LoRaWAN Sensors for Temperature Monitoring in Plants
LoRaWAN sensors are transforming how industrial plants monitor temperature across large areas. These wireless sensors use low-power, long-range communication to provide real-time data on temperature, humidity, and air quality. Unlike traditional systems, they eliminate the need for extensive cabling, reduce maintenance costs, and last 5–10 years on battery power. A single gateway can handle thousands of sensors, making it easy to scale operations.
Key benefits include:
- Cost Savings: Reduce installation costs by up to 80%.
- Energy Efficiency: Optimize HVAC systems and cut energy use by 10–25%.
- High Accuracy: Modern sensors handle extreme temperatures with precision.
- Easy Deployment: Systems like GoBee IoT offer pre-configured solutions for quick setup.
However, challenges include signal interference in dense environments and limitations on transmission frequency due to regulations. Despite these, LoRaWAN has proven effective for large-scale industrial monitoring, with many plants seeing ROI within 8–14 months.
Pricing Snapshot: GoBee IoT offers plans starting at $1.49 per sensor/month, with discounts for larger setups and a free trial for new users.
LoRaWAN Temperature Sensors: Key Benefits and ROI for Industrial Plants
Research Studies on LoRaWAN Temperature Monitoring
Industrial and Agricultural Applications
From 2020 to 2023, researchers at Széchenyi István University deployed a LoRaWAN IoT system across a 23-hectare (57-acre) experimental field. Using Libelium Smart Environment Pro probes and BME280 sensors, they tracked air temperature, soil temperature, and ammonia emissions at 10-minute intervals. The study revealed that peak ammonia emissions of 1.94 ppm in 2020 aligned with air temperatures ranging from 77°F to 88°F (25–31°C). This research highlighted the potential of LoRaWAN technology to replace costly micrometeorological methods for real-time, high-resolution environmental monitoring. Additionally, the findings indicated that 65.8% of the variability in environmental data could be attributed to temperature and soil moisture levels. These insights laid the groundwork for assessing the broader operational benefits and technical aspects of LoRaWAN networks.
Advantages of LoRaWAN Networks
The field results emphasized several operational benefits of LoRaWAN. Real-time data collection enables the detection of short-lived environmental fluctuations that manual monthly sampling often misses. Battery-powered sensors, capable of running for years on just two AA batteries, significantly lower maintenance requirements and reduce costs by 60–80% compared to traditional wired systems. This longer battery life and cost efficiency make the technology particularly appealing for industrial applications. Furthermore, a single LoRaWAN gateway can manage between 1,000 and over 10,000 sensors, depending on factors like transmission frequency and payload size, showcasing its scalability for large-scale operations.
Implementation Challenges
Despite its advantages, LoRaWAN does come with some hurdles. The ALOHA-based medium access control can lead to inefficiencies in crowded industrial environments, resulting in packet collisions. Additionally, regional regulations impose a 1% duty-cycle limit, restricting how often data can be transmitted and preventing burst messaging. Structural barriers like dense steel and concrete in facilities such as steel plants can weaken signals, often necessitating extra gateways to address blind spots. Jarosław Ganczarenko from Fabrity noted:
LoRaWAN is not the best fit in scenarios that require high data throughput, deterministic timing, or frequent downlink communication.
For reliable performance in complex environments, sensors must undergo rigorous calibration, including zero checks with scrubbed air and span checks using certified standards. Overcoming these challenges is essential to ensure accurate and dependable temperature monitoring in industrial settings.
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LoRaWAN Temperature Sensor Types and Technical Details
High-Temperature Industrial Sensors
Industrial LoRaWAN sensors are tailored for demanding environments, falling into two primary categories: standard units designed for temperatures between –67°F and 257°F (–55°C to 125°C) and external RTD (Resistance Temperature Detector) sensors capable of handling extreme ranges from –328°F to 1,472°F (–200°C to 800°C). RTD models utilize external probes to measure temperatures in challenging conditions like liquids, ovens, or deep-freeze environments, with customizable configurations to suit specific needs. For instance, the Linovision IOT-S500PT, available for $189.00, offers an accuracy of ±0.9°F (±0.5°C) and a resolution of 0.18°F (0.1°C), along with IP66/IP67 waterproof ratings. These sensors also come with versatile mounting options, such as straight tube, armored, threaded, and magnet mounts, making them adaptable to various industrial setups. Their durability ensures they are well-suited for long-term usage in demanding applications.
