
IoT-based Real-time Temperature Monitoring in Critical Systems: A Review
Biomedical EngineeringReceived 25 Apr 2025 Accepted 14 May 2025 Published online 15 May 2025
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Received 25 Apr 2025 Accepted 14 May 2025 Published online 15 May 2025
The accurate monitoring of temperature is critical in a wide range of sectors, including healthcare, pharmaceuticals, food logistics, and data centers, where even minor thermal deviations can compromise safety, quality, and operational efficiency. Over recent years, the evolution of the Internet of Things (IoT) and embedded systems has significantly enhanced real-time temperature monitoring, enabling precise control via interconnected and autonomous systems.
This work aims to review and analyze current temperature measurement systems designed for critical environments. It identifies the strengths and weaknesses of different architectural approaches and their core components—such as sensors, actuators, microcontrollers, and gateways—focusing on aspects like scalability, reliability, energy efficiency, and response time. The study also highlights challenges and gaps in current technologies.
The review was conducted using a traditional literature analysis methodology, drawing from scientific databases including IEEE Xplore, B-on, and Google Scholar. Key research was synthesized to provide a comprehensive and up-to-date perspective on IoT-based temperature monitoring technologies and their applications.
The paper contributes a structured evaluation of the field and supports future research by outlining essential requirements, comparing technologies, and proposing directions for improvement in the development of adaptive, secure, and efficient temperature monitoring systems for high-risk environments.
In many critical environments, such as pharmaceutical warehouses, medical facilities, food logistics, and data centers, maintaining precise temperature control is essential to ensure product safety, system efficiency, and regulatory compliance. The failure to detect and respond to thermal deviations in real time can lead to material degradation, system downtime, and even risks to human health. As such, robust and continuous temperature monitoring is essential.
The rise of the Internet of Things (IoT) and advances in embedded systems have enabled the development of smarter, more connected, and autonomous monitoring solutions. These systems support distributed sensor deployment and local data processing via edge computing, and efficient communication between nodes and centralized platforms. This paradigm shift has improved the responsiveness, scalability, and reliability of environmental monitoring infrastructures, making them suitable for complex, real-world deployments.
The primary objective of this work is to explore the current technological landscape of IoT-based temperature monitoring systems in high-precision scenarios. This includes a comparative analysis of various system architectures and core components such as sensors, actuators, microcontrollers, gateways, interconnection protocols, and software platforms. The study also aims to identify existing limitations, practical trade-offs, and open challenges that still hinder broader adoption or long-term reliability in demanding applications.
To support this analysis, a traditional literature review methodology was employed, with relevant publications sourced from reputable scientific databases including IEEE Xplore, B-on, and Google Scholar. The review focused on identifying the most impactful research and technological solutions applied in real-world scenarios.
The structure of this article is as follows: the next section presents typical IoT architectures for temperature monitoring, followed by an in-depth overview of sensing technologies and actuators, along with a discussion of edge node implementation and communication strategies. The paper also evaluates IoT software platforms and orchestration approaches, presents a critical assessment of emerging technologies, and concludes with the main findings and proposed directions for future research.
