlled fans, refrigeration units, and heating elements to maintain the precise environmental setpoints required for GPS. These PLCs also communicated via Modbus RTU over RS485, allowing the Precisol’s gateway to read their status and, more importantly, send control commands.
- Customization for Non-Standard Settings: A key differentiator for Precisol was their ability to provide customization on updating the CAN serial settings (like baud rate) and Modbus register mapping. Customer’s specialized vehicle systems often had proprietary or non-standard communication parameters, which our engineers meticulously configured the gateways to match, ensuring flawless data acquisition where off-the-shelf solutions would fail.
- PreciCloud Dashboard & PreciView Mobile Application: All aggregated data (location, temperature, humidity, ventilation status, PLC alarms) was securely transmitted via the Precisols gateway’s LTE modem to customer’s central PreciCloud cloud dashboard. This platform offered:
- Real-time Visualization: Live maps showing vehicle locations, current environmental conditions, and system status.
- Automated Alerting: Instant SMS and email alerts for any deviation from pre-defined temperature/humidity ranges, ventilation failures, or geofence breaches.
- Remote Control: Authorized personnel could remotely adjust environmental setpoints (e.g., temperature, fan speed) or initiate emergency ventilation via the cloud dashboard, sending commands back through the Precisol’s gateway to the on-board PLCs.
- Push Notifications in Precisol’s PreciView mobile application: Ensuring critical alerts reached field managers and drivers immediately, enabling rapid intervention.
- Comprehensive Data Logging: Tamper-proof historical records for regulatory compliance, post-shipment analysis, and dispute resolution.
Transformative Results: Maximized Viability, Compliance, and Economic Returns
The deployment of this integrated Precisols solution delivered immediate and profound benefits for customer:
- Maximized GPS Viability & Genetic Integrity: Continuous, precise environmental control prevented stress and mortality, ensuring that GPS arrived at their destination in optimal health, ready for breeding. This directly protected the genetic investment.
- Reduced Product Loss and Claims: Proactive detection and immediate intervention in case of temperature excursions virtually eliminated losses due to compromised shipments, drastically reducing financial write-offs and client disputes.
- Guaranteed Regulatory Compliance & Biosecurity: Automated data logging provided irrefutable proof of adherence to animal welfare regulations and biosecurity protocols, simplifying audits and enhancing customer’s reputation.
- Enhanced Operational Efficiency: Automated monitoring eliminated the need for manual checks, saving significant labour costs and reducing fuel consumption by optimizing refrigeration cycles and routes.
- Proactive Maintenance & Uptime: Early detection of refrigeration or ventilation system malfunctions allowed for predictive maintenance, preventing costly breakdowns and ensuring continuous, reliable transport.
- Superior Client Confidence: Clients gained peace of mind knowing their high-value GPS were being transported under meticulously monitored and controlled conditions, strengthening customer’s market position.
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Arima Leonardo
Electrician
Alex Piter
Designer
Mariya Komola
Developer
David Malan
Developer
Arima Leonardo
Electrician
Alex Piter
Designer
Mariya Komola
Developer
David Malan
Developer
