Myths and realities of grain storage: technology is not a solution, but a tool!

The illusion of total control

Grain storage is a bit like playing a long game of chess against nature. Every move counts: temperature, moisture, air circulation, impurities, weather, and even storage duration. Yet over the years, a myth has taken hold in the agricultural world: that technology can solve everything.

With the rise of automated monitoring systems and connected platforms, some producers believe that the risk of grain loss or deterioration is a thing of the past. “After all, if a computer is monitoring my bin in real time, what could possibly go wrong?” The reality, however, is quite different.

Technology does not replace good practices; it is an extension of them. It cannot compensate for a poorly managed bin: grain that is too wet, a high presence of waste, poor cooling, or poor aeration.

In this article, we aim to demystify the beliefs surrounding warehousing and remind you of the essential fundamentals of storage, which no technology can replace. 😉

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1. The myth of the “smart bin”: when technology gives a false sense of security

1.1 The seductive appeal of technology

Manufacturers of connected storage systems often talk about “smart storage,” “24/7 monitoring,” and even “systems that do the work for you.” These terms, which are very effective from a marketing perspective, create an illusion: that a farm equipped with such a system is immune to all problems, but a sensor alone won’t fix anything.

A monitoring system only measures, activates, and alerts. It can inform you that there is a problem, but it does not solve the cause: an uncalibrated moisture meter, calibration error in the dryer sensors, too much moisture, poor aeration distribution, compacted grain, too many soybean pods, etc.

1.2 The risk of lax practices

Many producers recognize that after installing an automated system, vigilance tends to decline. People trust the machine. This is not surprising, since it is much more efficient at certain tasks, such as turning on aeration at the right time.

The result is that bins are inspected less often, installations are checked less frequently, and humidity in the dryer is measured less often. However, problems such as storage issues, mold, heating, germination, and insects do not appear all at once. They develop gradually, often in areas that are not directly measured by sensors.

A traditional cable monitoring system may therefore not signal anything while, a few feet away, a damp pocket begins to heat up slowly.

2. The physical realities of storage: immutable laws of nature

2.1 The physics of grain

Stored grain is not an inert substance. It is a living mass that breathes and exchanges heat and moisture with the surrounding air.

Temperature contrasts cause air and humidity to move within the bin. An underestimated phenomenon is that when cold air enters through the fan intake of a warm bin, the air warms up and rises, creating convective air circulation. The result is a buildup of moisture and heat in the attic, which promotes condensation. This is one of the main causes of storage problems seen in winter when fall temperatures are warm. If you let your guard down, you will be systematically caught out.

Technology can help you maintain a uniform grain temperature to greatly reduce condensation. But you still need adequate aeration! Imagine putting cruise control on a car without an engine. The results would certainly be disappointing.

2.2 Moisture, the number one enemy

Grain moisture content is the primary risk factor. If too high, it accelerates grain respiration, promotes microbial growth, and causes heating. If too low, it leads to economic losses due to additional drying costs and weight loss. The key is balance.

But this balance cannot be achieved at the press of a button. It is achieved through a series of best practices:

• Check the moisture content on receipt with a good calibrated moisture meter;

• Ensure uniform and well-controlled drying;

• Cool the grain gradually after drying;

• Aerate regularly, depending on outside air conditions;

• Inspect your facilities on a weekly basis.

Technology helps measure and automate certain tasks, but humans are responsible for inspecting and programming the system.

CAUTION: Keep in mind that for every 2% of moisture, the grain's cellular respiration doubles.

2.3 Temperature, the second potential enemy

Even if your grain is dry, temperature can cause serious problems. It accelerates cellular respiration, increasing the risk of heating, but can also attract insects and pests. Pretty interesting, right? Abundant food and a warm place to take refuge when temperatures drop in the fall.

CAUTION: Keep in mind that for every 5 degrees Celsius, the grain's cellular respiration doubles.

3. Best practices: the foundation of successful storage

3.1 Before storage: preparing the harvest

Storage begins in the field. Mechanically damaged or poorly cleaned grain will not store well, regardless of the technology used.

Here are some essential principles:

• Harvest at the right maturity;

• Adjust the combine harvester to minimize split grains;

• Clean the grains to reduce impurities;

• Avoid mixing batches with large moisture differences in the same bin.

3.2 During drying: uniformity above all 

At harvest time, grain is not uniform! Grain size varies, as does the moisture content of each grain. This means that the drying time for each grain also fluctuates. When you take the grain out of your dryer, you end up with a “mixture” of grains with an average moisture content that you try to measure. Moreover, is your moisture meter properly calibrated?

Unfortunately, your dryer is also imperfect! It does not dry your grain uniformly. Dryers such as bin dryers and Topdry dryers dry batches in a variable manner. Even small column dryers do not do this! Simply because each column will tend to dry differently.

Inevitably, moisture content is variable and can range from 10% to 24%. This heterogeneity is one of the main causes of storage problems.

It is therefore crucial to:

• calibrate your moisture probes properly using a good testing protocol;

• take several samples at the dryer outlet;

• ventilate for a long time after drying to homogenize the moisture content.

3.3 After storage: constant monitoring

Once the bins are full, the work has only just begun! Best practices include:

• Successive cooling cycles to prevent condensation and temperature differences;

• Regular ventilation cycles, especially after harvest;

• Physical checks (visible condensation, surface inspection, water or snow infiltration);

• Analysis of CO₂ concentration, an excellent indicator of biological activity!

