CASE STUDY
Beyond the Diesel Gauge
Transforming Diesel Distribution with Smart IoT Pro Sensors
P.H. Borg Ltd., a leading diesel distributor in Malta specialising in fuel delivery and distribution services to hundreds of commercial and residential clients, with a fleet of 13 ADR-compliant fuel delivery vehicles. Through the Connect Brand, IoT Solutions Malta Ltd. deployed smart diesel monitoring sensors on end client stationary tanks to provide real-time fuel level data, enabling proactive refuelling management, theft prevention, and operational transparency, ensuring uninterrupted fuel supply and enhanced service quality.
What Prompted the Project
P.H. Borg Ltd., sought to enhance service quality for its client and operational efficiency for its services. The fuel distributor faced challenges in effectively managing fuel levels for its client, leading to reactive refuelling, missed delivery windows, and potential fuel shortages for clients.
Key challenges
The real-world problems that needed solving
End users lacked a clear visual or automated alert system to indicate low fuel levels, increasing the risk of unexpected fuel shortages that could disrupt critical operations.
Diesel tank monitoring relied heavily on manual checks, requiring staff to physically inspect each tank—a time-consuming and error-prone process—leading to operational delays and increased labour costs.
Without accurate, real-time data on fuel levels, route planning for refuelling trips was based on predetermined intervals or client calls, rather than actual consumption data, leading to unnecessary trips, missed refuelling opportunities, or inefficient fuel allocation.
Without real-time data, diesel theft often went unnoticed, impacting operational costs and eroding client trust.
In some cases, diesel tanks were located in hard-to-reach or hazardous areas, making manual checks risky for personnel, especially during adverse weather conditions.
Our Solution Architecture
Hardware
The IoT Pro Submersible is deployed as a plug-and-play sensor system for diesel tank installations, requiring minimal calibration which can be done remotely to accurately measure fuel levels with standard attachments.
The device can be either battery-powered or connected to a power supply, with a built-in battery backup system to ensure data continuity during power outages and to report power disruptions.
The IoT Pro Submersible features a visual alert mechanism, activating a physical light to signal low diesel levels as configured by the client.
The device can be integrated with an iButton identification system, requiring users to authenticate before fuel can be dispensed, adding a layer of security and accountability.
The IoT Pro system is also connected to a fuel meter with a pulse output to accurately log the litres of fuel taken by each individual.
Network
SIM-based, wireless over 4G/5G Cellular Grade NB-IoT technology, widely available throughout Malta via various network operators, even in remote areas, working on a licensed spectrum and supported by multiple gateways.
The IoT Pro communicates over the UDP protocol to IoT Solutions cloud servers.
Software
IoT Pro Cloud Software unified all diesel tanks monitoring into one platform capable of live reporting on Google Maps and providing sub-tenant access to end-clients.
The software included a comprehensive asset management database storing tank details, location, capacity, maintenance history, and photos.
Historical reporting ensures all data can be retrieved, including fill times and litres delivered per consignment.
Alerts and automated reporting notify key personnel via Emails, SMS, and Phone Calls when levels fall below a threshold or when tanks are filled.
Competitive Advantage
IoT Pro Hardware integrates all Diesel monitoring functions including absolute level monitoring, diesel pump control, user identification, accurate metering, and visual indication in a single cost-effective device.
IoT Pro can operate on DC power, monitor a fixed power supply, or run from a battery for over 10 years in remote locations.
For battery-powered systems, the internal microampere current meter ensures fault detection, extends battery lifetime, and allows for preventive maintenance.
Full Firmware Upgrade over the network allows deployment of new features or security updates without on-site visits.
Waterproof IP68 and IK10 Industrial housing suitable for harsh industrial environments.
Results and Impact
Key Performance Indicators & Achievements
98%
decrease
in unplanned fuel outages due to proactive refill alerts.
30%
reduction
in unnecessary delivery trips by optimising routing based on real-time data.
100%
of fuel deliveries
now based on actual consumption data, increasing operational efficiency.
85%
reduction
in manual inspections, saving approximately 4 man-hours per month per tank and eliminating human error.
Full
traceability
of diesel withdrawals via iButton authentication and fuel meter logging, resulting in a 90% reduction in unaccounted-for fuel.
100+
diesel tanks
monitored via IoT Pro Cloud, with 24/7 live access to clients via the sub-tenant portal, enhancing trust and client retention.
