ENERGY-EFFICIENT HYBRID INTERFACE FOR

TEA INDUSTRIES
A PROJECT REPORT
Submitted by
PADMANITHI G (612921101083)
PRIYANKA M (612921101087)
SHALINI R (612921101106)

In partial fulfillment for the award of the degree of

BACHELOR OF ENGINEERING
IN

COMPUTER SCIENCE AND ENGINEERING

VIVEKANANDHA
COLLEGE OF ENGINEERING FOR WOMEN
[Autonomous]
An ISO 9001:2015Certified Institution
(Approved by AICTE, New Delhi and Affiliated to Anna University, Chennai,
Accredited by NAAC with ‘A++’and NBA Tier –I UG: CSE, EEE, ECE, IT and Bio-Tech.)

Tiruchengode – 637205, Namakkal Dt., Tamil Nadu

APRIL 2025

i
 VIVEKANANDHA
COLLEGE OF ENGINEERING FOR WOMEN
[Autonomous]

BONAFIDE CERTIFICATE

Certified that this project report “ENERGY-EFFICIENT HYBRID

INTERFACE FOR TEA INDUSTRIES” is the Bonafide work of “PADMANITHI G
(612921101083), PRIYANKA M (612921101087), and SHALINI R (612921101106)”
who carried out the project work under my supervision.

SIGNATURE SIGNATURE

Dr. C. Poongodi Mrs. E. Sowmiya

HEAD OF THE DEPARTMENT SUPERVISOR
Department of Computer Science Assistant Professor,
&Engineering, Department of Computer Science &
Vivekananda College of Engineering for Engineering,
Women, Vivekananda College of
Namakkal Engineering for Women,
Namakkal

Submitted to the Viva voce Examination held on

INTERNAL EXAMINER EXTERNAL EXAMINER

ii
 ACKNOWLEGDEMENT

We thank and praise the Lord almighty for providing in Knowledge, strength and all the
necessary facilities to do this project successfully.

We are immensely grateful to our Chairman and Secretary, “VidyaRathna”

Professor Dr.M. KARUNANITHI, [Link]., M.S., Ph.D., [Link]., Vivekanandha
Educational Institutions, who is our inspiration.

We are extremely grateful to our beloved and honorable Executive Director, Professor
S. KUPPUSWAMI, B.E., [Link]. Engg., Dr. Ing (Ph.D. in Engg)., for his motivation and
guidance of our report preparation.

We wish to express our profound thanks to our beloved Principal,

[Link], M.E., Ph.D., F.I.E., for all the facilities and support provided
during the period of our project successfully.

We would like to acknowledge our Head of the Department, Dr. C. POONGODI.,

M.E., Ph.D., Department of Computer Science and Engineering, for her encouragement and
support for completing the report successfully.

We wish to thank our project Coordinators Dr. R. NITHYA, B.E., M.E., Ph. D
ASP/CSE and Mrs. A. SARANYADEVI, [Link]., M.E., AP/CSE for their kind and
support and guidance in completion of our project.

We express our sincere thanks and regards to our Faculty Guide Mrs. E. SOWMIYA,
B.E., M.E., AP/CSE, for his support and encouragement throughout the preparation of
project report.

We are thankful and fortunate enough to get constant encouragement, support and
guidance from our parents and all Teaching staff members of Department of Computer
Science and Engineering, who helped us in successfully completing our report.

iii
INSTITUTION VISION

To impart value-based education in Engineering and Technology to empower young women

to meet the societal exigency with a global outlook.

INSTITUTION MISSION

• To provide holistic education through innovative teaching-learning practices

• To instill self confidence among rural students by supplementing with co-curricular and
extra-curricular activities

• To inculcate the spirit of innovation through training, research and development

• To provide industrial exposure to meet the global challenges

• To create an environment for continual progress through lifelong learning

DEPARTMENT VISION
To empower women technocrats in the field of Computer Science and Engineering and
prepare them for globalized high-tech society to orient them towards serving the dynamic
needs of our nation.

DEPARTMENT MISSION
• To foster and strengthen the core competence of Computer Science by adopting
innovative methods.
• To elevate the research, entrepreneurial and employability skills in women technocrats
through quality education.
• To induce values of professional ethics and spirit of social commitment among the
students.

iv
PROGRAMME EDUCATIONAL OBJECTIVES

PEO1Graduates will have successful careers with strong fundamental and technical skills in
industry that meet the needs of Indian and multinational companies.

PEO2 Graduates will become successful entrepreneurs with determination, development, self-
reliance, leadership, ethic and moral values to exploit employability.

PEO3 Graduates will pursue higher education and engage in lifelong learning to foster
personal and organizational growth.

PROGRAM OUTCOMES

Graduates of Computer Science and Engineering will be able to

PO1 Engineering Knowledge: Apply the knowledge of mathematics, science, engineering

fundamentals, and an engineering specialization to the solution of complex engineering
problems.

PO2 Problem Analysis: Identify, formulate, research literature, and analyze complex
engineering problems reaching substantiated conclusions using first principles of mathematics,
natural sciences, and engineering sciences.

PO3 Design/Development of solutions: Design solutions for complex engineering problems

and design system components or processes that meet the specified needs with appropriate
consideration for the public health and safety, and the cultural, societal, and environmental
considerations.

PO4 Conduct Investigations of Complex problems: Use research-based knowledge and

research methods including design of experiments, analysis and interpretation of data, and
synthesis of the information to provide valid conclusions.

v
PO5 Modern Tool Usage: Create, select, and apply appropriate techniques, resources, and
modern engineering and IT tools including prediction and modelling to complex engineering
activities with an understanding of the limitations.

PO6 The Engineer and Society: Apply reasoning informed by the contextual knowledge to
assess societal, health, safety, legal and cultural issues and the consequent responsibilities
relevant to the professional engineering practice.

PO7 Environment and Sustainability: Understand the impact of the professional

engineering solutions in societal and environmental contexts, and demonstrate the knowledge
of, and need for sustainable development.

PO8 Ethics: Apply ethical principles and commit to professional ethics and responsibilities
and norms of the engineering practice.

PO9 Individual and Team Work: Function effectively as an individual, and as a member or
leader in diverse teams, and in multidisciplinary settings.

PO10 Communication: Communicate effectively on complex engineering activities with the

engineering community and with society at large, such as, being able to comprehend and write
effective reports and design documentation, make effective presentations, and give and receive
clear instructions.

PO11 Project Management and Finance: Demonstrate knowledge and understanding of the
engineering and management principles and apply these to one's own work, as a member and
leader in a team, to manage projects and in multidisciplinary environments.

PO12 Life-Long Learning: Recognize the need for, and have the preparation and ability to
engage in independent and life-long learning in the broadest context of technological change.

vi
PROGRAM SPECIFIC OUTCOMES
Graduates of Computer Science and Engineering will be able to

PSO1 Develop computational solution to complex real-world problems with modern

programming tools.

PSO2 Demonstrate basic knowledge of computer applications and apply standard practices in
developing feasible solutions for IT enabled services.

