Concrete batching plant automation

PLC-based process control

Aggregate bins, conveyors, cement screws, water and admixture lines, and the mixer require a sequence tailored to the plant layout. The PLC manages field signals, permissives and interlocks. Operator software provides supervision; it does not replace physical safety circuits.

• Automatic and authorised manual operation
• Motor, valve and sensor feedback
• Mixer sequencing, discharge permissives and process alarms
• Power-loss and communication-failure scenarios

Aggregate, cement, water and admixture dosing

The measurement method is assessed for each material. Load cells, indicators, flow meters and interfaces are selected for capacity, resolution and environmental conditions. Coarse/fine feeding and cutoff settings require commissioning tests. Numerical accuracy is not promised without plant-specific measurements.

• Aggregate and cement weigh hoppers
• Water quantity and admixture dosing
• Zero, tare and calibration procedures
• Operator alerts for out-of-tolerance batches

PC-based SCADA and recipe management

Recipe values, material definitions, production targets and operator permissions should be traceable. Recipe changes and actual weights are separate records; planned quantities must not be reported as actual production. HMI or PC-based supervision is selected according to maintainability and reporting needs.

Production records, orders and dispatch

Batch material quantities, timestamps, recipe references and process status can be included in the reporting scope. Order, vehicle and dispatch data exchange with ERP or Turkish e-dispatch systems requires review of the external API, permissions and data model. These integrations are project options, not advertised as verified off-the-shelf modules.

Communication and remote visibility

Modbus TCP/RTU links need defined device addresses, register maps, update intervals and failure behaviour. Web and mobile reporting should use a data layer separated from the control network. Remote commands, when required, need explicit authorisation, connection security and local operating priority.

Information needed for a proposal

For a new plant, control retrofit or reporting extension, the installed system is assessed first. These details help establish a useful initial scope.

• Plant type, capacity and aggregate bin count
• PLC / HMI models and existing electrical drawings
• Load cell and indicator models, communication interfaces
• Required production reports and external integrations