A tank is located at a customer site, another is installed at an external warehouse, several IBCs are moving through the supply chain, and a production facility needs to maintain a reliable supply of different liquids. As long as fill levels are only checked locally or manually at fixed intervals, companies have limited visibility into what happens between those inspections.
This is where Tank Level Monitoring comes in.
Modern Tank Level Monitoring Software combines sensor technology, wireless data transmission and a centralized software platform. Instead of sending employees to individual tanks or containers to read fill levels manually, companies can monitor stationary and mobile liquid containers remotely. At the same time, individual measurements become part of a continuous data stream that provides far more value than simply displaying a current fill level.
With the Packwise Smart Cap and Packwise Flow 2.0, Packwise connects physical measurements at the container with a central IIoT platform. The Smart Cap captures fill level data as well as additional information such as location, temperature, movement and orientation. Packwise Flow brings these data points together and makes them available for dashboards, notifications, analytics, reporting and downstream processes.
With Flow 2.0, a new generation of the Packwise software platform has just been launched. The new release focuses on faster workflows, improved visibility across large container fleets, deeper analytics and simpler management of complex corporate structures. Together, Smart Cap and Flow turn a conventional fill level sensor into a comprehensive Remote Tank Monitoring System that helps companies improve inventory transparency, plan replenishment more efficiently and increasingly manage their operations based on real-time data.
Tank Level Monitoring refers to the digital monitoring of the fill level inside a tank or liquid container. In a modern system, measurements are not only captured directly at the container but are also transmitted automatically to a central software platform.
The key difference compared with a simple digital level indicator lies in how the data can be accessed, analyzed and used.
A local display primarily answers one question:
How full is this tank right now?
A connected Tank Level Monitoring Software platform can answer much more.
How are inventory levels developing over several days or weeks? When is a critical minimum level likely to be reached? Which tanks require attention? Where are mobile containers currently located? Which sites show unusual consumption patterns? And when should the next delivery be scheduled?
This transforms tank monitoring from a pure measurement task into an operational management tool.
For companies managing distributed tank inventories, customer locations or mobile liquid containers, the difference between an isolated measurement and a fully connected Remote Tank Level Monitoring System can be substantial.
Many companies still rely on experience, manual inspections, phone calls or fixed delivery intervals to manage liquid inventories.
This can work when only a small number of tanks are involved. As the number of containers, sites and people involved grows, however, the administrative effort increases significantly.
There is another fundamental problem: a fixed inspection or delivery schedule does not reflect actual consumption.
A tank that is normally replenished every four weeks may reach a critical level after only three weeks during a period of higher demand. In another month, the same tank may still contain sufficient material after five weeks.
If inspections and deliveries continue to follow a rigid schedule, companies risk unnecessary trips, inefficient deliveries or, in the worst case, unexpected stockouts.
Remote Tank Level Monitoring creates transparency where operations previously had to rely on assumptions.
Actual fill level data can become the basis for replenishment, dispatching, production planning, inventory management and service processes.
The objective is not to generate as much data as possible.
The objective is to know where action is required, and when.
A powerful Remote Tank Monitoring System essentially consists of three layers: measurement at the container, wireless data transmission and intelligent processing within a software platform.
With Packwise, the Smart Cap and Packwise Flow 2.0 form a continuous digital data chain.
The Packwise Smart Cap is mounted on the liquid container and uses radar technology for contactless fill level measurement.
The sensor determines the fill level without requiring a probe to remain immersed in the liquid. In addition, it can capture further information such as temperature, movement, orientation and location.
This approach is particularly useful in industrial environments because existing tanks and containers can be digitized without replacing the entire infrastructure.
The Smart Cap is designed for a wide range of liquid containers, including:
This versatility makes it possible to monitor very different container types within one digital infrastructure instead of operating separate systems for every application.
For Remote Tank Level Monitoring to work effectively, the information captured at the container must be transmitted reliably to the digital platform.
The Smart Cap sends its data wirelessly via cellular communication technologies. This makes the solution suitable for decentralized locations where a traditional network connection is not available for every individual tank.
