ITC^PRO: Event-Based Level Measurement

Level measurement using the Rhenus ITC^PRO level sensor addresses the key question of how waste management logistics can be improved - both environmentally and economically - through event-based level measurement.

The low-cost, contactless fill-level sensor uses ultra-low power, monitors the fill status of safety and recycling containers on an event-driven basis, transmits the data via NB-IoT, and triggers on-demand pickups. Smart contracts on a distributed ledger infrastructure create tamper-proof process chains, extending all the way to automated payment processing.

The Rhenus Enterprise Lab was launched in 2017 with the goal of largely automating container management for waste management companies and, in the next step, making it autonomous.

At the heart of the project is the ITC^PRO, a fill-level sensor based on non-imaging laser time-of-flight technology that records fill levels in data protection and recycling containers on an event-driven basis. The measurement data flows directly into ERP systems as raw data, automating the recording of fill levels, organizing pickups, and supporting route optimization. Rhenus also pursued an local infrastructure sensor design: The ITC^PRO uses standardized cellular networks, can be integrated into existing or new software, and delivers unfiltered data without preprocessing. The energy-efficient, cost-effective ITC^PRO fill-level sensor is suitable for large container fleets; this energy-efficient fill-level measurement supports long-term deployment scenarios.

The industry faces several challenges: Data protection regulations such as the EU-GDPR, the German Federal Data Protection Act (Bundesdatenschutzgesetz, BDSG), and DIN 66399 require legally compliant processes. Until now, service providers have estimated the fill levels of many containers, leading to unnecessary trips, overflows, additional resource consumption, and a higher carbon footprint.

In addition, numerous self-contained, isolated solutions and heterogeneous infrastructures complicate the widespread adoption of event-based level measurement.

Our services:

• IoT solutions for data-driven waste management logistics, particularly the cost-effective, energy-efficient ITC^PRO fill level sensor based on non-imaging laser time-of-flight technology
• Event-based measurement and transmission of fill levels for waste containers and recycling bins
• Real-time data transmission via the NB-IoT cellular standard for deep building penetration and wide-area coverage
• Integration of measurement data as raw data into service providers’ ERP or other backend systems for automated pickup
• Use in both indoor and outdoor areas thanks to a robust, low-maintenance design that requires no local infrastructure
• Energy-efficient electronics with an ultra-low-power fill-level sensor for long battery life
• Scalability for large fleets of security and recycling containers
• Validation of process data via smart contracts with automated payment processing

Learn about the Enterprise Lab for Logistics Research

Learn about the Enterprise Lab for Logistics Research

“Thanks to the ITCPRO level sensor, the number of empty runs is reduced. Pickup trips can be planned in an energy- and cost-efficient manner, and customers’ CO2 footprints are reduced. Level measurement thus becomes a measurable lever for ecological and economic improvements in waste management logistics.”
Leon Siebel-Achenbach, MBA, Project Manager at the Rhenus Enterprise Lab, Fraunhofer IML

The Solution: ITC^PRO for event-based fill level measurement

The project solution is based on the Rhenus fill level sensor ITC^PRO, which uses non-imaging laser time-of-flight technology to detect the fill level inside a container. The sensor operates as an ultra-low-power fill-level sensor and measures without physical contact. Transmission is triggered event-based, such as when defined fill levels are reached. The sensor can be addressed bidirectionally via the NB-IoT IoT cellular standard; users can flexibly adjust threshold values and deploy the sensor in various container types. The data is transmitted via the NB-IoT IoT mobile communication standard directly to the service provider’s ERP or other backend systems as raw data without preprocessing.

The sensor is designed as a low-cost solution with energy-efficient electronics. This design supports long battery life with minimal maintenance. The construction is robust, suitable for both indoor and outdoor use, and requires no local infrastructure. Installation, hardware, and commissioning form a cost-optimized overall concept that facilitates widespread rollouts.

Building on the series launch at Deutsche Telekom IoT GmbH, Rhenus and Commerzbank are expanding the scope of the solution. Process data is written decentrally to the Corda distributed ledger, which serves as an alternative to centrally hosted platform solutions. A smart contract verifies write permissions, accuracy, ownership, and dependencies of the data. Once conditions are met, the system automatically triggers payment for the service, including digital confirmation and an invoice. Decentralized storage across multiple partners enhances data sovereignty and traceability in the circular economy.

Use an Enterprise Lab to develop logistics innovations in a structured manner together with companies and our research institute.

Our services:

• Joint development of logistics innovations by companies and researchers in an Enterprise Lab
• Access to state-of-the-art laboratories, a prototyping center, test halls, and test areas for rapid prototyping
• Agile, interdisciplinary teams that iteratively develop and test new solutions
• Direct translation of research results into applications for industry partners
• Scalable concepts for supply chain, circular economy, and information logistics

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The first use case involves security containers for files and data storage media that are locked for data protection reasons. For a long time, emtying of replacement of containers was based on a fixed schedule. Until now, many service providers had to estimate the fill level, which put a strain on route planning, personnel resources (especially drivers), CO2 emissions, and service quality.