Course Outcome mapping with PO’s and PSO’s

Course code & U19CS834 & Project Programme B.E. Computer Science and
Name work & Branch Engineering
Faculty Name Regulation
Dr. R. Nithya 2019
Academic Semester
Year 2024-25 VIII

Title of the
Project Energy-Efficient Hybrid Interface for Tea Industries

COURSE OUTCOMES (Cos)

Course Bloom’s
Outcome Description Taxonomy
(CO) Level
Identify the project domain and formulate the Remembering,
CO1
problem statement based on real-world needs. Understanding
Conduct a detailed literature review to Understanding,
CO2 understand existing solutions and research gaps. Analyzing
Develop a comprehensive plan of action and design
appropriate methodologies or prototypes. Applying,
CO3 Creating
Perform experimentation or design analysis, Analyzing,
CO4
and critically evaluate the results. Evaluating
Document the findings with conclusions,
Evaluating,
CO5 highlight the scope for future work, and present the Creating
report.

vii
CO - PO /PSO Mapping

CO / PO Mapping CO/PSO
(3/2/1 indicates strength of correlation) 3-Strong, 2 – Medium, 1 – Weak Mapping
Programme Outcomes (Pos) PSOs
Cos PO PO PO PSO PSO
PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9
10 11 12 1 2
CO 1 2 3 2 2 3 2 2 2 3 3 3 3
CO 2 1 3 3 3 3 2 2 2 2 2 2 3 3 3
CO 3 1 3 3 2 3 2 2 2 2 3 2 2
CO 4 3 3 2 2 2 3 3 2 3
CO 5 1 3 3 3 2 2 0 2 3 2 3

Relevance to PO’s and PSO’s

PO1 The project applies core knowledge of electronics, embedded systems, and IoT to
develop an intelligent solution for real-world issues in tea processing industries.

PO2 Systematic analysis of problems like overheating, energy inefficiency, and fire
hazards demonstrates critical thinking and effective problem-solving skills.

PO3 Designing an integrated system using sensors, actuators, and cloud technologies
showcases creativity and innovation in industrial automation.

PO4 The project addresses complex industrial challenges by combining knowledge

from electronics, embedded systems, and sustainability, offering a holistic
solution.

PO5 Modern tools such as Arduino IDE, NodeMCU, and cloud dashboards were
employed for development, simulation, and real-time implementation.

viii
PO6 By optimizing energy usage and improving workplace safety, the project benefits
society through sustainable engineering and reduced operational risks.

PO7 Sustainable practices are embedded in the system design, such as power efficiency
and hazard prevention, aligning with environmental and industrial sustainability.

PO8 Safety and ethics are prioritized by automating hazard detection and responses,
ensuring worker safety and responsible system behavior.

PO9 Effective team collaboration was demonstrated in managing both hardware and
software development, including system integration and testing.

PO10 Clear communication of technical data was achieved through dashboards, mobile
interfaces, and real-time visualizations, enhancing user interaction and
understanding.

PO11 Project planning included resource allocation, iterative testing, and debugging,
showing strong skills in project management and execution.

PO12 Engagement with evolving technologies in IoT and automation fostered self-
learning and adaptability to new engineering methods and tools.

PSO1 The project applies foundational electronics and embedded system concepts,
including real-time data acquisition, signal processing, and sensor integration.

PSO2 Advanced techniques in IoT, such as cloud-based data communication, smart

control, and predictive maintenance, were utilized to optimize process
performance.

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 ABSTRACT

The tea industry heavily relies on traditional machinery, leading to excessive energy

consumption, high operational costs, and frequent machine downtime due to the lack of

automated monitoring and control systems. Conventional tea-processing machines operate

inefficiently, consuming more power than necessary, while manual monitoring delays fault

detection, resulting in increased maintenance expenses and production losses. Moreover, the

absence of real-time monitoring and predictive maintenance mechanisms heightens the risk

of electrical failures and fire hazards, threatening factory safety and sustainability. In

proposed work, an IoT-enabled smart energy management system to optimize energy

consumption, enhance machine performance, and improve operational reliability in tea

factories.

Smart sensors continuously collect data on temperature, vibration, humidity, and power

consumption, transmitting it to a cloud server via an IoT gateway. The data is processed

using advanced analytics to detect anomalies, predict potential failures, and provide

actionable insights for timely intervention. The microcontroller-based control system

dynamically adjusts machine operations, optimizing energy usage based on real-time

demand while maintaining production efficiency. Automated control of lights, ventilation,

and machinery reduces power wastage, while remote monitoring through a web or mobile

application enables supervisors to track performance from anywhere. Emergency alerts and

notifications warn operators of potential issues, minimizing production losses and unplanned

maintenance costs. By leveraging IoT and AI technologies, this system reduces energy

consumption, extends machinery lifespan, lowers operational costs, enhances factory safety.

x
 TABLE OF CONTENTS

CHAPTER NO TITLE PAGE NO.

ABSTRACT x
LIST OF FIGURES xiii
LIST OF ABBREVIATIONS xiv

1 INTRODUCTION 1
1.1 INTRODUCTION TO 1
DOMAIN
1.2 ABOUT EMBEDDED 2
SYSTEM
1.3 OVERVIEW 3
1.4 GOALS AND OBJECTIVES 3
2 LITERATURE SURVEY 4
3 SYSTEM ANALYSIS 9
3.1 EXISTING SYSTEM 9
3.1.1 DRAWBACKS 10
3.2 PROPOSED SYSTEM 10
3.2.1 ADVANTAGES 11
4 SYSTEM SPECIFICATION 13
4.1 HARDWARE 13
CONFIGURATION

xi
 4.2 SOFTWARE 13
SPECIFICATION
5 SOFTWARE DESCRIPTION 14
5.1 FRONT END 14
5.2 BACKEND 15
6 PROJECT DESCRIPTION 16
6.1 PROBLEM DEFINITION 16
6.2 MODULE DESCRIPTION 16
6.3 SYSTEM FLOW 19
DIAGRAM
6.4 INPUT DESIGN 21
6.5 OUTPUT DESIGN 21
7 SYSTEM TESTING AND 22
IMPLEMENTATION
7.1 SYSTEM TESTING 22
7.2 SYSTEM 22
IMPLEMENTATION
8 CONCLUSION AND 24
FUTURE WORK
24
8.1 CONCLUSION
8.2 FUTURE WORK 25
9 APPENDICES 26
9.1 SOURCE CODE 26
9.2 OUTPUT 32
10 REFERENCE 35

