Real-time RFID tracking for liquid ammonia cylinders, across every ASCO plant.
ASCO tracked heavy metal cylinders across 14 manufacturing plants by hand — no reliable way to know where a cylinder was, where it had been, or what state it was in. Aeologic deployed rugged on-metal RFID tagging, fixed and handheld readers, and a centralized monitoring platform to replace paper-based tracking with continuous, automated visibility.
In short
Aeologic built a real-time RFID cylinder tracking system for ASCO, a multi-plant manufacturer handling liquid ammonia. Rugged on-metal RFID tags, fixed checkpoint readers, and handheld readers replaced manual inward/outward/dispatch logs across 14 plants, feeding one centralized monitoring platform.
- Client Corporate multi-plant manufacturer (ASCO)
- Problem Manual, paper-based cylinder tracking with no real-time visibility
- Solution On-metal RFID tags + fixed/handheld readers + centralized platform
- Scale 14 plants, each with its own layout and configuration
Manual tracking couldn't keep up with 14 plants' worth of ammonia cylinders in motion.
ASCO's liquid ammonia cylinders moved constantly — inward, outward, dispatched, shifted between internal stations — and every one of those events was logged by hand. With no automated way to confirm a cylinder's location or status, visibility gaps widened as volume grew, and the risk of a misplaced heavy metal cylinder carrying a hazardous product sat behind every shift. Each of the 14 plants also ran its own layout, environment, and workflow, which ruled out a single fixed setup and meant any fix had to flex plant to plant while still rolling up to one picture.
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Cylinder inward, outward, and dispatch recorded by hand, plant by plant
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No real-time read on a cylinder's location or movement history
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Rising risk of misplacement across high-volume, harsh-environment handling
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14 plants, 14 layouts — no shared configuration or view
What the deployment had to achieve.
Replace manual cylinder tracking with automated RFID-based identification and tracking.
Enable real-time visibility into cylinder inward, outward, dispatch, and movement across plants.
Reduce cylinder misplacement through accurate, continuous location tracking.
Support deployment across 14 plants with varying layouts and operational workflows.
Provide centralized monitoring and historical movement records for all facilities.
An RFID platform built for metal cylinders and liquid ammonia — configured plant by plant, unified on one screen.
Rugged on-metal RFID tags
Cylinders are fitted with tags engineered to read reliably on metal surfaces and hold up in harsh conditions around liquid ammonia handling.
Fixed + handheld readers
Fixed readers at key checkpoints log movement automatically as tagged cylinders pass; handheld readers cover manual checks and verification.
One monitoring platform
Every plant's data feeds a single platform — one consolidated view of cylinder status and history in place of 14 separate processes.
Automated movement tracking
Inward, outward, dispatch, and internal movement events are captured and logged automatically, replacing manual entry and paper records.
Plant-specific configuration
Each of the 14 plants runs its own layout, environment, and workflow on a shared RFID platform — no forced one-size-fits-all rollout.
Centralized monitoring
All plant data rolls up to one platform, giving ASCO a single consolidated view of cylinder status and history across every facility.
Built for the environment
Standard tags don't hold up on metal or around liquid ammonia — the deployed tags and readers are engineered specifically for these conditions.
Four specific problems, four specific fixes.
Tagging cylinders for harsh industrial conditions
Standard RFID tags don't perform reliably on metal surfaces or in environments handling liquid ammonia.
Rugged on-metal tags
We deployed rugged, on-metal RFID tags engineered for these exact conditions.
Standardizing tracking across 14 different plants
Each plant had its own layout, environment, and workflow, ruling out a single fixed configuration.
Plant-specific configurations, one platform
We built plant-specific configurations on a shared RFID platform so each facility could run its own layout while feeding into one system.
Capturing movement without disrupting operations
Manual scanning at every step wasn't practical for high-volume cylinder movement.
Fixed + handheld readers, combined
Fixed readers at key checkpoints handle automatic capture; handheld readers cover manual checks where needed.
Consolidating data from distributed facilities
Movement data generated across 14 plants needed a single source of truth.
Centralized monitoring platform
We built a centralized platform that aggregates data from every plant into one view.
"Standardizing across 14 different plants ruled out a single fixed configuration. We built plant-specific configurations on a shared RFID platform, so every facility could run its own layout while feeding into one system."
From plant-by-plant paperwork to one real-time source of truth.
Real-time visibility into cylinder location and status across all 14 plants.
Reduced cylinder misplacement through continuous, automated tracking.
Complete historical movement records supporting traceability and data-driven decisions.
Centralized monitoring replacing plant-by-plant manual processes with one consolidated view.
One system, 14 plants, real-time cylinder traceability.
The RFID-based cylinder tracking solution replaced ASCO's manual tracking processes with automated, real-time visibility into liquid ammonia cylinder movement across 14 manufacturing plants. By combining rugged on-metal tags, handheld and fixed readers, and plant-specific configurations feeding into a centralized platform, the solution reduced cylinder misplacement, improved inventory visibility, and gave ASCO consolidated, data-driven oversight across its entire multi-plant operation.
Common questions about this deployment.
Find quick answers to the most common questions about our RFID deployment.
Why don't standard RFID tags work on gas cylinders?
Standard RFID tags don't perform reliably on metal surfaces or in environments handling liquid ammonia — the metal detunes the tag's antenna and harsh conditions degrade standard adhesives and housings. Aeologic addressed this with rugged, on-metal RFID tags engineered specifically for these conditions.
How do you standardize RFID tracking across many plants with different layouts?
Rather than forcing one fixed configuration, Aeologic built plant-specific configurations on a shared RFID platform, so each of ASCO's 14 plants can run its own layout, environment, and workflow while still feeding one centralized system.
What cylinder movement events does the system track?
The system automatically captures and logs cylinder inward, outward, dispatch, and internal movement events, replacing manual entry and paper records with continuous, automated tracking.
What results did ASCO see after deployment?
ASCO gained real-time visibility into cylinder location and status across all 14 plants, reduced cylinder misplacement, complete historical movement records for traceability, and one centralized view replacing plant-by-plant manual processes.
Tracking heavy or hazardous assets by hand?
Our architects will map an on-metal RFID rollout for your plants — tagging, reader layout, and a centralized view — starting with a working pilot, not a slide deck.
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