Typical applications include external storage areas, production sites, customer facilities, logistics hubs, construction sites and mobile liquid containers.
Fill level information therefore no longer remains available only at the physical location of the tank.
It can be accessed centrally and used throughout the organization.
The process does not end once the data has been transmitted.
For many companies, this is where the most valuable part of tank monitoring begins.
Packwise Flow 2.0 brings data from connected liquid containers together within a central software environment. Users can view current fill levels, historical trends, locations and additional sensor information and place this data in the context of their operational processes.
Dashboards provide transparency.
Notifications help ensure that employees do not need to check every individual tank or IBC manually.
Historical data enables analysis.
Interfaces make the information available to other business systems.
With the launch of Flow 2.0, this entire data chain has been significantly enhanced. The goal of the new software generation is not simply to add more functions, but to make working with large volumes of tank, IBC and sensor data considerably faster, clearer and more intuitive.
As a result, employees spend less time searching for information. The system helps highlight the situations where attention and action are actually required.
With Packwise Flow 2.0, the next generation of the platform has just gone live. The new version builds on experience from real customer projects, a wide variety of measurement scenarios and numerous industrial use cases.
At the heart of the new release is a simple question:
How can growing volumes of sensor and container data be presented in a way that helps users understand what is happening and where action is required more quickly?
To address this, many areas of the platform have been redesigned and expanded.
Key workflows have been streamlined and reorganized. Fewer clicks and optimized user journeys make everyday tasks quicker and more efficient.
This becomes increasingly important as container fleets grow. Tank monitoring software should not create additional administrative work. It should make working with data easier.
The map plays a much more prominent role in Flow 2.0. A full-screen map experience makes it easier to understand large numbers of tanks, IBCs and sites geographically.
Relevant asset and process information can also be accessed directly from the map.
For companies managing multiple customer sites, depots, production locations or mobile liquid containers, this provides a clearer overview of where assets are located and where attention may be required.
With mobile liquid containers, the current location is only part of the picture.
Flow 2.0 provides more detailed information about container journeys and individual stops. Measurement data is more closely linked to the corresponding journey elements.
This creates a clearer relationship between sensor data and the actual logistical process.
Companies can therefore understand not only what was measured, but also where within a container journey or operational process that measurement occurred.
This is particularly relevant for mobile assets such as plastic IBCs, stainless steel IBCs and ISO tanks that move between production sites, logistics providers and customer locations.
The process of digitizing the physical container has also been simplified.
The new Packwise Scan App for iOS and Android makes it easier to connect a physical container with its digital counterpart. This supports the creation and assignment of digital twins directly within operational workflows.
This can be especially important during larger rollouts.
A scalable IoT solution must not only analyze data effectively. It must also make it as straightforward as possible to onboard and manage large numbers of tanks, IBCs and other liquid containers.
One of the most important developments in modern Tank Monitoring Software is the shift away from simply showing users more information.
Instead, the system should identify relevant events and bring them to the user's attention.
For this reason, the configuration of notifications has also been simplified in Flow 2.0.
Users can now configure notifications more directly without first having to create an additional group structure.
At first glance, this may appear to be primarily a usability improvement. Strategically, however, it is more significant.
The easier it becomes to define rules and notifications, the easier it becomes to translate data into operational processes.
A measurement becomes information.
Information triggers a notification.
And a notification can increasingly become the starting point for an automated process.
Another major element of Flow 2.0 is the new Analytics section.
Prepared analyses help users identify patterns and relationships within their measurement and process data more quickly and make better-informed decisions.
This is an important step beyond simply displaying current fill levels.
The long-term question is no longer only:
What is happening right now?
It increasingly becomes:
Why is it happening, what is likely to happen next, and what should we do about it?
Flow 2.0 therefore creates an important foundation for forecasting, anomaly detection and future AI applications.
Flow 2.0 has also been optimized for use across different devices.
A more consistent and modern user experience makes the platform easier to use both on desktop and mobile devices.
This is particularly relevant for Tank Level Monitoring because users do not work exclusively from a desk.