With the ITC^PRO, bins become “smart security containers.” The sensor measures the fill level on an event-based , reports when a defined fill level is reached, and triggers the pickup process. The measurement data is fed into the waste management company’s ERP system and enables autonomous verhicle dispatch planning. The solution helps waste management companies such as Rhenus Data Office GmbH comply with the EU GDPR, the German Federal Data Protection Act (BDSG), and DIN 66399. NB-IoT ensures deep building penetration, for example, for containers located in basements or interior areas.

Key benefits of the use case:

• Reduction of empty runs and demand-based waste collection
• Prevention of overflowing containers in sensitive office areas
• Relief for customers from manually scheduling emptying
• Improvement of customers’ carbon footprint through optimized route planning
• Scalable level measurement for large fleets of secure containers
• Better utilization of scarce driver resources through data-driven route planning
• Transmission of solution to other usecases

In the “Smart Waste Management” application area, Rhenus and Commerzbank are jointly digitizing the supply chain from the sensor’s ping to billing. Building on the fill-level data from the ITC^PRO and event-based fill-level measurement, a transparent process chain is created. The project partners store the data decentrally, including at the customer’s site, and use the Corda distributed ledger as an alternative to centrally hosted platform solutions. This allows all parties involved to retain data sovereignty while meeting the documentation requirements of the circular economy.

Process data flows into the distributed ledger in real time. A smart contract validates the incoming datasets, verifying write permissions, accuracy, ownership, and dependencies. If the specified conditions are met, the system automatically triggers payment for the disposal service; confirmation of the transaction and the invoice are available digitally.

Commerzbank integrates payment and financing functions directly into the supply chain and helps companies maintain control over payment timelines. Rhenus and Fraunhofer IML are using this use case to test legally compliant, paperless billing processes and prepare for future regulatory requirements in the areas of document destruction, data carrier disposal, and smart waste management.

Another use case involves applying level measurement to municipal recycling containers. Rhenus is in discussions with a recycling service provider that wishes to implement the system for glass and paper recycling containers. The goal is comprehensive, event-based level measurement that supports municipal waste management processes. Electronic fill-level measurement is becoming an important criterion in municipal tenders for reducing emissions and resource consumption.

The sensor system measures container fill levels using non-imaging laser time-of-flight technology. Data transmission via NB-IoT is well-suited for public spaces due to its large cell radii, making it suitable even for locations without conventional cellular reception or existing communication infrastructure. This allows recycling bins to become smart containers that track their status and trigger pickups.

Potential benefits:

• Prevention of overflowing glass and paper recycling containers in municipal areas
• Reduction of unnecessary trips to barely filled containers
• Improved utilization of vehicle fleets in municipal waste management services
• Scalability of the solution to other recycling categories and locations

The Enterprise Lab of Rhenus and Fraunhofer IML provides the organizational framework for the project. Rhenus has more than a century of experience in logistics and covers supply chain management, warehousing, and transportation. Our institute established the Enterprise Labs concept in 2013 and provides modern laboratories, a prototypecenter, test halls, test areas, and coworking spaces.

Interdisciplinary teams collaborate agilely at the Rhenus Enterprise Lab. Researchers and practitioners develop prototypes, support rapid prototyping, test components, and validate new digital processes. The ITC^PRO followed this path from concept through prototyping and field deployment to series production readiness. In 2020, the system proved its worth in a pilot project, and in the same year, the rollout to several major customers began.

Collaboration with other lab partners, such as Deutsche Telekom and Commerzbank, broadens the scope. Telekom experts contributed expertise in narrowband IoT, while Commerzbank specialists developed smart contract solutions based on distributed ledgers. The Enterprise Lab thus serves as a platform where level measurement, IoT, and distributed ledger technologies converge to form integrated logistics systems.

The Rhenus level sensor ITC^PRO is already in use in large quantities. Production projects demonstrate economic benefits, particularly for larger container fleets and longer periods of use.

The solution is aimed at waste management companies seeking to ensure legally compliant disposal of documents and data storage media and to reduce emissions from transportation. Rhenus and Fraunhofer IML are examining the extent to which this experience can be applied to other internal and external logistics processes within the Rhenus Group. This also includes municipal recycling bins and other container systems. Electronic, energy-efficient level measurement is emerging as a key component of the circular economy.

At the same time, the partners are driving forward the expansion of the distributed ledger infrastructure. This infrastructure serves as an alternative to centrally hosted platform solutions. In cooperation with Commerzbank, audit-proof documentation procedures with integrated payment processing based on smart contracts are being developed. In doing so, the project partners are laying the groundwork to meet future customer requirements and legal mandates in the areas of document destruction, data carrier disposal, and smart waste management.