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OPTIMIZING LPG SUPPLY CHAIN EFFICIENCY

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Why PeGASus in the LPG Industry?

Next to filling plants, gas cylinders are one of the most important assets in the LPG industry. Due to the huge number
of cylinders and the geographical spread of LPG distribution, most companies lose track of the exact amount of
cylinders owned, their physical and technical conditions, their present and historical locations and rotation cycles.
A large majority of LPG businesses suffer from lost, damaged and dirty cylinders returned without having any possibility to correct this situation, due to the lack of physical tracking and management information.
This lack of information leads to the fact that approx. 5 % of the cylinder park needs to be repurchased every year
although the existing park is already oversized with respect to an optimized cylinder supply chain.
Based on these requirements, the IDtek team launched in year 2000 PeGASus Filling Automation, the first LPG Management Information System and in 2004, the first Mobile Cylinder Distribution and Sales Computing Solution, called
PeGASus Supply Chain.

The PeGASus Solution Architecture

PeGASus consists of a modular toolbox that can be implemented simultaneously or in a staging process. Each
module can also be acquired separately. These are:

PeGASus Middleware, the Management Information System linked and fully compatible with the customer's
IT infrastructure.

PeGASus Filling Automation, a qualified RFID platform at Factory level.

PeGASus Supply Chain, through-the-line mobile computing from the plant through transport logistics to the
final distribution.

IT Backend
Systems

ERP
Entreprise
Resource
Planning

Customer
Business Rules

Middleware
Modules

Track & Trace

Platform

WMS
Warehouse
Management
Systems

PCS
Process
Control
Systems

MES
Manufacturing
Execution
Systems

1 PeGASus Management Information System

Reader
Control

Front-end
Database

Data
Synchro

2 PeGASus Filling Automation

Application
Manager

Reporting
Module

3 PeGASus Supply Chain

Physical Tracking
& Transactions
Cylinders
and Pallets

Filling
Plant

ATEX RFID
Readers

Trucks
and Drivers

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Mobile
Computing

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The PeGASus Middleware

The ultimate Management Information System that connects RFID Item Level Tracking to the entreprise's ERP.
The PeGASus Middleware flexibly collects, stores and automates the processing of all data from the physical tracking
layer and uploads the required information to the IT backend systems. It consists of the following Modules:

Reader Control : Collects all tracking data in the

field and allows to remote control every single
reader.

Cylinder Database : Stores all tracking data and

contains the cylinder master data for clearing and
applications.

Application Manager : Performs all specified

functions, contains all required business rules.

Data Synchronization : Uploads all data from

mobile computing devices and to the IT backend.

Reporting Module : Queries the database and

displays the requested information in a
configurable format.

Examples for the Middleware Reporting Module

5 times
4 times
Filled cylin d ers
Pa in t ed cylin d ers
O-rin g ch a n g es
3 times

Va lve ch a n g es
2 times

Hyd ro t est ed
CRC

Maintenance & Filing Records

10 / 2002

09 / 2002

08 / 2002

07 / 2002

06 / 2002

Filling Cycle Distribution

1995

05 / 2002

Productivity Benchmarks

1996

1997

1998

1999

2000

2001

Asset & Logistics Control

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2002

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PeGASus Filling Automation

A fully operational quantum leap for LPG filling by using RFID.

9.

10.

1.

2.

4.
3.

7.
5.

6.

8.

Functional Features of PeGASus Filling Automation

1. Association of returned pallets/cylinders at arrival

and booking to the empty asset account in the
ERP resp. WMS system.
2. Incoming cylinder machine-count and database
record.

6. Underfilling/Overfilling records.
7. Value exchange records.
8. Unmanned leakage test record.
9. Outgoing cylinder machine-count.
10. Pallet/cylinder association at filling line exit and

3. Retest date check and push-out if NOK.

real-time booking to available products in the

ERP/WMS system.

4. Paint job record.

5. Operator-free tare weight input to the carousel
controller.

These functions are realized by means of the PeGASus RFID platform implemented at appropriate spots in the
filling process. The required information is extracted from the PeGASus database by the Application Manager
and sent to the respective IT backbend system.

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PeGASus Supply Chain

An efficient, intelligent through-the-line Field Data Capture solution for the LPG industry.

