Level and weight monitoring of mesh box pallets – digital, wireless, efficient
Wireless data transmission via Bluetooth Mesh with analysis in moneo
Goal of the project
In almost all industrial sectors – from the food and plastics industries to the automotive industry and its suppliers – large quantities of waste are generated every day. These are collected in containers or mesh boxes and require regular collection. Proper timing is essential: If the waste disposal company arrives too early, unnecessary costs arise. If it arrives too late, containers may become overfilled, creating additional work for personnel. Both the level and the weight are therefore key factors in monitoring containers. Reliable monitoring is often expensive, especially when long cable runs make sensor integration difficult.
Bluetooth Mesh adapters allow sensors to be connected wirelessly to machines, PLCs and the IIoT platform moneo – without any additional wiring. This makes it possible to digitalise and optimise the entire container logistics workflow. Level and weight data provide a solid basis for deciding when containers should be collected based on actual demand.
The result: Less effort, lower costs, predictable maintenance – and another step towards digital production.
 Cost savings through |
 Elimination of routine |
 Automation reduces the workload for personnel |
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Advantages of smart mesh box pallet monitoring with moneo and Bluetooth Mesh
The digitalisation of container monitoring delivers tangible efficiency gains. By using the IIoT platform moneo together with Bluetooth Mesh, monitoring mesh box pallets and containers becomes not only easier but also more cost-effective:
- Fewer site visits, greater visibility: Automatic level detection eliminates the need for routine checks.
- Automated exchange process: The replacement of mesh box pallets and containers is triggered by email – reliably and without manual intervention or the risk of human error.
- Inventory optimisation: The number of empty containers can be planned based on demand and reduced accordingly.
- Wireless sensor integration: IO-Link sensors can be easily connected to moneo via Bluetooth Mesh – without complex wiring.
- Fast implementation, low costs: through simple and time-saving installation.
- Scalable by design: can be expanded with up to 50 adapters per base station and modular IO-Link input/output modules.
- Versatile load cells: Whether pallets, gas cylinders, containers or vehicles – the sensors are suitable for a wide range of applications.
- Wide sensor compatibility – no PLC required: Level sensors and weighing cells can be flexibly combined without the need for a PLC.
- Manufacturer independence: Thanks to standardised 4–20 mA analogue signals, the solution is compatible with sensors from a wide range of manufacturers.
Value proposition
 Process quality |
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Intelligent monitoring: Why level monitoring alone is sometimes not enough
Previously, the container level was continuously monitored using an ultrasonic sensor and processed in moneo as a process value ranging from 0% (empty) to 100% (full). Once the container is detected as full, the system automatically creates a ticket, sends an email to the responsible employees and orders an empty container. After the replacement, the ticket can be closed in moneo – creating a fully digital, end-to-end process. In practice, level measurement alone has proven insufficient for certain materials. Metal scrap, for example, tends to pile up in a cone shape inside the container – with a high level in the centre (100 %) and significantly lower values at the sides (e.g. 50 %). This can lead to premature orders for container emptying even though the container is not yet completely full.
In addition, the disposed material can vary significantly in both volume and weight. A container may still appear to be within the “green range” according to the level sensor, yet already be too heavy to transport. In such cases, staff must manually redistribute the scrap – an additional effort that could be avoided.
Conclusion: Combined monitoring of level and weight is essential to accurately determine when containers actually need to be collected and avoid unnecessary work steps.
From sensor to moneo: How data is transmitted
Sensors mounted directly on the container continuously measure level and weight. This data is transmitted wirelessly to the moneo Bluetooth Base via Bluetooth Mesh adapters – with up to 50 adapters supported per base station. From there, the information is forwarded to the IIoT platform moneo, where it is analysed, evaluated and clearly visualised. This gives you full visibility of your container processes at all times – without complex cabling.
System structure
- Ultrasonic sensors
- IO-Link input/output module
- Bluetooth Mesh adapter
- Bluetooth Mesh base station
- IIoT platform moneo
Easy integration of mesh box pallet or container monitoring
A pallet scale is sourced from a supplier to ensure precise weight measurement of the mesh box pallet or container. It consists of four strain gauge sensors connected in parallel. Reliable signal processing requires a suitable strain gauge amplifier designed to operate with four parallel-connected sensors.
The amplifier provides an analogue current signal in the range of 4...20 mA – corresponding to 4 mA when the scale is empty (0 kg) and 20 mA at full load (600 kg). The existing level sensors also operate with an analogue current output and are connected to the AL2301 IO-Link input/output module. The remaining available ports of this module were used to seamlessly integrate the pallet scale into the existing system.