IoT-based temperature monitoring systems require well-structured architectures to ensure reliability, scalability, and efficiency across all stages of data collection, processing, and transmission. Several architectural models have emerged over time, including the widely adopted three-layer, five-layer, and seven-layer designs. In addition to layered architectures, these systems can be categorized as centralized or decentralized. The choice of architecture depends on multiple factors such as the number of devices, communication requirements, energy efficiency, and processing capabilities [
].The three-layer architecture, composed of perception, network, and application layers, is the most common and is valued for its simplicity and effectiveness [
]. In this model, environmental data from temperature sensors is collected at the perception layer, transmitted via protocols like Wi-Fi, LoRa, or ESP-based communication (e.g., ESP-NOW, ESP-MESH in mesh or star topologies) at the network layer, and then processed and visualized at the application layer through mobile or web interfaces. While this structure is easy to implement and integrate, it may struggle with scalability and centralized processing bottlenecks.To address these issues, the five-layer architecture introduces two additional layers: processing and management. These layers enable edge-level data filtering, compression, OTA updates, device authentication, and centralized coordination of devices. While this architecture provides greater robustness and is better suited to large-scale or mission-critical applications requiring cloud integration and artificial intelligence, it also increases system complexity and potential latency due to additional processing overhead [
].The seven-layer architecture, inspired by the OSI model, provides a comprehensive structure for critical applications such as medical monitoring or pharmaceutical cold chains [
, ]. It includes the physical layer (temperature sensors and actuators), the data link layer (communication protocols like ESP-MESH or Zigbee), the network layer (routing), the transport layer (reliable delivery via TCP/UDP), the session layer (persistent connections), the presentation layer (data encryption and compression), and the application layer (user interfaces and data analysis).Regarding performance metrics, communication protocols differ significantly under varying conditions. LoRaWAN, for example, offers excellent long-range coverage but operates at low data rates (0.3 - 50 kbps) and exhibits uplink latencies between 1 and 3 seconds per transmission, depending on payload size and transmission mode. It is therefore better suited for low-frequency measurements rather than real-time monitoring [
]. On the other hand, ESP-NOW and ESP-MESH support higher throughput (typically ~200 kbps) and significantly lower latency, often under 100 milliseconds per hop, making them ideal for real-time applications with multiple sensor nodes operating in local environments [ ].In terms of system organization, centralized architectures gather all data in a single server, simplifying management and integration with applications, but introducing a single point of failure and scalability limitations [
]. Decentralized architectures, by contrast, distribute processing across multiple nodes, allowing devices to communicate directly. This enhances resilience, reduces latency through local processing, and is especially effective with ESP-MESH networks. However, it also increases system complexity and demands more capable edge devices [ ].For systems based on ESP32 microcontrollers and ESP-MESH communication, a decentralized five-layer architecture has proven particularly effective. This model supports large-scale deployments without overwhelming a central server, takes full advantage of direct device-to-device communication, and includes dedicated layers for device management and security. When combined with cloud integration, it provides a robust, secure, and energy-efficient architecture that is well-suited for high-reliability use cases such as hospital monitoring, cold chain logistics, and industrial environments [
].Sensors and actuators are key components in temperature monitoring systems, enabling precise environmental data acquisition and automated responses to thermal changes. Working as complementary elements in a closed-loop control system, sensors collect temperature data while actuators execute corrective actions based on those inputs, ensuring real-time environmental regulation [
].These devices are typically integrated through a microcontroller, such as the ESP32, which processes the sensor data and coordinates actuator responses. This setup enables fast and energy-efficient reactions to temperature fluctuations, maintaining environmental conditions within predefined thresholds [
].Sensor selection plays a critical role in ensuring precision and reliability, especially in sensitive environments. Among the most suitable sensors are the DS18B20, a robust digital sensor with ± 0.5 °C accuracy and one-wire interface ideal for industrial and cold chain applications; the SHT31, offering high-precision temperature (±0.2 °C) and humidity (±2%) readings with excellent long-term stability, is suitable for scientific and industrial uses; and the BME680, a multi-sensor capable of measuring temperature, humidity, pressure, and air quality (VOCs), ideal for comprehensive environmental monitoring in healthcare and pharmaceutical settings [
, ].The ESP32 facilitates the integration of these sensors through native support for I2C and 1-Wire protocols, ensuring low power consumption and reliable data transmission over wireless interfaces such as Wi-Fi and Bluetooth Low Energy [
].Edge nodes are essential components in IoT architectures for temperature monitoring, acting as intermediaries between sensor devices and centralized cloud infrastructure. These nodes enable not only data collection but also local filtering and preliminary processing, significantly reducing the computational load on central servers and enhancing system efficiency [
]. Edge nodes are especially relevant in industrial and mission-critical environments where latency and autonomous operation are key factors.In temperature monitoring systems, edge nodes process thermal data locally before transmission to the cloud, minimizing both latency and bandwidth consumption. Hardware selection depends on system requirements: low-power microcontrollers like the ESP32 and ESP8266 are suitable for energy-efficient deployments, while more powerful microcomputers like the Raspberry Pi or Jetson Nano are used for applications requiring advanced processing capabilities [
, ].Microcontrollers are ideal for accurate data acquisition and wireless communication via protocols such as Wi-Fi or Bluetooth Low Energy. Microcomputers, on the other hand, support storage and machine learning-based analysis for predictive insights [
]. This local decision-making capacity enhances system responsiveness and reduces dependence on constant cloud connectivity, which is crucial in applications like pharmaceutical cold chain monitoring or data center thermal management [ ].The proposed architecture follows a hybrid model
(Figure 1): ESP32 microcontrollers are deployed as peripheral sensor nodes, communicating via ESP-MESH—a scalable, low-power mesh protocol [ , ]. The Raspberry Pi 4 acts as the central gateway, aggregating and pre-processing data before cloud transmission, while also acting as a local storage buffer during connectivity interruptions [ ].
