Barrel Tag: WiLO / LoRa / Zigbee / RFID, what's optimal?

Choosing the right tag for your barrel tracking needs depends on the size of your operation, budget, and the level of sensing and AI integration required. Below, we analyze the pros and cons of each option, rating them on key factors such as cost, range, localization accuracy, inventory management, and sensor support.

RFID (passive): Passive RFID tags are the most widely used in the spirits industry due to their low cost and simplicity for basic inventory management. However, their short range requires manual inventory checks, increasing labor costs and reducing accuracy as barrels move over time. Passive RFID tags generally don’t support sensor data logging.

Pros:
✔️ Low tag cost
✔️ Simple implementation for inventory management

Cons:
❌ Short range requires manual labor
❌ No sensor support

RFID (active — BLE / Zigbee): Active RFID tags typically rely on BLE (Bluetooth Low Energy) or Zigbee. These tags are battery-powered (coin-cell) and are commonly used in devices like car keys and garage door openers. BLE is generally cheaper due to its broad adoption across consumer electronics. BLE 5.0 has further improved range and supports indoor localization using channel hopping and RF fingerprinting. Zigbee offers similar benefits but tends to have a bit higher hardware costs.

Pros:
✔️ Cost-effective
✔️ Supports indoor localization
✔️ Sufficient range for warehouse connectivity

Cons:
❌ Mesh network requires multiple PoE supported routers
❌ High leakage chips (2-4uA), requiring large battery (>350mAh) for 10 yr lifetime

LoRa: LoRa (Long Range) is designed for low-power, long-range communication, making it ideal for large-scale, track-and-trace applications. It offers one of the longest available ranges, but the proprietary nature of the technology (by Semtech) increases costs. Localization using RSSI (Received Signal Strength Indicator) is possible but tends to be inaccurate in barrelhouses due to interference from liquid-filled barrels.

Pros:
✔️ Long range
✔️ Strong sensor support

Cons:
❌ High cost for barrel tags
❌ Poor localization accuracy
❌ High leakage chips (2-4 uA), requiring large battery (>350mAh) for 10 yr lifetime

WiLO: WiLO combines the strengths of Zigbee, BLE, and RFID to address the unique challenges of high sensor density and multi-path environments. It uses off-the-shelf chips for routers and gateways that support Zigbee and BLE but runs on a custom network protocol to enable battery-powered mesh networks. WiLO routers support both active RFID and BLE tags, and WiLO includes a dedicated low-power long-range chip supporting RFID and BLE protocols for automated inventory management and barrel sensing. Tags automatically connect to warehouse routers when in range for data logging. By supporting RFID and BLE tags, WiLO keeps the cost of barrel tags low, making it scalable for high-volume operations.

Pros:
✔️ Balanced cost and performance
✔️ Single PoE gateway covers entire warehouse (tested and deployed)
✔️ Supports both inventory management and sensor data logging
✔️ Reliable localization and network support
✔️ Range tested in both rick-houses and palletized warehouses
✔️ Low leakage chips (<100 nA), allowing small batteries (10 mAh) to last 10 years

Cons:
❌ Higher cost than passive RFID

Cost vs Scale: At low volume (warehouse-level sensors), costs are primarily driven by C1D2 certification requirements, as well as the cost of dashboards and analytics support. There, printed tags limit the sensing capabilities, while not providing much cost benefits either. At high volume (barrel-level sensors), the per-tag cost becomes a critical factor, where WiLO’s scalability and balanced feature set provide a strategic advantage.

Why WiLO?: The WiLO solution is designed by experienced RFIC experts with deep expertise in LoRa, Zigbee, and BLE-based radios, gained through both research and industrial deployments. The design reflects carefully considered trade-offs to address the unique challenges of high-density sensors operating in tough environments. If you have any questions or need guidance on selecting the right option, feel free to schedule a meeting or contact us using the details below.