xii
 LIST OF FIGURES

FIGURES TITLE PAGE NO

NO
6.3.1 FLOW DIAGRAM 19

6.3.2 BLOCK DIAGRAM 20

9.2.1 MAIN OUTPUT FOLDER 32

9.2.2 SAMPLE IMAGE 32

9.2.3 IOT CLOUD APPLICATION 33

9.2.4 APP HOME PAGE 33

9.2.5 DETECTING PAGE 34

xiii
 LIST OF ABBREVATION

[Link] ACRONYM ABBREVATION

1 MCU Microcontroller Unit

2 ESP8266 Espressif Systems 8266 (Wi-Fi module)

3 PWM Pulse Width Modulation

4 LCD Liquid Crystal Display

5 Wi-Fi Wireless Fidelity

6 LED Light Emitting Diode

7 MQTT Message Queuing Telemetry Transport

8 API Application Programming Interface

9 OTA Over-The-Air (firmware updates)

10 DC Direct Current

11 GND Ground

12 VCC Voltage Common Collector (Power Supply)

13 UI User Interface

14 HTML HyperText Markup Language

15 GSM Global System for Mobile Communications

16 RFID Radio Frequency Identification

17 IDE Integrated Development Environment

xiv
 CHAPTER 1

1. INTRODUCTION

The tea industry relies heavily on traditional machines that are energy efficient in terms of
automation. This means that more energy is used and surgical inefficiency is caused.
Traditional systems require manual intervention that causes delays in error detection,
increased maintenance costs, and regular production losses. Inefficient energy management
in TEA processing plants not only increases operational costs, but also leads to waste of
unnecessary resources. Without an actual monitoring and automatic control system, the
machine will function without the need for it, leading to unnecessary power consumption
and safety risks, such as electrical errors and fire risks. To alleviate these issues,
improvements in the tea processing industry with IoT-based smart automation are necessary
to improve efficiency, reduce costs and provide a sustainable production environment.
Intelligent sensors monitor machine performance, environmental factors and power
consumption, so analysis can be identified with AI-based abnormalities to avoid sudden
failures. The automatic control system manages the operation, lighting and ventilation of the
machine and ensures that energy is used when necessary. Long distance access and real-time
alerts continue to promote operational flexibility, allowing your boss to make healthy
decisions everywhere. IoT-based automation in TEA processing allows industries to achieve
significant cost benefits, improved security and reduced environmental impact without
affecting production standards.

1.1 INTRODUCTION TO DOMAIN

The Internet of Things (IoT) refers to a network of interconnected devices embedded with
sensors, software, and communication technologies that collect and exchange data in real
time. IoT has transformed industrial automation by enabling remote monitoring, predictive
maintenance, and intelligent decision-making. In manufacturing, IoT plays a crucial role in
optimizing machine performance, reducing downtime, and ensuring efficient energy
utilization. By integrating IoT with AI-driven analytics, industries can automate control
processes, detect anomalies, and enhance overall productivity. In the context of tea
processing, IoT-based automation can modernize traditional factories, improving efficiency

1
while promoting sustainable practices.

1.2 EMBEDDED SYSTEM

A system is an arrangement in which all its unit assemble work together according to a set
of rules. It can also be defined as a way of working, organizing or doing one or many tasks
according to a fixed plan. For example, a watch is a time displaying system. Its components
follow a set of rules to show time. If one of its parts fails, the watch will stop working. So
we can say, in a system, all its subcomponents depend on each other. As its name suggests,
Embedded means something that is attached to another thing. An embedded system can be
thought of as a computer hardware system having software embedded in it. An embedded
system can be an independent system or it can be a part of a large system. An embedded
system is a microcontroller or microprocessor-based system which is designed to perform a
specific task. For example, a fire alarm is an embedded system; it will sense only smoke.

An embedded system has three components −

• It has hardware.

• It has application software.

• It has Real Time Operating system (RTOS) that supervises the application
software and provide mechanism to let the processor run a process as per
scheduling by following a plan to control the latencies. RTOS defines the way
the system works. It sets the rules during the execution of application program.
A small-scale embedded system may not have RTOS.

2
1.3 OVERVIEW
The tea industry faces inefficiencies due to outdated machinery, excessive energy use, and
high maintenance costs. An IoT-enabled smart energy management system integrates
sensors, AI-driven analytics, and adaptive controls to optimize energy consumption,
automate monitoring, and enable predictive maintenance. Real-time data processing
improves machine performance, reduces downtime, and enhances operational efficiency.
Remote monitoring and automated controls further minimize energy wastage while ensuring
sustainability. This transformation modernizes tea factories, bridging the gap between
traditional practices and Industry 4.0, leading to cost-effective, efficient, and
environmentally friendly production.
1.4 GOALS AND OBJECTIVES

Goals
To develop an IoT-enabled smart energy management system that optimizes energy
consumption, automates machine operations, and enhances predictive maintenance in tea-
processing industries.
Objectives
• Energy Optimization: Implement adaptive control mechanisms to minimize energy
wastage and improve machine efficiency.
• Predictive Maintenance: Utilize AI-driven analytics to detect potential failures and
prevent unplanned downtime.
• Real-Time Monitoring: Develop a cloud-based platform for remote tracking of
machine performance and energy usage.
• Automated Control Systems: Integrate smart sensors and microcontrollers for dynamic
machine operation adjustments.
• Safety Enhancement: Implement fault detection mechanisms to prevent electrical
failures and fire hazards.
• Sustainability: Reduce greenhouse gas emissions and promote eco-friendly production
practices.

3
 CHAPTER 2

LITERATURE REVIEW

2.1 MULTIPLE REGRESSION ANALYSIS FOR THE PREDICTION

OF EXTRACTION EFFICIENCY IN MINING INDUSTRY WITH
INDUSTRIAL IOT

This study, published in Production Engineering (vol. 14, no. 4, pp. 457-471, 2020),
explores the application of multiple regression analysis for predicting extraction efficiency
in the mining industry using Industrial Internet of Things (IIoT) technologies. The research
addresses the need for accurate and dynamic predictive models to optimize resource
extraction processes, reduce downtime, and improve overall productivity. The authors
propose a framework where IIoT sensors collect real-time data on various operational
parameters, such as equipment performance, environmental conditions, and material
characteristics, feeding this data into a multiple regression model to forecast extraction
efficiency. The model identifies key factors influencing productivity, including machinery
load, vibration levels, temperature, and energy consumption. By analyzing these parameters,
the system can predict efficiency levels and provide actionable insights for process
adjustments. This approach allows mining operations to shift from reactive to proactive
management, minimizing equipment failures and optimizing resource allocation. The paper
highlights the advantage of integrating IIoT with statistical modeling, enabling continuous
performance monitoring and adaptive decision-making. The authors also discuss the
system’s scalability, noting that as more data is collected, the model can be refined for even
higher accuracy. Real-world experiments show that the proposed approach significantly
improves efficiency predictions compared to traditional methods, demonstrating its potential
for large-scale industrial applications. The study concludes by suggesting future
enhancements, such as incorporating machine learning algorithms to complement regression
analysis, enabling the system to learn complex, non-linear patterns over time. Overall, this
research offers a valuable contribution to smart manufacturing and industrial automation,
showcasing the power of data-driven strategies for optimizing extraction processes in the
mining sector.
4
2.2 5G/IOT-ENABLED UAVS FOR MULTIMEDIA DELIVERY IN
INDUSTRY-ORIENTED APPLICATIONS