Information may also be needed while travelling, in a warehouse, at a production site or directly next to a tank or IBC.
As a deployment grows, managing individual tanks and individual users is no longer enough.
International companies, suppliers and service providers often need to represent different legal entities, sites, customers or accounts within one platform.
Flow 2.0 supports Multi-Tenancy, making it easier to map and manage corporate structures and multiple accounts.
For larger rollouts, Tank Level Monitoring can therefore evolve from an isolated application into a scalable enterprise solution.
A common misconception is that digital tank monitoring is simply a digital version of a conventional level indicator. It is not. A digital indicator primarily replaces manual reading. A comprehensive Tank Monitoring System, on the other hand, connects measurements over time with locations, events, consumption patterns and business processes.
A traditional inspection provides a single measurement at a specific point in time.
Remote Tank Level Monitoring creates a continuous data foundation.
Instead of travelling to a site simply to check a tank, employees can view the fill level remotely. Instead of reacting only when a shortage becomes visible, thresholds and notifications can identify critical situations earlier.
Historical data also provides insight into how consumption changes over time.
The real economic value therefore does not come from displaying a percentage on a screen.
It comes from using that information to improve the next step in the process.
With ten tanks, a manual overview may still be manageable.
With hundreds or thousands of liquid containers, a simple list quickly becomes difficult to use.
Professional Tank Monitoring Software must therefore do more than display data. It needs to help users prioritize information.
Which tanks are developing normally?
Which IBCs are approaching a defined minimum level?
Where is consumption changing unusually quickly?
Which stationary tanks may require replenishment over the next few days?
Which mobile containers are currently in transit?
Which locations currently need attention?
This transition from simply displaying data to prioritizing action is essential for scalable Tank Level Monitoring.
The enhancements introduced with Flow 2.0, including the expanded map experience, more information directly within the map, the new Analytics section and the redesigned navigation, are aimed precisely at this challenge.
Instead of placing more data in front of the user, the software is designed to make relevant relationships easier to understand.
One of the most valuable use cases for digital tank monitoring is automatic notification.
An employee should not need to review hundreds of tanks and IBCs every morning just to determine whether one of them has reached a critical level.
Instead, relevant thresholds can be defined in advance.
If a tank falls below a specified minimum level, for example, the system can trigger a notification.
Other sensor data and events can also be incorporated into monitoring rules.
With Flow 2.0, configuring these notifications has become easier, allowing rules to be adapted more quickly to specific workflows and use cases.
This changes fill level monitoring from a permanent inspection task into management by exception.
Under normal conditions, not every tank or IBC requires attention. Users can focus on the situations where a decision actually needs to be made.
For supply chain managers, dispatchers, production managers and service organizations, this is an important step toward scalable operations.
A current fill level answers only part of the question.
Tank Level Monitoring becomes significantly more valuable when historical fill level trends are available.
A time series can show how quickly material is being consumed, whether seasonal patterns exist and whether usage at a particular location is changing.
A tank with 30 percent remaining may be completely uncritical if average consumption is only one percent per day.
If the same location consumes ten percent per day, the situation is very different.
The individual measurement therefore gains much of its value from context.
With historical tank data, companies can gradually move from asking:
“How full is the tank?”
to asking:
“When are we likely to need to act?”
This creates the foundation for forecasting and proactive replenishment planning.
A simple alert responds to a condition.
A forecast attempts to determine when that condition is likely to occur.
This distinction is particularly important for modern Tank Level Monitoring Software.
If a company can identify several days in advance that a tank is likely to reach a critical level, it gains more options.
Deliveries can be consolidated.
Routes can be planned more effectively.
Material can be scheduled in advance.
Service visits can be prepared.
Instead of responding to an urgent situation, the task becomes something that can be planned.
Historical measurements, analytics and connected processes provide the foundation for this shift.
The new Analytics section within Flow 2.0 represents another step away from simply displaying sensor readings and toward software that helps users derive meaningful insights from their data.
Remote Tank Level Monitoring becomes particularly valuable when the fill level is directly connected to the supply of a customer or production location.
