Abstract: This paper presents an Industry 4.0-based Smart Yarn Monitoring and Alert System designed to enhance efficiency, accuracy, and automation in textile production environments. The proposed system utilizes an ESP32 microcontroller with integrated Wi-Fi capability to enable real-time monitoring and remote data access. An E18-D80 infrared (IR) sensor is employed for continuous yarn thread detection, allowing immediate identification of thread breakage. Additionally, a proximity sensor is used to count roller rotations, enabling indirect estimation of yarn weight through calibrated per-rotation measurements.The system provides both local and remote monitoring functionalities. A 16×2 LCD with I2C interface displays real-time parameters such as yarn status, rotation count, and estimated weight.

Simultaneously, data is transmitted to the Blynk IoT platform, facilitating live monitoring and instant alert notifications via a mobile application. The hardware is powered by a 12V LiFePO₄ battery, with an LM2596 buck converter ensuring stable voltage regulation for system components.The proposed solution offers a cost-effective, reliable, and scalable approach for automated yarn production monitoring. It significantly reduces manual intervention, minimizes material wastage, and improves operational productivity. The system demonstrates strong potential for deployment in smart textile industries, aligning with Industry 4.0 principles of digitalization, real-time analytics, and remote accessibility.

Keywords: ESP32, Internet of Things (IoT), Yarn Monitoring System, Industry 4.0, Infrared Sensor, Proximity Sensor, Real-Time Monitoring, Smart Textile System, Weight Estimation, Blynk Platform, Automation, Wireless Monitoring, Fault Detection.

Downloads: | DOI: 10.17148/IARJSET.2026.133107