An automated system facilitates ventilation and early detection of storage problems, but it does not replace physical inspections. It should be seen as a tool to improve your practices, not as comprehensive insurance.

4. The limitations of automation

4.1 Sensors have a limited range

A sensor measures a specific point. In a bin containing several hundred tons, moisture and temperature cables only “detect or monitor” a small area around them. A hot spot or moldy area may go unnoticed if it is located between two probes. Even cable manufacturers say so!

4.2 Drift and calibration

Temperature and moisture sensors must be inspected and calibrated. A moisture sensor that is off by 2% can skew aeration decisions, creating a grain moisture variance of 0.5%.

Advanced algorithms can compensate for some drift, but nothing beats human precision and rigor. Good monitoring and periodic calibration are essential.

4.3 Algorithms are no substitute for judgment

Some technologies allow you to automatically analyze conditions to decide when to aerate. But an algorithm does not know whether grain is biologically active, or whether the weather will be favorable in the coming days. Nor does it know the specifics of a silo: fan type, ventilation efficiency, cleanliness of stored grain, storage duration, etc.

The producer's judgment, based on their experience and knowledge of grain behavior, remains irreplaceable. Are you getting started in grain production? In drying and storage? Have you thought about taking one of our training courses on drying and storage? Click here to register. 👉 Reserve a meeting

5. The real benefits of technology: a leverage for precision and responsiveness

This is not about putting down technology. Modern tools (online monitoring systems, CO₂ sensors, fan management platforms) are awesome when used right.

5.1. Early detection of anomalies

These systems make it possible to identify storage problems sooner, such as mold, condensation, and overheating. 

Did you know? Agrilog's CO₂ sensors are wireless and can detect problems 4 to 5 weeks earlier than other solutions on the market.

5.2. Energy optimization

Automated platforms can help you optimize energy consumption by activating the fan only when outdoor conditions are favorable (ambient air temperature and relative humidity).

Our observations show that automated aeration is 65% more efficient than manual aeration. To learn more, read our article on automatic aeration.

5.3. Remote monitoring and time savings

Being able to monitor your operations in real time from a phone or computer is a major step forward. It allows you to anticipate interventions, avoid unnecessary travel, coordinate your teams, and have a complete history of operations.

But once again, these benefits are in addition to the rigor of best practices. They do not replace them!

6. Case studies: when technology is not enough

Case 1 — Drying corn at ambient temperature: success

Because a bin that is properly assembled according to best practices makes all the difference (YouTube - Silo PressureCure). This is the case for Jocelyn Michon, owner of the la ferme Jocelyn Michon in La Présentation. With his PressureCure bin dryers, Jocelyn dries 900 tons of corn each year, from 25% to 14.5%, using only air pressure.

CAUTION: Many producers are not as successful as Mr. Michon. Some have even lost their entire bin! A major loss. Why? Poorly cleaned grain, poor aeration, too much grain—in short, best practices were not followed to the letter.

Technology that improves technique

In addition to a good bin, Mr. Michon automates the airflow in his PressureCure bin at the end of drying to save energy. According to him, depending on harvest conditions, he saves 30 to 60% in electricity per year. (Testimonial)

Case 2 — Drying corn in ambient air: Failure

One day, I received a call from a producer who had purchased a PressureCure silo but was not following the required criteria for drying with ambient air aeration. The result was that approximately 250 tons of organic corn, with a market value of $500 at the time, was severely damaged. The loss was estimated at approximately $100,000.

However, the bin had an automated aeration system with monitoring cables. So what happened? Quite simply, the PressureCure drying technique REQUIRES strong aeration to create sufficient air pressure to dry the entire bin evenly. Inadequate airflow creates preferential air channels, causing the bin to ventilate like Swiss cheese. In addition, the bin was not properly cooled in the winter, which also contributed to the grain heating up.

These examples illustrate a simple truth: Technology is powerless if your installation is not adequate.

Want to dry with ambient air? Keep in mind that this technique is widely used, has its advantages, and is safe as long as you have a silo that COMPLIES with the method and you follow the instructions. Need help? Book a meeting with me 👇[Calendrier consultation Mathieu]

7. Towards a balance: human intelligence + technological tools

The future of storage depends on the right balance between technology and human expertise. Automation provides precision, consistency, and rapid detection, but it is humans who provide context, intuition, and the ability to take action.

There is no need to choose between technology and practice, but rather to bring them together:

• Draw up a work plan aligned with good storage practices.

• Keep your facility in perfect condition.

• Calibrate your instruments and sensors to always have the right information;

• Use data to guide your decision-making;

• Plan and automate your aeration;

• Configure alerts according to the reality of the site;

• Perform periodic follow-ups on your portal;

• Continue physical inspections.

Conclusion: Human expertise and vigilance are the keys to success

Grain storage is not an exact science; it is an art supported by science. Technology transforms this art, but does not replace it.

Believing that an automated system can make storage 100% secure overlooks the fact that the root causes of problems are physical, biological, and human. Digital monitoring is useless if the grain is poorly dried (too moist with lots of impurities), if aeration is inadequate, or if no physical monitoring is done.

The producers who succeed year after year are not those with the most sensors, but those with the most rigor. Of course, this takes time and energy. And it is this rigor, supported by technology, that makes all the difference between risky storage and controlled storage.

Source: 

Caractéristiques des grains à différentes positions dans une colonne de séchage. (Tiré de D. Désilets, 1996)