In a traditional model, customers monitor their own inventories and place an order once material starts to run low.
This often leads to short-notice orders and additional coordination.
Digital tank monitoring allows this process to be organized differently.
Provided the appropriate commercial and technical setup is in place, suppliers can gain visibility into material inventories and plan replenishment proactively.
This enables models such as Vendor Managed Inventory, or VMI, as well as data-driven replenishment processes.
Instead of waiting for a customer to report that a tank is almost empty, demand can be identified based on actual fill level data.
For suppliers, this creates the opportunity to plan routes more efficiently, consolidate deliveries and provide customers with a more reliable service.
For customers, it reduces manual monitoring and lowers the risk of unexpected stockouts.
Tank Level Monitoring therefore evolves from a technical measurement solution into an enabler for new service and business models.
Tank monitoring is often associated primarily with large stationary storage tanks.
Industrial liquids, however, are not stored exclusively in fixed tanks.
They also move through supply chains in plastic IBCs, stainless steel IBCs and ISO tanks, while other liquids remain in stationary tanks at production sites, customer locations or decentralized facilities.
For many companies, it therefore makes little sense to view stationary and mobile liquid containers as completely separate environments.
The Packwise Smart Cap enables different types of liquid containers to be digitized and monitored within one software environment, including:
For mobile assets, additional location and movement data provides further context.
Flow 2.0 strengthens this approach by offering more detailed route information, individual stops and a closer link between measurement data and the corresponding stages of a container journey.
The system can therefore answer more than the question of how much liquid is currently inside a container.
Depending on the use case, companies can also understand where a container is located, which stages of its journey it has completed and in what operational context a particular measurement occurred.
Digital fill level monitoring can be used far beyond a single industry.
It is particularly relevant wherever liquid inventories affect supply security, production, logistics or service operations.
Chemical raw materials and liquid products are often distributed across plastic IBCs, stainless steel IBCs, stationary tanks and ISO tanks at production sites, logistics hubs and customer locations.
Digital fill level data can help identify shortages earlier, plan replenishment and create greater transparency across distributed inventories.
For diesel, HVO, AdBlue, lubricants and other liquids, tank inventory is closely linked to availability and delivery planning.
Remote Tank Level Monitoring allows suppliers to consider actual consumption trends instead of relying exclusively on fixed delivery intervals.
If an essential raw material is unavailable, production may come to a standstill.
Digital Tank Level Monitoring can therefore become part of production and material planning by making critical inventory levels visible earlier.
Remote monitoring can also be used for water, wastewater and process liquids stored in stationary or mobile tanks.
At difficult-to-access or geographically distributed sites, remote monitoring can significantly reduce the need for manual inspections.
Fuel, water and operating fluid tanks are often located at decentralized sites.
Wireless fill level monitoring can reduce unnecessary inspection trips and help ensure that replenishment is organized in time.
Car wash facilities and similar operations use different liquids that are essential to day-to-day operations.
Declining fill levels can be monitored centrally, allowing replenishment to be planned before a shortage affects operations.
When selecting a solution for remote tank monitoring, companies should not evaluate the sensor in isolation.
Hardware and software form one system.
A future-ready solution should therefore be assessed on more than its ability to display a fill level.
Can the hardware be used with existing plastic IBCs, stainless steel IBCs, stationary tanks and ISO tanks?
How complex is installation?
Does wireless communication work reliably at decentralized locations?
Can large numbers of tanks and IBCs be managed efficiently?
Can thresholds and notifications be configured flexibly?
Are historical data and analytics available?
Can different users, companies and account structures be represented?
Can tank data be integrated into ERP, logistics, BI or other business systems?
Can the system scale as the number of containers and locations grows?
Can users work effectively on both desktop and mobile devices?
And does the architecture provide the data foundation required for forecasting, automation and future AI applications?
In the long term, these questions matter far more than simply displaying a percentage value.
The launch of Packwise Flow 2.0 represents more than a conventional software update.
The new generation has been developed to address the growing volume and complexity of IoT data, combining a modernized user interface with more efficient workflows, analytics and scalable account structures.
