IoT Enabled Real Time Monitoring and Management of Tobacco Curing Barns

Talha Jan; Hasnain Hidayat; Muhammad Usman; Sarwar Shah Khan

Authors

Talha Jan Department of Computer Science, University of Engineering and Technology, Mardan, Pakistan
Hasnain Hidayat Department of Computer Science, University of Engineering and Technology, Mardan, Pakistan
Muhammad Usman Department of Computer Science, University of Engineering and Technology, Mardan, Pakistan
Sarwar Shah Khan Department of Computer Science, Iqra National University, Swat Campus, Pakistan

Keywords:

Tobacco Curing, Internet of Things (IoT), ESP32 microcontroller, Real-Time System, Flutter Mobile Application, Sensor-Based Automation

Abstract

Tobacco is one of the major cash crops in Pakistan, and its quality and market value greatly depend on its curing process. Proper curing requires continuous maintenance of temperature and humidity during the yellowing, leaf drying, and stem drying stages. Traditional curing methods commonly used in Pakistan rely on manual supervision and human judgment, often resulting in inconsistent curing quality, high labor costs, excessive energy consumption, and inefficient environmental management. These limitations create the need for an intelligent and automated tobacco curing solution. This research proposes an Internet of Things (IoT)-based real-time monitoring and management system for tobacco curing barns. The system uses a DHT11 sensor to continuously collect temperature and humidity data from the curing barn. An ESP32 microcontroller processes the sensor readings and automatically controls fans and a mist maker to maintain optimal curing conditions. A Firebase Realtime Database is integrated for cloud-based data storage and synchronization, while a Flutter-based mobile application enables real-time monitoring and control operations. The developed prototype demonstrated successful monitoring and automated control of temperature and humidity under controlled testing conditions, enabling real-time environmental management during the tobacco curing process. The system exhibited an average response time of approximately 2 seconds during stage transitions and successfully supported automated stage-wise operation for the yellowing, leaf drying, and stem drying phases. The prototype evaluation focused on validating system functionality, sensor-actuator integration, and cloud-based monitoring capabilities. The proposed automated approach provides a framework for improving operational efficiency, enhancing environmental control consistency, and reducing dependence on continuous manual supervision during the curing process. Overall, the proposed IoT-based tobacco curing system presents a low-cost and scalable solution for real-time monitoring and automated environmental management in tobacco barns, with potential benefits for curing consistency and operational efficiency in Pakistan.

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