Silo control 4.0: How to ensure traceability with the digital twin


In modern industry, the traceability of raw materials is a decisive factor for efficiency and safety. With silo control 4.0, operators and manufacturers of silos can meet these requirements and optimize their processes at the same time. By communicating the asset and the administration shell in accordance with RAMI 4.0, you can create a digital twin from the silo and manage the delivery and booking of raw materials fully automatically. In this blog post, you can find out how silo control 4.0 ensures traceability and what benefits it offers for operators and manufacturers.

What is RAMI 4.0 and the digital twin?

RAMI 4.0 (Reference Architecture Model Industry 4.0) is a three-dimensional model that depicts all relevant aspects of Industry 4.0. It integrates the different perspectives on an asset and supports the structured management of data and processes.

A digital twin is the virtual image of a physical object. In Silo Control 4.0, the digital twin enables real-time monitoring and control of silos. It collects and analyzes data to increase efficiency and ensure traceability.

Advantages of silo control 4.0 for silo operators

The implementation of silo control 4.0 offers operators numerous advantages:

  • Automated management: The delivery and debiting of raw materials are managed fully automatically via the digital twin. This reduces manual effort and minimizes errors.
  • Real-time monitoring: With silo control 4.0, you have an overview of the fill level of your silos and the stocks of your raw materials at all times. This enables precise planning and optimization of warehousing.
  • Transparency and traceability: The digital twin ensures complete transparency regarding the movements and stocks of raw materials. Every change is documented and can be traced at any time.
  • Safety and efficiency: Automated control and monitoring minimize safety risks and maximize process efficiency.
  • Sustainability: Optimized warehousing and reduced waste contribute to more sustainable production.

Advantages of silo control 4.0 for silo manufacturers

Silo control 4.0 also offers silo manufacturers numerous advantages that increase their sales opportunities:

  • Innovative technology: Integrating silo control 4.0 into your products shows your customers that you are at the cutting edge of technology and offer future-proof solutions.
  • Customer satisfaction: The benefits of automated management and real-time monitoring improve efficiency and security for your customers, resulting in higher customer satisfaction.
  • Competitive advantage: Silo control 4.0 sets you apart from the competition and offers your customers real added value.
  • Sustainability: By optimizing warehousing and reducing waste, you can help your customers achieve their sustainability goals.
  • Sales promotion: The ability to guarantee the traceability and efficiency of raw material management makes your products particularly attractive to potential customers.

How does silo control 4.0 work?

Communication between the asset and the administration shell in accordance with RAMI 4.0 creates a digital twin from the silo. This intelligently networks the systems and enables fully automated management of the raw materials:

  1. Delivery: When new raw materials arrive, the data is automatically fed into the system and the stock is updated in the digital twin.
  2. Debit: When raw materials are consumed, the stock in the digital twin is automatically reduced and the data adjusted accordingly.
  3. Real-time monitoring: The digital twin provides a real-time view of the silo fill level and all stock movements, enabling precise planning and management.
  4. Data evaluation: The collected data is analyzed in order to continuously optimize processes and increase efficiency.

API interfaces for comprehensive integration

A key component of silo control 4.0 is the ability to communicate with other assets in the value stream via API interfaces. This enables seamless integration and further optimization options:

  • Truck scale: The connection of the truck scales via an API interface enables the automatic recording and updating of delivery data directly in the digital twin. This ensures accurate accounting and transparency.
  • Cargoclix: Integration with Cargoclix optimizes time slot management and logistics processes. Real-time data from the digital twin can be used to improve the supply chain and resource planning.
  • IXARO software: The connection with the IXARO software enables comprehensive control and management of logistics and warehouse processes. The digital twin ensures that all data is consistent and up-to-date, which increases efficiency and transparency.


The vision of Industry 4.0 and the importance of the administration shell

The fourth industrial revolution, known as Industry 4.0, is striving for a networked and interoperable value chain. In this context, all elements, known as assets, communicate with each other as autonomously as possible in order to make production processes efficient and resilient. An asset can be both a physical object (such as a machine) and a virtual entity (such as software or a document). To enable this efficient communication, assets must be defined and represented uniformly in the virtual world. This is where the asset administration shell comes into play, which serves as a concrete implementation of a digital twin and is currently in the standardization process (IEC 63278)

Silo content in kg or tons


We achieve this on an interdisciplinary basis by ensuring that everyone involved has access to all relevant data in the value stream. This promotes cooperation between all departments and creates the basis for streamlining organizations without introducing more bureaucracy, but finding solutions as a team. An example from the plastics industry shows how raw material handling can be optimized in a heating/cooling mixer combination so that up to five orders can be processed fully automatically at the same time. This not only significantly reduces the workload for employees, but also creates transparency right through to the end product.


An often overlooked but significant benefit of the Digital Twin is the promotion of mindfulness in the industry. Through real-time monitoring and detailed data collection, companies can:

Silo content in kg or tons
Mr. Opdenhoff: Contact person for mixer systems

Do you have further questions about DIGITAL ZWILLING and industrial data for solo control and silo management? Then simply book a personal consultation appointment with us now. Free of charge and without obligation!

Important links and resources

For more information and detailed specifications you can visit the following links:



Industrial Digital Twin Association (IDTA)

ECLASS Standardization



Battery Pass


The use of industrial data as the basis for the Digital Product Passport and the Digital Twin offers enormous potential for optimizing production processes and promoting sustainability. Companies that adopt these technologies at an early stage can not only improve their efficiency and product quality, but also gain important competitive advantages. Creating a modern data ecosystem, overcoming data silos and integrating them into the value stream and raw material handling are key steps in achieving these goals. Digital twins also promote awareness of people, machines, products and systems and improve collaborative working.
Mr. Brunetti: Contact person for dosing systems

 Book a free and non-binding personal consultation appointment now in terms of digital twins in raw materials handling with us.

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