The Smart Cap delivers data from the field.
Flow makes that data visible, structured and operationally useful.
The expanded map experience improves geographical visibility.
More detailed routes provide greater transparency for mobile containers.
Closer links between measurements and journey elements add context.
Analytics helps users understand developments more effectively.
Simplified notification configuration shortens the path from measurement to action.
Multi-Tenancy supports more complex corporate structures.
And the Scan App makes it easier to connect the physical container with its digital twin.
Taken together, these capabilities create a platform whose purpose is not to display as much data as possible.
Its purpose is to help companies make better decisions faster, based on real operational data.
Many industrial companies already use ERP systems, logistics software, BI solutions or proprietary dashboards.
A modern IIoT platform should not necessarily replace these systems. It should be able to complement and connect with them.
Packwise Flow can make data available through interfaces such as APIs.
Webhooks enable event-driven communication between different systems.
The distinction is straightforward.
Using an API, another system can actively request information such as the current fill level of a tank.
A webhook can automatically notify another system when a relevant event occurs or a defined condition changes.
This means the information does not have to remain inside Packwise Flow.
A critical fill level could, for example, trigger a process within an ERP system, a replenishment workflow, a dashboard or an internal application.
This turns Tank Level Monitoring Software into part of a wider digital process landscape.
As artificial intelligence becomes more widely used, another important question arises:
What data does an AI system actually receive?
AI can only provide meaningful recommendations on inventories, replenishment requirements or anomalies if it has access to current and reliable operational data.
This is where an important connection between Remote Tank Level Monitoring and AI begins to emerge.
Continuous measurements create historical data series.
These data sets can reveal consumption patterns.
Patterns can support forecasting.
Deviations can reveal unusual situations.
And forecasts or anomalies can ultimately form the basis for increasingly intelligent recommendations.
The important point is not AI as an isolated feature.
The important point is having a reliable data foundation.
With the new Analytics capabilities and the continued development of Flow 2.0 toward connected data and increasingly automated processes, Packwise is creating the technological basis for this next step.
Through APIs, Webhooks and future interfaces, operational tank data can increasingly become part of automated and AI-supported workflows.
The specific benefits depend on the business model, industry and application. However, several advantages are common across many projects.
Greater transparency: Companies gain a centralized overview of liquid inventories without having to gather information manually from different sites.
Fewer manual inspections: Employees no longer need to visit every tank or IBC simply to check its fill level.
Improved supply security: Critical inventory levels can be detected earlier, allowing replenishment to be initiated in time.
Better delivery planning: Replenishment can be based more closely on actual consumption.
More efficient logistics: Deliveries and routes can be planned according to real demand and consolidated where appropriate.
Fewer emergency processes: Earlier information reduces the likelihood of unexpected stockouts and urgent deliveries.
A stronger data foundation: Historical fill level trends support consumption analysis, reporting and forecasting.
Greater potential for automation: Thresholds, notifications and system integrations can trigger downstream workflows.
Scalability: Large numbers of geographically distributed tanks, IBCs and ISO tanks can be monitored centrally.
Tank Level Monitoring is therefore not simply a measurement technology.
It connects sensing technology, IIoT, supply chain management, logistics and software.
Before introducing a solution, it is worth looking beyond the purchase price of an individual sensor.
The entire lifecycle of the system matters.
How easily can the hardware be installed?
Which types of liquid containers can be equipped?
Is the measurement technology suitable for the application?
How reliably does communication work at the intended location?
How is the data presented?
Which alerts and rules can be configured?
Can different companies, sites and accounts be managed?
Are historical analysis and analytics available?
Which interfaces are provided?
Can the solution later be extended to additional locations and container types?
And most importantly:
Does the solution simply provide a measurement, or does it actually support an operational process?
This is one of the fundamental differences between a digital fill level indicator and genuine Tank Level Monitoring Software.
Digitizing a tank begins with the sensor.
It should not end there.
The greater value emerges when measurement data is automatically available wherever decisions are made.
A fill level can trigger an alert.