This architecture offers four main advantages: (1) long-term battery operation through the ESP32’s ultra-low power modes [
], (2) mesh network scalability without dedicated Wi-Fi infrastructure [ ], (3) data integrity through local buffering on the Raspberry Pi [ ], and (4) real-time decision-making with reduced cloud dependency, leveraging local algorithms for basic system operations [ ].Tables 1,2 list the hardware and software components used in the proposed IoT Edge Monitoring System, respectively.
Efficient interconnection of devices is a foundational pillar in developing robust IoT systems for temperature monitoring, ensuring reliable communication among sensors, actuators, and edge nodes. Selecting the appropriate communication protocol requires a multidimensional analysis that balances coverage, bandwidth, energy consumption, implementation cost, and scalability [
].For continuous thermal monitoring systems, three key features are essential: low energy consumption for prolonged operation, sufficient communication range, and native support for decentralized architectures to improve system resilience. In this context, wireless mesh networks are particularly relevant due to their ability to eliminate single points of failure by allowing direct device-to-device communication [
].IoT communication technologies fall into two main categories: wired solutions like Ethernet and RS-485, known for reliability but limited in flexibility; and wireless protocols such as Wi-Fi, BLE, LoRaWAN, Zigbee, and ESP-MESH. Each has strengths suited to different use cases, and a comparative evaluation should consider four criteria: range, energy efficiency, data throughput, and resistance to electromagnetic interference.
In traditional centralized IoT architectures, all sensor nodes communicate directly with a single gateway or cloud server, which handles all data processing and routing. While simple to implement, this model introduces a single point of failure and may struggle to scale efficiently in environments with a high density of devices. In contrast, decentralized architectures, such as those based on mesh networking, enable devices to communicate with each other directly, forming a distributed communication network (Figure 1). ESP-MESH, specifically, is a mesh protocol developed by Espressif for ESP32 devices that allows nodes to relay data between each other until it reaches the gateway. This greatly improves coverage, network resilience, and fault tolerance, as the system can adapt dynamically to changes in topology or connectivity. By enabling communication across multiple hops, ESP-MESH reduces the load on individual nodes and eliminates reliance on a single access point, making it especially suitable for large-scale or critical applications where connectivity and robustness are essential [
, ].On the software side, the proposed architecture adopts Go (Golang) as the primary development language because of its resource efficiency, native support for concurrency, and compatibility with various communication protocols and APIs. This enables seamless integration from sensor-level data acquisition over ESP-MESH [
, ] to communication with cloud-based analytics platforms via RESTful APIs and WebSockets [ ].As the solution is still under development, one of the proposed security mechanisms includes the design of a dedicated Encryption API, which is responsible for securely managing all encryption and decryption processes. The core encryption algorithm considered is AES-256 in CBC (Cipher Block Chaining) mode, chosen for its balance between strong security and performance in constrained environments. For secure key exchange, RSA-2048 or Elliptic Curve Diffie-Hellman (ECDH) are being evaluated, depending on the trade-off between computational load and cryptographic strength [
, ].Offloading cryptographic operations to an external API is necessary due to the resource constraints of the ESP32, which has restricted RAM (~520 KB) and limited CPU headroom, making it less suitable for handling complex key exchanges and real-time encryption of continuous sensor data. The Encryption API will be hosted on the gateway device (e.g., Raspberry Pi), which has sufficient processing capability to manage cryptographic workloads while maintaining low-latency communication with sensor nodes [
, ]The API will also handle key management strategies, including secure key generation, periodic key rotation, and secure key storage (either in encrypted files or via integration with hardware secure modules if available). Each ESP32 device will be assigned a unique identifier and access token to authenticate requests to the API, ensuring that only authorized nodes can request encryption services. This centralized security approach not only reduces the attack surface on edge nodes but also simplifies updates, revocations, and audits [
]These strategies align with best practices in IoT security and are expected to enhance the overall confidentiality, integrity, and availability of the temperature monitoring system while maintaining high operational efficiency.