PDA Application Software

On-Board Computing

Functional Features of PeGASus Supply Chain

4
4
4
4
4
4
4
4
4

Initialisation of the PDA with date and time through an integrated real-time clock
Identification of the truck and truck driver by RFID or other electronic identification methods
Download from the ERP system of a trip list, including customer data with contact details accessible through
scroll menus
Display of the delivery data incl. tagged and untagged cylinders for customer approval
Capture of the customer signature on the PDA touch screen
Receipt print-out by wireless communication
Bidirectional data uploads with the ERP system
Upload of transaction and modified customer data from the PDA to the ERP system
Balanced truck function at loading, on the delivery trip and at factory return

A unique versatile Management Information tool that works both with and without RFID.
PeGASus Supply Chain has fully automated functions when used with RFID tagged cylinders, but performs a majority
of functions also when cylinders remain untagged or are barcoded.
PeGASus Supply Chain can also be used for automated LPG bulk sales and distribution.

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The PeGASus RFID Platform

100% Operational in large scale LPG operations.

A technological break-through for RFID on metal.

Using low-frequency radio frequency identification (RFID), PeGASus is today the only commercially available, fully
operational and already implemented tracking solution operating inside and directly on metal. It only requires one
single over-head antenna with unsurpassed reading distance tolerating multiple cylinder formats that can be
implemented at any point on the conveyor without spacing or cylinder orientation devices.
LPG cylinders of any type, shape and material can be RFID tagged.
LPG cylinders of any type, shape and material can be equipped with an RFID transponder (tag) in seconds and at
minimum cost without modifying or altering the cylinder. Cylinder tagging can take place at manufacturing, during
refurbishment or inside the filling plant.

Superior Customer-Value of PeGASus

4 Savings of >10 % of the cylinder park
4 Reduction of lost and damaged cylinders through automated supply chain monitoring
4 Manpower savings of 1-4 operators/ plant
4 State-of-the-art mouse-click operations statistics
4 Real-time availability of all tagged assets
4 Security and quality level increase e.g. at registration of successful leakage tests
4 Cylinder filling to 3 decimals precision enabled
4 Increase in delivery efficiency by PDA field terminals and transaction software
4 Return-on-Investment of 2 - 5 years

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Other LPG Solutions by IDtek

Tank X

Tank 3

Tank 1

Central
Server with
Transactions
Database

Tank 2

Aside PeGASus, the IDtek Group also offers the following LPG solutions:

ERP Database
Gateway PC

Entrance/
Exit Reader

Filling
Spot Readers

WLAN
Access Point

WLAN

Weighing
Bridge Reader

RFID-secured Bulk
Filling of Tanker Trucks

On-Board
Truck Computing

Automated
Tour Planning

GPS Navigation
& Geo-fencing

About IDtek
The IDtek Group, formed as a result of the management buy-out of a subsidiary of a world market leader in RFID, is
today a leading provider of custom-tailored RFID Business Solutions and Asset Management Tools for hazardous,
perishable and high-value products.
Headquartered in Switzerland, IDtek has a relentless commitment to customer value, system reliability, and quality.
Our solutions are qualified in the Automotive, Consumer Goods and Energy (LPG) industries and are in daily use by
Fortune 500 customers on 4 continents.

Contact
The IDtek Headquarters/Switzerland/France
IDtek Track-and-Trace SA
Avenue Mon-Repos 24
CH-1005 Lausanne

Phone:
Fax:
E-Mail:
Web:

+41 21 321 82 49
+41 21 311 62 77
info@idtek.ch
www.idtekgroup.com

Germany/Austria
IDtek Identifikationslsungen GmbH
Industriestrasse 29
D-82194 Grbenzell

Phone:
Fax:
E-Mail:
Web:

+49 8142 444 578-17

+49 8142 444 578-29
info@idtek.de
www.idtekgroup.com

Spain/Portugal
Kosan Crisplant Portugal
Rua Serpa Pinto 407
P-4250-466 Porto

Phone:
Fax:
E-Mail:
Web:

+351 22 834 80 50
+351 22 834 80 59
info@emporgas.com
www.kosancrisplant.com

Turkey
Panel Elektro AS
Emek Mah, Onur Cad. N.55
TK-34785 Sarigazi-Istanbul

Phone:
Fax:
E-Mail:
Web:

+90 216 621 00 00 (pbx)

+90 216 621 00 09
panel@panel.com.tr
www.panel.com.tr

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