This study, published in Multimedia Tools and Applications (vol. 79, no. 13–14, pp.
8627–8648, 2020), investigates the use of 5G and IoT-enabled unmanned aerial vehicles
(UAVs) for efficient multimedia delivery in industrial applications. The paper addresses the
growing demand for real-time, high-bandwidth multimedia communication in sectors like
manufacturing, logistics, and remote monitoring, where traditional wired or terrestrial
networks may fall short. The authors propose an integrated system where UAVs equipped
with multimedia sensors and IoT modules leverage ultra-fast 5G networks to capture,
process, and transmit multimedia content to centralized control systems or edge devices. The
research highlights key advantages of using UAVs, such as their ability to access hard-to-
reach locations, provide flexible coverage, and rapidly adapt to dynamic environments. The
authors present a framework for optimizing UAV flight paths and data transmission
strategies to balance energy consumption, latency, and multimedia quality. The system is
designed to handle high-definition video streams, sensor data, and control signals with
minimal delay, making it suitable for applications like infrastructure inspections, disaster
response, and industrial surveillance. The paper also explores the challenges of integrating
5G and IoT with UAVs, including network congestion, interference, and UAV battery
limitations. The authors propose solutions like dynamic bandwidth allocation, edge
computing for real-time data processing, and energy-aware routing algorithms to enhance
system performance. Simulation results demonstrate that the proposed approach
significantly reduces latency and packet loss compared to legacy communication systems,
while maintaining high-quality multimedia delivery. The study concludes by emphasizing
the transformative potential of 5G/IoT-enabled UAVs in industry, suggesting that future
work could explore AI-powered decision-making for autonomous UAV coordination and
further improvements in energy efficiency. This research offers valuable insights for
designing next-generation industrial multimedia systems, bridging the gap between wireless
communication, robotics, and real-time data processing.

5
2.3 A CLOUD-BASED MONITORING SYSTEM FOR
PERFORMANCE ANALYSIS IN IOT INDUSTRY

This study, published in the Journal of Supercomputing (vol. 77, no. 8, pp. 9266–9289,
2021), presents a cloud-based monitoring system designed to enhance performance analysis
in IoT-enabled industrial environments. As industrial IoT (IIoT) systems generate vast
amounts of real-time data from interconnected sensors and devices, the need for scalable,
efficient monitoring and performance evaluation becomes critical. The authors propose a
cloud-based architecture that collects, processes, and analyzes IoT device data to identify
performance bottlenecks, predict failures, and optimize system operations. The monitoring
system leverages distributed cloud computing to handle large-scale data streams, applying
advanced analytics and machine learning algorithms to detect anomalies and generate
predictive insights. Key performance metrics, such as device latency, energy consumption,
and network throughput, are continuously evaluated, enabling proactive decision-making to
prevent downtime or resource inefficiencies. A notable feature of the system is its ability to
visualize complex industrial processes through dynamic dashboards, allowing operators to
track real-time performance and receive alerts for abnormal behavior. The paper also
highlights the system’s scalability, showing that cloud resources can dynamically scale up
or down based on data volume, reducing infrastructure costs while maintaining high
availability. Experimental results demonstrate that the proposed system significantly
improves failure detection rates and response times compared to traditional monitoring
methods. The authors conclude by suggesting potential enhancements, including integrating
edge computing for faster local analysis and refining machine learning models to better
handle diverse industrial workloads. Overall, this research underscores the transformative
impact of cloud computing in industrial IoT, providing a robust framework for real-time
monitoring and performance optimization across complex, data-intensive environments.

6
2.4 SDN–IOT EMPOWERED INTELLIGENT FRAMEWORK FOR
INDUSTRY 4.0 APPLICATIONS DURING COVID-19 PANDEMIC

This study, published in Cluster Computing (vol. 25, no. 4, pp. 2351–2368, 2022),
proposes an intelligent framework integrating Software-Defined Networking (SDN) and the
Internet of Things (IoT) to enhance Industry 4.0 applications, particularly during the
COVID-19 pandemic. The authors address the heightened need for resilient, adaptable
industrial systems capable of remote monitoring, automation, and real-time decision-making
to ensure continuous production and worker safety during crises. The framework leverages
SDN to provide centralized network control, dynamically managing data traffic and
optimizing resource allocation across IoT devices. This architecture supports seamless
device connectivity, even in complex industrial environments, enabling real-time data
exchange between sensors, machines, and cloud platforms. The system uses IoT-enabled
sensors for health monitoring, environmental sensing, and predictive maintenance,
enhancing workplace safety and operational efficiency. A standout feature of the framework
is its use of AI-driven analytics to process the vast amounts of data generated by IoT devices.
For instance, machine learning algorithms can predict equipment failures, reducing
unplanned downtime, while health sensors can monitor worker vitals, triggering alerts if
abnormalities are detected. The SDN layer enhances system adaptability, quickly
reconfiguring network flows to prioritize critical data, such as emergency alerts or high-
priority machine readings. The paper’s experimental results show that the SDN–IoT
framework improves data processing speed, reduces latency, and enhances fault detection
accuracy compared to traditional Industry 4.0 setups. The authors also discuss the
framework’s long-term potential beyond the pandemic, suggesting it could support future
smart factories and autonomous production lines. Overall, this research highlights the
powerful synergy between SDN and IoT, demonstrating how intelligent, flexible networking
can fortify industrial systems against disruptions while driving innovation and sustainability
in smart manufacturing.

7
2.5 EMERGING ENABLING TECHNOLOGIES FOR INDUSTRY 4.0
AND BEYOND

This study, published in Production Engineering (vol. 24, no. 4, pp. 935–944, September
2022), explores the transformative impact of emerging digital technologies that are
redefining modern industrial systems in the context of Industry 4.0 and paving the way for
future advancements, including Industry 5.0. L. Da Xu presents a comprehensive overview
of the key enabling technologies that support smart manufacturing and intelligent
automation. These include the Internet of Things (IoT), which facilitates the connection of
physical devices for data exchange; Artificial Intelligence (AI), which enables predictive
analytics and intelligent decision-making; Cyber-Physical Systems (CPS), which integrate
computation with physical processes; Big Data analytics, used for processing and
interpreting vast amounts of operational data; and Cloud and Edge Computing, which ensure
efficient data storage, access, and processing across distributed systems. The paper
emphasizes that these technologies are not isolated innovations but are most effective when
integrated into a cohesive, interconnected digital ecosystem. Together, they enable advanced
functionalities such as real-time monitoring and control, remote diagnostics, smart
maintenance, and flexible manufacturing. Xu also highlights the transition toward Industry
5.0, which moves beyond automation and efficiency to focus on human-centric, sustainable,
and resilient industrial systems. This shift requires not only technological upgrades but also
strategic planning, workforce development, and organizational change.
In addition, the study discusses the challenges associated with the adoption of these
technologies, including cybersecurity risks, interoperability issues, and the need for scalable
infrastructure. Xu suggests that addressing these challenges will require collaborative efforts
from industry leaders, governments, and academic researchers. Overall, this work serves as
a foundational guide for understanding the complex and rapidly evolving landscape of
modern industry, providing valuable insights for stakeholders involved in digital
transformation initiatives.