A series of measurements can reveal a consumption trend.
A consumption trend can indicate a future replenishment requirement.
A predicted requirement can influence dispatch planning.
And a defined workflow can ultimately become increasingly automated.
This is the direction in which modern Remote Tank Level Monitoring is developing.
The goal is no longer simply to see remotely how full a tank is.
The goal is to use tank data to create better processes.
Modern fill level monitoring therefore goes far beyond answering the question of how full a tank is at any given moment.
The real value emerges when measurement data becomes automatically available, developments can be identified early and this information can be translated into better decisions across supply, logistics and production.
With the Packwise Smart Cap and the recently launched new generation of Packwise Flow 2.0, Packwise connects contactless fill level measurement directly at the liquid container with a modern and scalable software platform.
The solution can be used across different industrial container types, from plastic IBCs and stainless steel IBCs to stationary tanks and ISO tanks, allowing companies to bring both stationary and mobile liquid inventories into a common digital environment.
Flow 2.0 expands this approach with faster workflows, a larger and more informative map experience, more detailed container routes, improved links between measurement and journey data, a new Scan App, simpler notification configuration, a new Analytics section and Multi-Tenancy for more complex organizational structures.
This enables companies not only to monitor their liquid containers remotely, but also to use their data to improve operational processes.
From the current fill level and automated notifications to historical analytics, forecasting, system integrations and future AI applications, the result is a continuous data foundation for modern Remote Tank Level Monitoring.
Tank Level Monitoring is the digital monitoring of fill levels in tanks and other liquid containers. Sensors capture the current fill level and transmit the data to a software or cloud platform. This enables companies to monitor tanks remotely and analyze how inventory levels develop over time.
A suitable fill level sensor is installed on the tank or liquid container and measures the current level. The sensor then transmits the information wirelessly to Tank Monitoring Software, where users can access current inventory levels, historical trends and alerts remotely.
Remote Tank Level Monitoring refers to monitoring the fill level of a tank or liquid container from a remote location. Measurements are automatically transmitted from the container to a central software platform.
Tank Monitoring Software enables companies to monitor large numbers of tanks and liquid containers centrally, configure automatic notifications, analyze historical data and use fill level information within supply, production and logistics processes. Modern solutions such as Packwise Flow 2.0 also combine these capabilities with analytics, map-based views, mobile applications and integrations with other enterprise systems.
Depending on the specific application and installation requirements, Packwise can be used with a wide range of industrial liquid containers. These include plastic IBCs such as Varibox or Rikutec containers, stainless steel IBCs such as Schäfer containers, stationary tanks including systems such as Sherman tanks, and ISO tanks.
Different measurement technologies can be used depending on the tank, liquid and application. Radar is particularly well suited to many industrial environments because fill levels can be measured without direct contact with the liquid. The Packwise Smart Cap uses radar technology to measure liquid fill levels.
Yes. In addition to stationary tanks, mobile liquid containers such as plastic IBCs, stainless steel IBCs and ISO tanks can be monitored digitally. Additional location and movement data can provide further information about the position and condition of the container.
Yes. Fill level data can provide the basis for automated replenishment processes. When inventory reaches a defined threshold or future demand is predicted, downstream processes can be initiated. Through interfaces, this information can also be passed to ERP, logistics or other business systems.
The sensor captures the physical measurement directly at the tank or container. The software collects and structures this data, displays trends, enables notifications and can make information available to other systems. A complete Remote Tank Monitoring System therefore combines hardware and software.
Every application is different. Container types, liquids, locations, existing processes and integration requirements all play an important role when selecting the right monitoring solution.
In a personal consultation, we will be happy to show you how the Packwise Smart Cap and Packwise Flow 2.0 can be used with your plastic IBCs, stainless steel IBCs, stationary tanks or ISO tanks. We can also explore which of the new Flow 2.0 capabilities are most relevant to your application and how monitoring, analytics, notifications, replenishment planning and automation can be integrated into your existing processes.
Simply choose a convenient time in the calendar below and speak directly with our team about your specific use case.
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