This architecture achieves a well-balanced combination of performance, security, and flexibility, supporting deployments ranging from small-scale local networks to enterprise-grade distributed solutions. Such versatility is particularly important in temperature monitoring, where operational requirements vary across industrial, medical, and logistics environments.
Recent advancements in IoT-based temperature monitoring have significantly improved metric accuracy, network scalability, and energy efficiency. However, a critical analysis reveals persistent gaps that represent both technical challenges and opportunities for innovation.
Among digital thermal sensors (Figure 2), the Sensirion SHT31 stands out for its ±0.2 °C accuracy and long-term stability, ideal for scientific and medical use. The DS18B20 remains relevant for its simple 1-Wire interface and robustness in industrial environments, despite slower response times and lower accuracy. The Bosch BME680 offers a comprehensive solution by integrating temperature, humidity, barometric pressure, and air quality (VOCs) sensing in a low-power, ESP32-compatible package [
] making it the preferred option for real-time environmental monitoring.Figure 3 presents a comparative analysis between different communication technologies, evaluating them according to six main dimensions: coverage, bandwidth, power consumption, cost, scalability, and overall suitability for edge computing environments. In summary, ESP-MESH enables decentralized, self-healing networks with extensive coverage and no single point of failure. LoRaWAN offers long-range, low-power communication but lacks data throughput for frequent updates. Wi-Fi and MQTT remain relevant for their cloud integration, but are energy-intensive [
].Figure 4 provides a comparative analysis of five edge computing platforms, evaluated across six technical dimensions: computing power, power efficiency, GPIO availability, connectivity, AI support, and price. The comparison suggests that combining ESP32 (low-power data collection) with Raspberry Pi gateways (local preprocessing and buffering) creates a balanced distributed architecture [
, ]. Docker containerization improves modularity, remote management, and update mechanisms [ ].A hybrid visualization system includes native mobile apps (Kotlin for Android, Swift for iOS) and a Next.js web dashboard. Secure REST APIs with OAuth 2.0 and TLS 1.3 ensure reliable 15-second updates [
, ]. Advanced analytics, real-time maps, anomaly detection, and remote configuration are supported via MQTT (QoS 1), WebSockets, and GraphQL APIs [ ]. Data persistence is handled by MongoDB due to its flexible schema, write performance, and native replication [ ].Challenges remain in cross-vendor interoperability, energy autonomy in harsh environments, and mesh network cybersecurity. Promising research includes federated learning for distributed sensor calibration and lightweight neural networks (tinyML) for local anomaly detection [
].ESP32 development can be done via Arduino (C/C++) for high-performance, memory-constrained applications, or MicroPython for rapid prototyping and interactive development [
, ]. Each approach offers trade-offs between control and ease of use.To evaluate the feasibility and performance of the proposed IoT-based temperature monitoring system, a preliminary prototype validation was conducted under controlled conditions. The test environment consisted of a closed indoor space with ambient temperature ranging from 18 °C to 27 °C, relative humidity between 40% and 80%. Environmental sensors such as the BME680 and LDR were used to monitor temperature and ambient light, respectively.