8
 CHAPTER 3

SYSTEM ANALYSIS

3.1 EXISTING SYSTEM

The tea industry, a cornerstone of global agriculture and a significant contributor to

regional economies, continues to rely on conventional processing methods that are often
energy-intensive, inefficient, and environmentally unsustainable. Outdated machinery and
the absence of intelligent energy management systems result in excessive power
consumption, high operational costs, and frequent production interruptions. Machines
typically operate at constant power levels regardless of demand, leading to unnecessary wear
and energy waste, while manual monitoring practices are labor-intensive and prone to errors,
delaying fault detection and increasing downtime. These inefficiencies also heighten the risk
of mechanical and electrical failures, posing safety hazards and incurring significant
maintenance expenses. To address these challenges, integrating Internet of Things (IoT)
technologies, smart sensors, and AI-driven predictive analytics offers a transformative
solution for modernizing tea factories. By embedding smart sensors into processing
equipment, factory managers can gain real-time insights into key operational parameters
such as temperature, vibration, humidity, and energy consumption. This data, transmitted
securely via IoT communication protocols to cloud or edge platforms, enables advanced
analytics that detect anomalies, forecast failures, and provide actionable recommendations.
Such systems empower operators to make informed decisions, dynamically adjust machine
operations based on real-time demand, and perform predictive maintenance to avoid
unplanned downtimes. Adaptive control systems further optimize energy usage by
automatically adjusting machine speeds or shutting down non-essential equipment during
low-load periods, while also managing lighting and ventilation systems based on factory
activity. Remote monitoring through mobile or web applications enhances operational
flexibility, allowing supervisors to oversee processes, receive alerts, and respond promptly
to issues from any location. The adoption of IoT-enabled smart systems not only enhances
operational reliability and extends equipment lifespan but also significantly reduces the
factory’s carbon footprint by lowering energy usage and minimizing waste. This approach
aligns with global sustainability goals and growing consumer demand for ethically produced
9
goods. Ultimately, the implementation of IoT, automation, and AI in tea-processing factories
represents a crucial step toward Industry 4.0, transforming traditional operations into
intelligent, data-driven ecosystems that are more efficient, sustainable, and resilient, setting
a precedent for digital transformation across the agricultural sector.

3.1.1 DRAWBACKS

• High Energy Consumption – Traditional tea-processing machines lack energy-

efficient controls, leading to excessive power usage and increased operational costs.

• Manual Fault Detection – Operators rely on manual inspections, causing delays in

identifying issues, increasing downtime, and reducing overall production efficiency.

• Frequent Machine Failures – Lack of predictive maintenance leads to unexpected

breakdowns, requiring costly repairs and disrupting the tea manufacturing process.

• Inconsistent Product Quality – Manual adjustments result in variations in

processing conditions, affecting the flavor, texture, and overall quality of tea
products.

• Safety Hazards – Electrical failures and overheating remain undetected, increasing

fire risks and endangering factory workers due to inadequate monitoring systems.

• Lack of Remote Monitoring – Supervisors must be physically present to oversee

operations, preventing real-time decision-making and optimization of machine
performance.

3.2 PROPOSED SYSTEM

The proposed system aims to revolutionize traditional tea-processing operations by

integrating Internet of Things (IoT), smart sensing, and AI-driven analytics to address the
critical inefficiencies associated with outdated machinery and manual operations.
Conventional tea factories face challenges such as excessive energy consumption due to lack
of intelligent energy controls, frequent machine downtime from delayed fault detection, and

10
increased operational costs and safety risks due to the absence of real-time monitoring and
predictive maintenance. The proposed system tackles these issues through the deployment
of smart sensors and IoT-enabled automation that enables real-time monitoring, adaptive
machine control, and predictive maintenance. By continuously collecting and analyzing
machine performance data—such as temperature, vibration, humidity, and power usage—
the system detects anomalies, forecasts potential failures, and enables timely interventions,
thus minimizing unplanned downtime and maintenance costs. AI-driven analytics adjust
machine operations dynamically based on real-time demand, ensuring optimal energy usage
and reducing unnecessary power consumption without compromising productivity. The
system also automates ancillary systems like lighting and ventilation to align with factory
workflows, contributing to significant energy savings and reducing the carbon footprint of
operations. Through a centralized, user-friendly interface accessible via computers or mobile
devices, factory managers can monitor performance, receive emergency alerts, and make
informed decisions remotely, enhancing responsiveness and management efficiency.
Additionally, the system improves workplace safety by identifying electrical anomalies and
triggering automated shutdowns in critical scenarios. Its modular and scalable design allows
seamless integration with existing machinery across varying factory sizes, making it a viable
solution for both small and large-scale operations. Economically, the system lowers energy
costs, reduces equipment downtime, extends machinery lifespan, and improves production
consistency—leading to higher profitability. Environmentally, it aligns with sustainability
goals by minimizing greenhouse gas emissions and promoting responsible energy use. With
strong cybersecurity protocols in place to protect operational data, and the potential for future
integration with technologies like blockchain and renewable energy, this IoT-based system
not only modernizes tea-processing practices but also paves the way for a smarter, safer, and
more sustainable tea industry.

3.2.1 ADVANTAGES

• Optimized Energy Consumption:

Adaptive controls and real-time monitoring allow machines to operate based on actual
production demand, significantly reducing unnecessary power usage and lowering electricity
costs.

11
• Predictive Maintenance:
AI-driven analytics detect early signs of equipment wear or failure, enabling timely
interventions that prevent sudden breakdowns, reduce downtime, and extend the lifespan of
machinery.

• Enhanced Operational Efficiency:

Automation of machine controls, lighting, and ventilation systems streamlines factory
processes, improves workflow, and ensures machines run at optimal performance levels.

• Reduced Maintenance Costs:

Early fault detection minimizes the need for emergency repairs and prevents major
equipment failures, lowering long-term maintenance expenses.

• Improved Safety:
Real-time monitoring of electrical parameters helps identify anomalies like overheating or
voltage fluctuations, reducing the risk of electrical fires and improving worker safety through
automatic shutdowns.

• Remote Monitoring and Control:

Supervisors can access real-time machine data, receive alerts, and manage operations
remotely via mobile or web applications, enhancing responsiveness and flexibility.

• Scalability and Easy Integration:

The modular design allows seamless integration with existing machinery in both small and
large-scale factories, without requiring extensive infrastructure changes.

• Cost Savings and Higher Profitability:

The combined impact of reduced energy use, fewer breakdowns, and optimized operations
leads to significant cost reductions and more consistent production output.

12
 CHAPTER 4

SYSTEM SPECIFICATION

4.1 HARDWARE CONFIGURATION

Arduino (ATMega328p): Main controller for system operations.

NodeMCU (ESP8266): Enables IoT connectivity and remote monitoring.

Temperature Sensor: Monitors ambient temperature in real time.

Fire Sensor: Detects fire or overheating for safety.

LCD Display: Shows sensor data and system status.

Relay: Controls high-power devices via microcontroller.

Buzzer: Gives alerts for faults or warnings.

DC Motor: Powers mechanical movements in the system.

4.2 SOFTWARE SPECIFICATION

MC Programming Language: Embedded C

The system leverages Embedded C for low-level programming to ensure efficient
control and communication with hardware components.

Programming Tool: Arduino IDE

Arduino Integrated Development Environment (IDE) is used to write, compile, and
upload the code to the microcontrollers, providing a streamlined development
environment.

13
 CHAPTER 5

SOFTWARE DESCRIPTION

5.1 FRONT-END

The front-end refers to the user interface and the components through which users interact
with the system. In this IoT project, the front-end is designed for real-time monitoring,
control, and alert display. It includes both the Arduino IoT Cloud dashboard and the mobile
interface.

KEY COMPONENTS:

IoT Cloud Dashboard:

Displays real-time sensor data such as temperature and flame detection. It allows users to
remotely control devices like fans, motors, and lights using toggle switches or buttons.

