Replacing Manual Cylinder Checks with a Real-Time IoT Monitoring System

BURAQ built an end-to-end IoT monitoring system that connects hardware, communication, and mobile interface into one continuous workflow. ESP-32 modules attached to cylinders capture weight and leakage data directly from the source. Sensor readings are transmitted over MQTT to a broker, then pulled into a Flutter mobile app that displays live cylinder status through a clean, operator-friendly interface. All monitoring data is stored in MongoDB, giving the client a complete activity history for review, reporting, and future analysis. The system was designed for real-time visibility rather than periodic checking — the mobile app updates as data changes, so operations teams see what's happening the moment it happens. System Architecture The system is built in four connected layers. At the edge, ESP-32 modules act as the data-capture layer, reading cylinder weight and detecting leakage conditions. The communication layer uses MQTT — a lightweight IoT messaging protocol ideal for real-time sensor data — to move readings from device to broker efficiently. The application layer, powered by Flutter, subscribes to the broker and renders live data in the mobile UI, keeping the operator experience simple and responsive. The data layer stores every reading in MongoDB, supporting historical review and future analytics. This layered architecture keeps the system reliable at scale and easy to extend as new cylinders or sensor types are added. Key Features Hardware Layer ESP-32 Sensor Integration: Captures cylinder weight and leakage data directly from the source. Communication Layer MQTT-Based Data Transmission: Sends real-time sensor readings from ESP-32 devices to the MQTT broker efficiently. Mobile Interface Real-Time Monitoring Dashboard: Displays live cylinder status, weight changes, and leakage alerts inside the Flutter app. Operator-Friendly UI: Clean interface designed for fast status review and quick action. Data & Persistence MongoDB Data Storage: Stores continuous monitoring data for tracking, historical reference, and reporting. Activity Monitoring System: Provides ongoing visibility into cylinder usage and leakage patterns.