The experimental setup included a total of two sensor nodes deployed over approximately 10 meters from the central gateway (a Raspberry Pi 4) in two opposite orientations. Each node transmitted temperature data at fixed 30-second intervals over a continuous 24-hour period. All transmitted data was received via MQTT.
This early-stage validation confirms the prototype’s ability to perform accurate and low-latency environmental monitoring with reasonable power efficiency. The results align with similar studies in the field and provide a basis for further optimization and scaling in more demanding environments. Future tests will extend to outdoor deployments and higher node densities to assess performance under more variable conditions.
The system demonstrates high reliability in data transmission, low latency due to edge computing, and scalability across different applications. The security measures, including encryption in both ESP Mesh communication and gateway-to-API transmission, ensure data integrity and confidentiality.
Although the proposed system shows promising results, several limitations must be acknowledged. In terms of scalability, the current prototype was tested with only two sensor nodes in an indoor environment with limited spatial distribution. While ESP-MESH supports the creation of larger and more complex mesh networks, increasing the number of nodes introduces challenges such as increased propagation delay, routing instability, and greater energy consumption. Future work should assess the performance of the system under larger-scale deployments with wider coverage areas and higher node densities to validate its scalability in real-world applications.
From a cybersecurity standpoint, mesh-based communication architectures such as ESP-MESH expose additional attack surfaces. If not properly secured, unauthorized devices might join the mesh and potentially intercept or alter data flows. Furthermore, lightweight communication protocols such as MQTT, while efficient, may be vulnerable to spoofing or man-in-the-middle attacks if encryption and authentication are not rigorously implemented. The proposed architecture mitigates these concerns through an Encryption API that centralizes key management and cryptographic operations, but practical deployment scenarios will require robust validation of these security mechanisms.
In addition, environmental constraints can impact the long-term reliability of the system. Sensors like the BME680 and LDR may experience performance degradation or calibration drift when subjected to extreme temperature fluctuations, high humidity, dust exposure, or electromagnetic interference. These factors can lead to reduced accuracy over time, especially in outdoor or industrial settings. To address this, future versions of the system should incorporate regular calibration routines, protective enclosures for hardware, and compensation algorithms to correct environmental bias and sensor aging.
The solution proposed in this work is currently under development and has been partially validated through the design and testing of a functional prototype. Preliminary results suggest that low-power microcontrollers such as the ESP32, when combined with decentralized communication models like ESP-MESH and lightweight protocols such as MQTT, can provide an effective foundation for real-time environmental data acquisition. The use of a Raspberry Pi as an edge gateway enables local data buffering and processing, as well as secure transmission to a backend API developed in Go, with data stored in a MongoDB database (Figure 1).
The architecture’s modular and containerized design facilitates flexibility, scalability, and simplified deployment, which are key advantages in scenarios such as agriculture, logistics, and smart infrastructure. These early insights support the findings in the literature review, which indicate that this approach helps overcome limitations of traditional monitoring systems—namely, high cost, poor energy efficiency, and limited interoperability—while enhancing data reliability and operational robustness.