Mobile Interface:

Offers remote access via smartphone or tablet, enabling users to monitor system status and
receive alerts on the go. It ensures ease of use and convenience for factory personnel.

LCD Display (On-site Front-End):

Installed on the hardware setup, this component displays current temperature readings and
fire status locally in the factory.

Functionality:

• Real-time data visualization

• User controls for automation

• Status updates and alerts

• Responsive and accessible UI

14
5.2 BACK-END

The back-end is responsible for processing data, managing logic, and ensuring
communication between hardware components and the cloud. It includes the
microcontrollers, sensors, actuators, and programming logic.

KEY COMPONENTS:

Arduino UNO (ATMega328p):

The core microcontroller that collects data from sensors and sends commands to actuators
based on programmed logic.

NodeMCU (ESP8266):

Acts as a Wi-Fi module that connects the system to the Arduino IoT Cloud for data exchange
and remote control.

Sensors:
• Temperature Sensor: Captures heat levels from machines and the environment.

• Fire Sensor: Detects smoke or flame indicating potential fire risks.

Actuators:
• DC Motor: Drives automation mechanisms.
• Relay Module: Switches high-voltage devices safely.
• Fan and Lights: Controlled based on sensor inputs.

• Buzzer: Triggers alerts in case of anomalies.

Programming Language & Tools:

Embedded C used in Arduino IDE to write and upload logic that governs the system.

Code integrates sensor data with cloud variables for real-time updates and actions.

Functionality:
• Sensor data collection and processing
• Decision-making based on conditions (e.g., turning on fan when temperature is high)
• Communication with the front-end via cloud
• Automation and alert system execution

15
 CHAPTER 6

PROJECT DESCRIPTION

6.1 PROBLEM DEFINITION

Tea-processing factories traditionally face multiple issues due to their reliance on

conventional, non-automated machinery. These machines typically operate at fixed power
levels regardless of actual production requirements, resulting in excessive energy
consumption and resource wastage. The lack of smart monitoring systems means that any
signs of malfunction or hazards such as overheating or fire often go undetected until they
escalate into critical failures, causing machine breakdowns, production losses, and high
maintenance costs. Manual monitoring is labor-intensive and prone to human error, further
delaying fault detection and reducing overall system efficiency. Additionally, the absence of
remote monitoring capabilities restricts the ability of factory supervisors to respond swiftly
to emergencies or make informed operational decisions from remote locations. As energy
prices rise and the demand for environmentally sustainable practices grows, these issues
have become more pronounced. Hence, there is a pressing need for a modern, IoT-based
system that can monitor critical parameters, control operations intelligently, and provide
predictive maintenance, ultimately leading to reduced energy consumption, improved safety,
and increased equipment lifespan.

6.2 MODULE DESCRIPTION

6.2.1 SENSOR MONITORING UNIT

The Sensor Monitoring Unit is designed to continuously track critical environmental

and machine-related parameters within the factory. It incorporates a temperature sensor to
detect overheating risks and a fire sensor to identify early signs of fire or smoke. Data from
these sensors is transmitted to the Arduino for real-time analysis, allowing the system to
identify abnormal conditions and enable proactive responses to ensure safety and operational
efficiency.

16
6.2.2 MICROCONTROLLER PROCESSING UNIT

The Microcontroller Processing Unit serves as the central decision-making component of

the system. Built around the Arduino Uno (ATMega328p) and programmed using
Embedded C, it receives inputs from various sensors and processes them based on predefined
thresholds. Depending on the sensor readings, it can initiate actions such as activating a
buzzer or displaying alerts. Additionally, it manages the operation of connected hardware
components like the relay and motor, ensuring smooth data handling and precise control of
system functions.

6.2.3 IOT COMMUNICATION UNIT

The IoT Communication Unit facilitates internet connectivity to enable seamless data
transmission from the factory to the cloud. Utilizing the NodeMCU (ESP8266) along with a
built-in Wi-Fi module, it connects to platforms such as ThingSpeak, Firebase, or Blynk for
cloud-based data logging and monitoring. This setup allows operators to remotely track
factory parameters, receive real-time alerts, and respond quickly through mobile or web
interfaces, thereby enhancing the overall responsiveness and control of the system.

6.2.4 OUTPUT AND ALERT SYSTEM

The Output and Alert System is responsible for communicating system status and initiating
appropriate responses based on sensor data. It includes an LCD display that presents real-
time sensor readings and system messages for easy monitoring. A buzzer is employed to
alert operators in case of danger or system faults. Additionally, a relay is used to control the
DC motor or other high-power devices, enabling automatic ON/OFF actions based on
environmental conditions. This module ensures both effective communication and timely
activation of safety mechanisms and machinery control.

6.2.5 ENERGY MANAGEMENT & AUTOMATION

The Energy Management & Automation module focuses on optimizing power consumption
within the system. It ensures that electrical energy is utilized only, when necessary, by
dynamically adjusting motor operation based on real-time demand. Additionally, it can
17
automatically shut down non-essential systems such as ventilation or lighting when they are
not in use. This intelligent control helps reduce energy wastage and enhances overall
efficiency through effective resource management and automation.

6.2.6 SAFETY & PREDICTIVE MAINTENANCE

The Safety & Predictive Maintenance module is designed to enhance the reliability and
safety of factory operations. By analyzing sensor data trends—such as rising temperatures
or irregular vibrations—it can forecast potential equipment failures and notify maintenance
personnel in advance, helping to prevent costly unplanned downtime. In critical situations
like fire or overheating, the system can automatically initiate alerts and perform emergency
shutdowns. This proactive approach not only extends the lifespan of machinery but also
significantly improves the overall safety of the operational environment.

6.2.7 USER INTERFACE & CONTROL DASHBOARD

The User Interface & Control Dashboard provides a comprehensive and centralized platform
that allows factory managers and operators to monitor, control, and analyze system
performance in real time. Accessible through both mobile applications and web-based
dashboards, it delivers live updates on sensor readings, operational status, and system alerts.
Historical logs are maintained for performance tracking, troubleshooting, and audit
purposes. The dashboard also includes manual override features, enabling users to take direct
control of machinery or system functions during maintenance or emergency conditions. One
of the key highlights of this module is its ability to present complex data through intuitive
visualizations—such as graphs, charts, and heatmaps—depicting energy consumption
patterns, motor usage, sensor fluctuations, and maintenance trends. These visual insights
support predictive maintenance strategies and resource optimization. Additionally, the
interface can be customized based on user roles, ensuring secure access to relevant
information for technicians, supervisors, or managers. Through real-time notifications,
mobile alerts, and cloud integration, this module enhances operational responsiveness,
improves transparency, and empowers users to make informed, data-driven decisions for
improved efficiency and safety.