Battery Performance and Service Requirements
LoRaWAN temperature sensors are powered by 19,000 mAh lithium batteries, offering a lifespan of 5–10 years depending on transmission intervals and spreading factors. For example, sensors reporting every 10 minutes typically last around 5 years, while optimized settings can extend this to over 10 years. This longevity minimizes maintenance needs and lowers operational costs. Additionally, NFC-enabled models streamline field servicing by enabling configuration through smartphones, eliminating the need for physical connections.
Multi-Parameter Monitoring Capabilities
Modern industrial setups benefit from temperature sensors that go beyond single-purpose monitoring. LoRaWAN networks can integrate over 100 different sensor types on a single platform, allowing facilities to combine temperature tracking with metrics like humidity, vibration, pressure, and gas detection for a more comprehensive view. Using 4-20mA loops and DIO connections, multiple probes can connect to a single LoRaWAN node, which helps reduce hardware expenses. By correlating temperature data with other metrics, predictive maintenance becomes more effective. For instance, a combination of temperature spikes and vibration data can pinpoint motor bearing wear, while pairing temperature with power consumption data can optimize HVAC systems or detect compressed air leaks.
Kristian Storm, Co-Founder & CEO of Waltero, highlights the importance of energy efficiency:
Energy efficiency is no longer a luxury – it’s a necessity. Rising energy costs, regulatory pressures, and sustainability goals push manufacturers and chemical plants to find smarter ways to manage consumption.
With these advanced monitoring capabilities, industrial facilities often see a return on investment within 12 to 18 months. Additionally, smart monitoring systems can cut energy expenses by 10% to 25%.
Network Design and Data Handling
LoRaWAN Network Structure
LoRaWAN networks use a three-layer architecture to transform physical measurements into actionable data. At the core, end-node sensors equipped with microcontrollers like the ESP32-C3 and LoRa modules such as the Semtech SX1262 collect and wirelessly transmit temperature data. These signals are picked up by gateways, which act as a bridge between the sensor network and the internet, using protocols like MQTT over Wi-Fi, Ethernet, or cellular connections. Once the data reaches the cloud, platforms like ThingsBoard decode and store it in time-series databases. These platforms also provide live dashboards and send automated alerts via email or SMS when temperatures exceed predefined thresholds.
This modular setup allows facilities to repurpose the same hardware to monitor different parameters, such as humidity or air quality, simplifying both deployment and scaling. LoRa modules operating on the 868/915 MHz spectrum can achieve communication ranges of up to 4.3 miles in open spaces and are designed to resist interference from machinery and metal structures. Some sensors even feature internal memory capable of storing up to 10,000 measurements, ensuring data backup during connectivity issues. This design ensures reliability and scalability, making it ideal for large facilities.
Managing Large-Scale Deployments
With its modular framework, the network server ensures session integrity and uses Adaptive Data Rate (ADR) to adjust transmission settings based on link quality. This optimizes battery life while maintaining network capacity, eliminating the need for additional repeaters or extensive cabling when expanding monitoring points.
To enhance reliability, gateways often include Uninterruptible Power Supply (UPS) features with integrated rechargeable batteries, ensuring network activity continues during power outages. Configuration files can be exported and imported to simplify setup across multiple gateways, while diagnostic tools monitor Packet Error Rate (PER) and Link Quality Indicator (LQI) to detect and block noisy RF channels in busy industrial settings. Automated quality-control measures flag packet loss and verify data ranges, maintaining the integrity of measurements. This adaptive and scalable design is essential for dependable temperature monitoring in industrial environments.
Swaroop Chitturi from Semtech highlights the cost efficiency of this approach:
The marginal cost of adding a sensor is just the sensor itself. A single gateway can support thousands of sensors across large areas, making it easy to start small and scale as needed.
GoBee IoT Total Solutions for LoRaWAN Monitoring
GoBee IoT Sensor Features
GoBee IoT Total Solutions makes industrial monitoring straightforward with its pre-configured LoRaWAN temperature sensors. These sensors are ready to use right out of the box, enabling plant operators to start gathering live data within minutes – no technical expertise required. The system’s backend, dashboards, and integrations are automatically configured, ensuring sensors connect instantly and seamlessly.
