Modernization and IoT Data Platform Integration of Inboxfarm Containers

For the digitalization and modernization of a container system for automated vegetable cultivation, SPIE AUTOMATION developed a holistic hardware and software solution for PUR GmbH. The project’s goal was to technologically modernize the existing container solution and further develop it for scalable use. In addition to migrating to a modern PLC, SPIE AUTOMATION designed an interactive web dashboard with remote access and central data evaluation in its IoT data platform. This resulted in a standardized hardware and software solution that enables the economical operation of an initial ten Inboxfarm containers and forms the basis for future expansions.

Challenge and Objective

PUR GmbH uses 20-foot containers for professional vegetable cultivation, designed as a plug-and-play solution. Each container features two rigs with a total of 940 planting spaces, two 480-liter water reservoirs with nutrient supply, a climate and ventilation system, a power connection, and automatic control of all components.

The containers and basic control system were already in place but were originally implemented using a different PLC. This solution increasingly reached its limits. A convenient option for remote maintenance, parameterization, or continuous analysis of operational data such as temperature, humidity, or other process values was not available. At the same time, a consistent digital infrastructure was lacking to monitor, control, and evaluate the complex processes of professional vegetable cultivation independently of location. All operational data were to be centrally collected, permanently stored, and made usable for optimization in the future.

The project’s goal was therefore not only to modernize the existing hardware but also to create a future-proof remote monitoring and control solution. The focus was on migrating to a more powerful PLC, establishing secure remote access, developing an intuitive web interface with read and write permissions, and integrating it into the IoT data platform for data acquisition, evaluation, and remote control. In the future, operational data was to be transmitted to the cloud via a 5G connection, persistently stored, and visualized via web dashboards. Simultaneously, the system was to become more flexibly expandable and create a scalable technical basis for operating additional containers. Additionally, a camera was integrated, allowing for continuous observation of both the current conditions inside the container and plant health.

Solution

The implementation was carried out by an interdisciplinary team from SPIE AUTOMATION in close and collaborative partnership with PUR GmbH. Project management, PLC programming, and visualization were handled by the Automation department. The department was also responsible for electrical design, including circuit diagram creation, and electrical assembly. Control cabinet construction took place at the Pfullendorf site. The conception of the cloud connection and integration into the IoT data platform were implemented by the Digital Solutions department. Through the close collaboration of the individual departments, SPIE AUTOMATION offers comprehensive solutions from a single source.

Initially, the project team analyzed the existing system, the current control, and the existing infrastructure. Based on this, a concept for migration to a modern PLC and a structured control concept was developed, forming the basis for a scalable series solution.

In the software area, the project started with a Proof of Concept (PoC) on a prototype container. Together with the customer, the control concept and the storyboards for the later dashboards were developed and continuously refined. After successful validation of data communication and the individual system components, the insights gained were transferred to the series of an initial ten containers.

The containers were electrically revised, and all relevant components were newly integrated and wired. Subsequently, the PLC was programmed, which takes over the complete control of climate functions – heating, cooling, dehumidifying, and ventilating – as well as automatic irrigation. Regulation is based on various sensor values and considers not only control algorithms but also malfunctions and protection mechanisms.

In parallel, SPIE AUTOMATION designed the web-based visualization, through which all operating states can be monitored in real-time and parameters can be comfortably adjusted. Secure VPN access also allows remote access to the PLC, as well as other components such as the integrated cameras.

The IoT data platform receives all operational data via a 5G connection, stores it permanently, and provides it via intuitive dashboards for live monitoring, analysis, and long-term evaluations. The integrated camera also enables permanent visual inspection of the container interior, so that both the system status and plant health can be assessed remotely at any time.

Particularly noteworthy is the short project duration: less than two months passed from the first storyboard draft to the commissioning of the first container on site. Thanks to the existing IoT data platform, the PoC could be implemented within this period, as the initial administrative effort for setup was minimized.

Another challenge was to reliably connect all systems. Control, web interface, VPN, OPC UA communication, cloud platform, 5G connectivity, and camera technology had to interact seamlessly. Furthermore, it was necessary to design the mobile connectivity to be stable even under demanding conditions and to synchronize the data streams of various sensors – including conductivity sensors – correctly in time to enable robust long-term analyses.

Benefits

With the new solution, PUR GmbH has a fully digitized and scalable platform solution for operating its Inboxfarm containers. All operational data are now monitored, evaluated, and documented in real-time, regardless of location. Temperature, humidity, and other process data can be controlled remotely and are available on any device for analysis. This forms the basis for continuous optimization of cultivation conditions. Secure remote access allows flexible parameter adjustments and maintenance and service work without requiring on-site deployment. At the same time, the integrated camera enables permanent control of the container status and plant health.

The central cloud solution creates high transparency across all operating states and enables continuous evaluation of historical data. This allows water, nutrients, and other resources to be used sustainably, and yields to be increased in the long term. Simultaneously, the solution reduces manual interventions, increases operational safety, and makes processes more efficient, traceable, and significantly more flexible. With the standardized hardware and software architecture, the technical basis has also been created to easily integrate additional containers into the system and flexibly expand the platform.

These SPIE AUTOMATION strengths were utilized

Holistic implementation from hardware planning, circuit diagram creation, control cabinet construction, and PLC programming to the cloud platform
Modernization of existing systems and development of future-proof automation solutions
Connection of automation and IT technologies such as OPC UA, VPN, 5G, and cloud connectivity
Conception of individual web dashboards for visualization, control, and analysis of operational data based on the IoT data platform
High agility and short development times from PoC to commissioning
Interdisciplinary collaboration of multiple business units and implementation of almost the entire SPIE AUTOMATION portfolio from a single source

About our customer
PUR GmbH develops and distributes modular indoor farming systems that allow herbs, salads, and other plants to be grown year-round in containers. The company relies on hydroponic cultivation technology, which reduces water consumption, avoids chemical pesticides, and shortens transport routes through regional cultivation. The goal is to enable a more sustainable and efficient form of food production.

Industry
Agri-tech/Indoor Farming

The collaboration is characterized by short communication channels and quick reactions to new findings and changes. Even as a small start-up, we always felt taken seriously and received excellent advice. All important measured values are available in almost real-time and allow for precise intervention in the system’s control without having to travel to the site. Furthermore, parameters can now be easily adjusted according to plant requirements or customer wishes. The software also allows our customers to take action remotely.

Roland Grimm
Managing Director
PUR GmbH

Thanks to the existing IoT data platform, the cloud connection of the containers could be implemented in a very short time. This allowed the focus to be on implementing customer requirements and individually developed dashboards, as no effort was required for setting up a new platform environment. Due to the well-thought-out concept, further containers can be integrated into the IoT data platform in the future with little time and monetary effort, which not only reduces our workload but also makes the customer happy.

Jan Bergmann
Software Developer
SPIE AUTOMATION

With the modernization of the existing system and the integration of a web interface and remote access, we were able to create real added value for PUR GmbH. The increased transparency and evaluability of operational data enable continuous optimization of the system and demonstrate our strength in combining automation and IT technologies.