18
6.3 SYSTEM FLOW DIAGRAM

6.3.1 FLOW DIAGRAM

Figure 6.3.1 Flow Diagram

19
6.3.2 BLOCK DIAGRAM

Figure 6.3.2 Block Diagram

20
6.4 INPUT DESIGN

The input design defines how data is captured from various components in the system and
converted into a format suitable for processing. In the proposed system, input is collected
primarily from hardware components such as temperature sensors, fire sensors, and
current/power sensors. These sensors continuously monitor key parameters including
machine temperature, environmental conditions, fire risk, and energy consumption. The data
is transmitted to microcontrollers (Arduino and NodeMCU) in real-time for further
processing. The NodeMCU enables wireless transmission of this data to a cloud or local
server for analytics and remote monitoring. Inputs also include manual overrides or
commands from users via mobile or web interfaces, allowing for remote control or
adjustments to machine settings. The input design ensures data accuracy, noise filtering, and
proper signal interpretation, which are crucial for the system's reliable operation and timely
decision-making.

6.5 OUTPUT DESIGN

The output design focuses on how processed data and system responses are communicated
to users and hardware components. In this system, outputs are generated based on sensor
data analysis and predefined conditions. Key outputs include real-time alerts via buzzer and
LCD display notifications, which provide immediate feedback on machine status, fault
detection, or abnormal conditions like overheating or fire risk. Additionally, outputs include
control signals sent to actuators such as relays and DC motors for automated actions, such
as switching off machines or reducing motor speed to conserve energy. Through NodeMCU,
the system also delivers outputs remotely, updating the cloud dashboard and notifying users
through mobile/web applications with real-time performance metrics and warnings. This
ensures timely user intervention and enhances system efficiency, safety, and energy
optimization. The output design prioritizes clarity, responsiveness, and user-friendliness to
support informed decision-making and automated factory operations.

21
 CHAPTER 7
SYSTEM TESTING AND IMPLEMENTATION

7.1 SYSTEM TESTING

System testing is a crucial phase in the development of the IoT-enabled smart tea-processing
automation and energy management system, aimed at validating the functionality,
performance, and reliability of the integrated hardware and software components under real-
world operating conditions. The testing process began with unit testing of individual
modules, such as temperature and fire sensors, LCD display, relay control, and buzzer, to
ensure each component performed its specific function accurately. Once individual
components were verified, integration testing was conducted to evaluate the communication
between Arduino, NodeMCU, sensors, actuators, and the cloud interface. The system was
tested for its ability to detect temperature anomalies and fire risks, respond with appropriate
alerts through buzzers and LCD notifications, and accurately transmit real-time data to
remote monitoring platforms. The IoT communication protocols were assessed for stability
and responsiveness, ensuring consistent remote access and control. Various fault scenarios
were simulated to check the system’s response to unexpected conditions, including sensor
disconnection and network interruptions. Performance and load testing ensured the system
could handle continuous data input and control multiple devices without delay or error.
Additionally, the user interface was evaluated for responsiveness and accessibility across
devices, confirming that real-time monitoring and alerts were successfully delivered to
authorized users. The testing phase concluded with the resolution of identified issues,
confirming the system's readiness for deployment in an industrial tea-processing
environment with improved operational reliability, energy efficiency, and proactive
maintenance capability.

7.2 SYSTEM IMPLEMENTATION

System implementation marks the crucial transition of the IoT-enabled smart tea-processing
and energy management system from the development and testing phase to real-time
application within the operational environment of a tea-processing factory. This phase

22
involved a structured and phased deployment strategy to ensure minimal disruption to
ongoing factory processes while achieving optimal system integration. Sensors—including
temperature and fire detectors—were mounted at critical points on machinery to ensure
comprehensive monitoring of environmental and operational parameters. These sensors
were wired to the Arduino microcontroller, which was preprogrammed using Embedded C
to interpret sensor data and trigger corresponding control actions. The NodeMCU (ESP8266)
module was configured to establish stable Wi-Fi-based communication with cloud servers
and mobile interfaces, enabling real-time data transmission for remote monitoring and
control. Relay modules were installed and linked with high-power devices to automate
machinery shutdown, activate buzzers, or control ventilation systems based on sensor input.
The implementation also included configuring a user-friendly cloud dashboard and mobile
interface that factory supervisors could use to visualize machine status, receive alerts, and
make data-driven decisions. A pilot run under controlled conditions was conducted to
validate system responsiveness, stability, and safety measures before full-scale deployment.
System performance was closely observed, and adjustments were made to improve accuracy
and timing. Once verified, the smart system was integrated with live factory operations.
Factory personnel were provided with training sessions covering system features, emergency
procedures, and troubleshooting techniques, ensuring a seamless adoption of the new
technology. Backup power systems and manual override options were also tested to ensure
reliability in case of unexpected failures. The successful implementation not only highlighted
the practical viability of IoT in traditional manufacturing settings but also demonstrated
measurable improvements in energy savings, safety responsiveness, equipment
maintenance, and overall production efficiency, marking a significant step toward digital
transformation in the tea industry.

23
 CHAPTER 8

CONCLUSION AND FUTURE WORK

8.1 CONCLUSION

The implementation of the IoT-enabled smart tea-processing system has demonstrated

significant advancements in energy efficiency, machine reliability, and overall operational
productivity. By integrating IoT, smart sensors, AI-driven predictive analytics, and adaptive
control mechanisms, the system effectively optimizes energy consumption, minimizes
downtime, and enhances production efficiency. The results of the study confirm that
conventional tea-processing operations, which typically suffer from high energy
consumption and inefficient fault detection, can greatly benefit from intelligent automation
and data-driven decision-making. One of the most impactful contributions of this system is
the reduction in energy wastage through automated control of machines, lighting, and
ventilation. By dynamically adjusting machine operations based on real-time production
demands, the system significantly lowers power consumption, leading to reduced operational
costs and improved sustainability. Additionally, predictive maintenance plays a crucial role
in preventing unexpected machine failures, ensuring continuous production, and reducing
maintenance expenses. These advantages contribute to both economic and environmental
sustainability in the tea industry. The scalability and adaptability of the system make it
suitable for different tea-processing environments, ranging from small-scale factories to
large industrial setups. The seamless integration with existing machinery, wireless
connectivity, and cloud-based data processing ensure ease of deployment and user-friendly
operation. The ability to remotely monitor machine performance and receive real-time alerts
further enhances the responsiveness and efficiency of factory management. In conclusion,
the proposed IoT-based smart tea-processing system offers a transformative approach to
improving efficiency, reducing costs, and promoting sustainability in tea production. Its
ability to optimize energy usage, enhance predictive maintenance, and facilitate remote
monitoring makes it a valuable investment for modern tea factories. Future developments
can focus on integrating renewable energy sources and expanding AI capabilities to further
enhance operational efficiency and environmental sustainability in the tea industry.

24
8.2 FUTURE WORK

In future work, the IoT-enabled Smart Tea-Processing Automation and Energy

Management System has significantly improved energy efficiency, predictive maintenance,
and operational productivity within tea-processing environments. However, further
enhancements can be explored to increase the system’s capabilities and extend its benefits
across the broader tea industry. Future developments should focus on advanced AI-driven
analytics, integration with renewable energy sources, enhanced automation, and scalability
for widespread adoption. One key area for improvement is the incorporation of more
sophisticated artificial intelligence and machine learning algorithms to strengthen predictive
analytics. By continuously learning from historical and real-time data, the system can refine
fault detection and anomaly prediction, enabling even more accurate maintenance
scheduling. Additionally, AI models can optimize energy usage by identifying patterns in
production cycles, environmental conditions, and machine behavior, thereby maximizing
operational efficiency. Integrating renewable energy sources such as solar or wind power
can further reduce the carbon footprint of tea-processing units. Smart energy management
systems can dynamically allocate power by prioritizing renewable input, minimizing
reliance on traditional energy supplies. This aligns with global sustainability goals and
contributes to long-term energy cost savings. Further automation through the introduction of
robotic systems for material handling, sorting, and packaging can reduce manual labor and
enhance production consistency. Moreover, AI-powered quality control using image
recognition can help maintain product standards and streamline inspection processes. These
future advancements will enhance the intelligence, sustainability, and efficiency of the
proposed smart tea-processing model, making it a robust solution for the evolving needs of
the tea industry.