With real-time data accessible through both a web portal and a mobile app, plant managers can monitor temperatures from anywhere – whether in the control room or directly on the factory floor. This easy setup highlights the practical advantages of LoRaWAN technology. Additionally, the system offers 12 months of data retention and supports unlimited gateways, including LoRaWAN, cellular, and satellite options. Operators can also set up advanced rules and alerts to help prevent equipment failures before they occur.
"Getting started with Gobee.io is as simple as subscribing and activating. Choose your sensors, enjoy a free 1-month trial, and let our backend automation handle the rest."
- GoBee IoT Total Solutions
Pricing Options
GoBee IoT offers flexible pricing to fit facilities of various sizes. The Basic plan is priced at $1.49 per sensor per month for setups with up to 50 sensors. For larger operations with more than 50 sensors, the Standard plan reduces costs to $0.99 per sensor per month – about a 33% savings. For even bigger facilities, the Enterprise plan provides account-level management at a flat rate of $99 per month.
Each plan includes a 1-month free trial, which can be extended up to 6 months. This trial period allows plant operators to verify the sensors’ accuracy and test the dashboard features before committing to a long-term solution. These pricing options make it easier to integrate advanced monitoring systems into daily operations.
Benefits for Plant Operations
GoBee IoT’s plug-and-play design drastically reduces installation time and eliminates the need for specialized technicians. The mobile app empowers technicians to address temperature changes on the plant floor immediately, ensuring quick responses when necessary.
Beyond just temperature monitoring, the platform extends its capabilities to include energy management, water leak detection, and asset tracking, creating a complete industrial IoT solution. To ensure data security, the system uses industry-standard encryption, restricting access to authorized personnel only.
EM500 PT100 LoRaWAN® Temperature Sensor Configuration Guide
Summary
LoRaWAN temperature sensors bring practical benefits to industrial plants by cutting installation costs by up to 80% – thanks to their wireless design that eliminates the need for cabling and conduit. With just one gateway, these systems can scale across large facilities with ease.
The sensors also boast a battery life of 5 to 10 years, minimizing maintenance demands. Their sub-GHz signals are strong enough to penetrate dense steel and concrete, overcoming the limitations of Wi-Fi in industrial environments. Many plants see a return on investment in just 8 to 14 months, alongside energy savings of 10–25% by identifying and addressing inefficiencies.
GoBee IoT Total Solutions takes these benefits further with pre-configured sensors that connect to live dashboards in minutes, requiring no technical expertise. Backend systems and dashboards are already set up, making deployment simple. Pricing starts at $1.49 per sensor/month for smaller setups and drops to $0.99 per sensor/month for larger deployments. Facilities can also try the system with a one-month free trial before committing. Beyond temperature monitoring, the platform supports energy management, water leak detection, and asset tracking, offering an all-in-one industrial IoT solution. With real-time data accessible on web and mobile platforms, plant managers can respond to temperature changes instantly – whether they’re on the factory floor or in the control room – making it an essential tool for modern industrial automation.
FAQs
How many gateways do I need for my plant?
The number of gateways you’ll need largely depends on the size of your plant and how much coverage is required. Often, a single gateway can handle several square kilometers, which means one gateway might be enough for efficient monitoring. That said, larger or more intricate setups might call for extra gateways to guarantee complete coverage.
How often can LoRaWAN sensors send temperature data?
LoRaWAN sensors are capable of transmitting temperature data at intervals that can be adjusted from just a few minutes to several hours, depending on their configuration. Certain models are built to send data less frequently, enabling them to run for years on a single battery. This makes them a practical choice for long-term, low-maintenance temperature monitoring, especially in industrial environments.
What’s the best way to avoid signal dead spots in metal buildings?
To reduce signal dead spots in metal buildings when using LoRaWAN sensors, position gateways in central and elevated spots. This helps cut down interference caused by the metal structures. Adding multiple gateways throughout the building creates overlapping coverage zones, which boosts the reliability of data transmission. For even better results, focus on proper antenna placement, use high-gain antennas, and take advantage of LoRaWAN’s long-range capabilities. These steps ensure strong signals and uninterrupted monitoring, even in challenging industrial setups.
