IoT-Based Smart Cool Fridge System with GPS Localization Using ESP32 Controller For The Frozen Food Industry

Abstract

This paper presents the design and implementation of an Internet of Things (IoT)-based monitoring system for industrial warehouse freezers and chillers. The proposed system enables continuous monitoring of electrical and operational parameters to enhance equipment reliability, energy efficiency, and operational safety. An ESP32 microcontroller is employed as the centralized processing unit, interfacing with multiple sensors including a BME280 sensor for monitoring ambient temperature, humidity, and pressure outside the freezer and chiller units, a proximity sensor for door status detection, industrial PE probe sensors for internal temperature and humidity monitoring, an SCT-013-000 THDC 100A split-core current transformer for energy monitoring, a GPS module for deployed unit location identification, and an industrial RS485 communication sensor to ensure reliable data acquisition in electrically noisy industrial environments. The acquired sensor data are transmitted via Wi-Fi to a cloud backend developed using Google Apps Script, with Google Sheets functioning as the centralized database. A web-based dashboard provides real-time visualization as well as historical data analysis for evaluating freezer and chiller performance. Overall, the proposed system offers a cost-effective, scalable, and reliable monitoring solution that supports predictive maintenance and minimizes the risk of temperature excursions in industrial applications.