25
 CHAPTER 9

APPENDICES

9.1 SOURCE CODE

[Link]

#include <ArduinoIoTCloud.h>
#include <Arduino_ConnectionHandler.h>

const char DEVICE_LOGIN_NAME[] = "da64fa92-b817-420a-aff6-874b4a964fad";

const char SSID[] = "projectiot";
const char PASS[] = "1234567890";
const char DEVICE_KEY[] = "viETp5qhgeIRd9yZPivJ4qbD3";

void onTemperatureChange();
void onFanChange();
void onFlameChange();
void onLightChange();
void onMotorChange();

int temperature;
bool fan;
bool flame;
bool light;
bool motor;

void initProperties(){

[Link](DEVICE_LOGIN_NAME);
[Link](DEVICE_KEY);
[Link](temperature, READWRITE, ON_CHANGE,
onTemperatureChange);
[Link](fan, READWRITE, ON_CHANGE, onFanChange);
[Link](flame, READWRITE, ON_CHANGE, onFlameChange);
[Link](light, READWRITE, ON_CHANGE, onLightChange);
[Link](motor, READWRITE, ON_CHANGE, onMotorChange);

WiFiConnectionHandler ArduinoIoTPreferredConnection(SSID, PASS);

void setup() {
[Link](9600);

26
 initProperties();
[Link](ArduinoIoTPreferredConnection);
setDebugMessageLevel(2);
[Link]();
pinMode(D7,OUTPUT);
pinMode(D8,OUTPUT);
pinMode(D3,OUTPUT);
pinMode(D4,OUTPUT);
pinMode(D5,OUTPUT);
pinMode(D6,OUTPUT);
}

void loop() {
[Link]();

if ([Link]() > 0) {
char identifier = [Link]();
//int value = [Link]();

[Link]("Received Identifier: ");

[Link](identifier);
// [Link]("Received Value: ");
// [Link](value);

switch (identifier) {
case 'T': temperature = [Link](); break;
case 'A': flame = true; break;
case 'a': flame = false; break;
// default: [Link]("Unknown identifier received.");
}
}
}

void onTemperatureChange() { [Link]("Distance changed to: " +

String(temperature));}
void onFlameChange() { [Link]("Distance changed to: " + String(flame));}
void onFanChange() {
if (fan) {

digitalWrite(D3,HIGH);
digitalWrite(D4,HIGH);
} else {

digitalWrite(D3,LOW);
digitalWrite(D4,LOW);
}

27
 }
void onMotorChange() {
if (motor) {
digitalWrite(D5,HIGH);
digitalWrite(D6,HIGH);
} else {
digitalWrite(D5,LOW);
digitalWrite(D6,LOW);
}

}
void onLightChange() {

if (light) {
digitalWrite(D7,HIGH);
digitalWrite(D8,HIGH);

} else {
digitalWrite(D7,LOW);
digitalWrite(D8,LOW);
}

CLOUD_INIT.INO

#include <LiquidCrystal.h>
#include <Adafruit_Sensor.h>
#include "DHT.h"

LiquidCrystal lcd(13, 12, 11, 10, 9, 8);

#define Light 7
#define machine 6
#define Fan 5
#define Buzzer 3
#define FireSensor 2
#define DHTPIN 4
#define DHTTYPE DHT11

28
DHT dht(DHTPIN, DHTTYPE);

void setup() {
[Link]();
[Link](9600);

[Link](16, 2);

pinMode(Light, OUTPUT);
pinMode(machine, OUTPUT);
pinMode(Fan, OUTPUT);
pinMode(A0, INPUT);
pinMode(A1, INPUT);
pinMode(A2, INPUT);
pinMode(FireSensor, INPUT);
pinMode(Buzzer, OUTPUT);

[Link](0, 0);
[Link]("IOT Based Indust.");
[Link](0, 1);
[Link](" AUTOMATION SYS ");
delay(2000);
[Link]();
}

void loop() {
int lightState = digitalRead(A0);
int machineState = digitalRead(A1);
int fanState = digitalRead(A2);
int fireDetected = digitalRead(FireSensor);

// Light Control
if (lightState == HIGH) {
digitalWrite(Light, HIGH);
[Link](6, 1);
[Link]("L-ON ");
} else {
digitalWrite(Light, LOW);
[Link](6, 1);
[Link]("L-OFF");
}

29
 // Machine Control
if (machineState == HIGH) {
digitalWrite(machine, HIGH);
[Link](0, 1);
[Link]("M-ON ");
} else {
digitalWrite(machine, LOW);
[Link](0, 1);
[Link]("M-OFF");
}

// Fan Control
if (fanState == HIGH) {
digitalWrite(Fan, HIGH);
[Link](12, 1);
[Link]("F-ON ");
} else {
digitalWrite(Fan, LOW);
[Link](12, 1);
[Link]("F-OFF");
}

// Fire Detection
if (fireDetected == LOW) { // Assuming LOW means fire detected
[Link](12, 0);
[Link]("F-H ");
digitalWrite(Buzzer, HIGH);
[Link]('A');
} else {
[Link](12, 0);
[Link]("F-L ");
digitalWrite(Buzzer, LOW);
[Link]('a');
}

// Read Temperature and Humidity

readDHT();
}

void readDHT() {

30
 int h = [Link]();
int t = [Link]();
float f = [Link](true);

if (isnan(h) || isnan(t) || isnan(f)) {

[Link]("DHT11 sensor error! No data.");
return;
}

[Link]('T');
[Link](t);

[Link](0, 0);
[Link]("T:");
[Link](t);
[Link](char(223)); // Degree symbol
[Link]("C ");

// [Link](9, 0);
// [Link]("H: ");
// [Link](h);
// [Link]("% ");

// Temperature Alert
if (t < 40) {
digitalWrite(Buzzer, LOW);
[Link](8, 0);
[Link]("T-L");
} else {
digitalWrite(Buzzer, HIGH);
[Link](8, 0);
[Link]("T-H");
}

delay(2000); // Add delay to allow stable readings

}

31
9.2 OUTPUT

9.2.1 MAIN OUTPUT FOLDER

Figure 9.2.1 Main Output Folder

9.2.2 SAMPLE IMAGE

Figure 9.2.2 Sample Image

32
 9.2.3 IOT CLOUD APPLICATION

Figure 9.2.3 IOT Cloud Application

9.2.4 APP HOME PAGE

Figure 9.2.4 App Home Page

33
9.2.5 DETECTING PAGE

Figure 9.2.5 Detecting Image

34
 CHAPTER 10

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