To further enhance system intelligence and autonomy, a concrete pipeline for integrating TinyML is proposed [
]. In this approach, sensor nodes equipped with ESP32 microcontrollers would perform local data analysis using lightweight models deployed with TensorFlow Lite for Microcontrollers. The typical data flow begins with temperature readings processed on-device to detect anomalies based on predefined thresholds [ ]. When anomalies are identified, alerts can be raised locally and transmitted to the gateway. For continuous learning and improvement, nodes participate in federated learning cycles by updating model weights based on locally observed data. These updates are transmitted securely to the edge gateway using the MQTT protocol. The gateway aggregates updates, refines the global model, and redistributes it across the network. This method ensures privacy by avoiding the transmission of raw sensor data while enabling the system to adapt to localized environmental patterns.Interoperability is also a critical consideration in the system design. The solution leverages OASIS MQTT, a widely adopted standard for IoT messaging that ensures compatibility with multiple platforms and vendors. At the network layer, communication protocols such as IEEE 802.15.4—the basis for Zigbee and Thread—and ESP-MESH are used to support device-to-device communication in heterogeneous deployments. Data formatting follows standard practices using lightweight JSON structures, and all API interfaces are REST-compliant, promoting seamless integration with cloud platforms and third-party services. These decisions aim to ensure that the system remains extensible and interoperable in diverse technological ecosystems [
].The evolution of temperature monitoring systems has demonstrated that IoT integration significantly enhances precision and efficiency. This project proposes a comprehensive architecture combining state-of-the-art technologies tailored for continuous thermal monitoring.
The core solution employs the BME680 sensor, offering accurate temperature measurements (±0.5 °C) alongside humidity, pressure, and air quality data, surpassing alternatives such as the SHT31 and DS18B20 in terms of multifunctionality. A hybrid communication model leverages ESP-MESH for self-organizing sensor networks and MQTT over TLS for secure cloud transmission, ensuring scalability and energy efficiency compared to conventional Wi-Fi or LoRaWAN approaches.
For data processing, MicroPython enables rapid prototyping on ESP32 nodes, while the Go (Golang) backend ensures high-performance concurrent data handling. MongoDB provides flexible time-series storage, and an interactive Next.js portal with Kotlin/Swift mobile apps delivers real-time thermal data visualization.
Key innovations address persistent challenges: optimized energy use via ESP32 Deep Sleep algorithms, end-to-end encryption, and edge computing to reduce cloud dependency. This architecture balances precision, scalability, and reliability, supporting deployments ranging from small-scale to enterprise systems while overcoming conventional limitations.
The authors declare no conflict of interest, financial or otherwise, related to the development or publication of this article.
The authors would like to acknowledge the support of the Polytechnic Institute of Coimbra – ISEC. No external funding or grants were used in the development of this work.
José Nabão: Conceptualization, system architecture design, investigation, data curation, sensor selection, electronics integration, development of backend API, integration of containers and orchestration, and original draft preparation.
Acácio M. R. Amaral: Conceptualization, methodology, investigation, resources, review and editing, supervision, project administration, and funding acquisition.
Filipe Sá: Conceptualization, methodology, investigation, resources, review and editing, project administration, and funding acquisition.
This study did not involve any experiments with human or animal subjects and therefore did not require ethical approval. All development and testing were conducted in compliance with institutional guidelines for academic and technological research.
No external funding was received for this work. The project was self-funded and partially supported through academic and professional resources provided by the Polytechnic Institute of Coimbra – ISEC.
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Nabão J, Amaral AMR, Sá F. IoT-based Real-time Temperature Monitoring in Critical Systems: A Review. IgMin Res. May 15, 2025; 3(5): 226-234. IgMin ID: igmin303; DOI:10.61927/igmin303; Available at: igmin.link/p303
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1Polytechnic Institute of Coimbra, Coimbra Institute of Engineering, Rua Pedro Nunes - Quinta da Nora, P – 3030-199 Coimbra, Portugal
2CISE - Electromechatronic Systems Research Centre, University of Beira Interior, Lameiro Fountain Sidewalk, P – 6201-01, Covilhã, Portugal
Address Correspondence:
Acácio Manuel Raposo Amaral, Polytechnic Institute of Coimbra, Coimbra Institute of Engineering, Rua Pedro Nunes - Quinta da Nora, P – 3030-199 Coimbra, Portugal, Email: [email protected]
How to cite this article:
Nabão J, Amaral AMR, Sá F. IoT-based Real-time Temperature Monitoring in Critical Systems: A Review. IgMin Res. May 15, 2025; 3(5): 226-234. IgMin ID: igmin303; DOI:10.61927/igmin303; Available at: igmin.link/p303
Copyright: © 2025 Nabão J, et al. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.
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