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BatchMaster Concrete Plant Automation System

BatchMaster Automation System

BatchMaster Automation System developed by Pro-4, facilities the follow-up and control of the production process and eliminates possible Production and Operator errors, Thus; provides uninterrupted and quick Production while saving time required for Production and cost for Maintenance.

An Automation and Scada System with full control over all parameters is as important as mechanical design for Concrete Batch Plants in order to operate with high efficiency.

Apart from the automation system’s ability to fulfill this requirement, the system has to be monitored and controlled remotely and integrated with the Accounting and ERP softwares.

Thanks to the System’s modular architecture, BatchMaster Concrete Batching Plant Automation System meets these requirements beyond Customer Satisfaction and Production Performance.

Features

User friendly interface
Multiple Language Support
Easy Commissioning
Fast Communication Architecture
Remote Connection and Service
Moduler Structure
Production from Order and Non-Stop Function

SUPERIOR PLANT PERFORMANCE AND EASY to USE

Our Concrete Batch Plant Automation and Scada software developed by our Engineers who have deep process know-how in the ready-mixed Concrete Industry, provides convenience to Operators in production, control and monitoring with user-friendly Interfaces.

Our system, which offers many features such as making production, editing Recipes, remote Monitoring and Reporting, has many References abroad.

BatchMaster has developed by our own Engineers who have deep process know-how

Customer-specific solutions in Automation and Scada software in line with the demands of the users, direct and quick technical support from the software developing team

Siemens PLC, circiuit brakers and contactors, Mixer Motors controlled by Softstarter

Siemens PLC, circuit brakers and contactors with widespread service network all over the world Longer motor life by using Softstarter to avoid mechanical and electrical stresses due to peak voltages in traditional Star-Delta starting

Maintenance and Service with Remote Connection

Location-independent technical support if Internet connection can be provided in the Plant

Pro-4 which has an extensive experience in Ready-Mixed Concrete Batch Plant, Stone Crushing-Screening Plant
and Asphalt Production Plant Automation and Scada projects, can offer customer-specific solutions in Automation and
Scada software in line with the demands of the users.

Our Concrete Batch Plant Automation system, which has references in a wide geography such as Russia, Georgia, Egypt,
Saudi Arabia, United Arab Emirates, Morocco, Jordan, Malawi, is offered in infrastructure that can be delivered both onsite
and via remote connection.

BatchMaster Automation System, which has been completely developed by Pro-4 technical team, facilitates followup
and control of the Production Process and eliminates possible Production and Operator errors. Thus; provides
uninterrupted and quick Production while saving time required for Production and cost for Maintenance.

With our BatchMaster Automation System, every Operator is experienced!

BatchMaster Automation System records all details of Production from the first production moment. The risk of
error is minimized by means of extra modules developed for specially designed concrete classes. Experienced operators
can increase the performance of the Concrete Batch Plants they use, while the BatchMaster Automation System
provides maximum efficiency with the operator in every experience.

In our Automation System, as optional integration with ERP and Accounting programs is possible. With Accounting
Program integration, it is ensured that dispatch records are automatically transferred either instantly or at the end of the
day.

In addition, you can monitor BatchMaster Automation System wherever you are in the world, report daily, weekly,
monthly or yearly, save these reports in pdf, excel or word, or print them.

REFERENCES

HARDWARE COMPONENTS

SIEMENS S7-1200 PLC

Modular and fast PLC with Ethernet communication

OPERATOR PANEL (HMI)

7 ” colored touch screen operator panel and software allow full automatic production in case of computer failure.
(OPTIONAL)

DIGITAL WEIGHT INDICATORS

The scale weight values transferred exactly and quickly to the PC system. It can be easily calibrated from the computer and
HMI, and provides visual convenience to the operator.

ENERGY ANALYZER

Thanks to the Energy Analyzer, instant energy values of the Plant can be monitored, and at the same time, by controlling the mixer current logs and trend analysis can be created.

CONTROL PANEL

Compact Control Panel that provides easy manual usage for the Operator including standard buttons, lamps and weight indicators.

POWER BOARD

IP54 protected and electrostatic powder painted Panel with 2mm sheet thickness and electro galvanized mounting plate.
Siemens circuit brakers and contactors are used.

FEATURES

Mixer Current Control

Mixer current is constantly controlled and current values are recorded in the database from the beginning to the end of the
production. Limit overruns are shown as a warning to the operator. It provides the opportunity to create retroactive current trends and reports for each production when requested.

Modular System Architecture

Possibility to change additional silo, weighing and Plant paremeters with modular System architecture.

Multi Language Support

In addition to Turkish, English, Russian, and French languages, languages such as Georgian, Arabic and Hebrew with different typefaces are fully supported.

Easy Installation

Simple and quick installation thanks to the setup wizard.

Authorization Panel

The authorization levels of the users can be controlled with a password and the access of unauthorized persons to the facility parameters can be prevented and the desired number of users with different authorizations can be defined.

Recipe Based Parameter Structure

You can create an unlimited number of recipes through the recipe-based parameter infrastructure, and the Plant parameters are optimized for each recipe.

Remote Connection and Service

With integrated VPN feature, remote service and trouble shooting wherever there is internet.

Advanced Log and Alarm Management

Operator is warned visually in alarm and log situations that occur during the operation of the plant and the alarms that occur are recorded on a date basis. Statistical reports can be obtained from alarm records and records of how solutions were produced in the past can be accessed.

Flow-dependent Vibration Control

By means of flow control algorithms, vibrations are activated only when needed and mechanical wear due to continuous vibration operation is prevented.

Waybill Design Opportunity

It allows users to design their own waybills through the waybill design screen. It allows automatic printing of waybills at the end of production.

User-Friendly Interface

Thanks to user-friendly interfaces, every stage of the production can be followed with animations, and the fast identification and selection screens allow the operators to use the Plant manually and automatically without special training. provides opportunity.

Automatic and Manual Moisture Calculation

By means of integrated moisture calculation algorithms, the water and aggregate ratios are automatically adjusted with the moisture sensor. In cases where there is no humidity sensor, it allows calculation with manual humidity rate.

Non-Stop and Production to Order

Daily order records can be defined and production can be made on the order list. As the production is made, the amount of production and remaining production amount can be followed separately for each order on the screen. Production can be started automatically, one after the other, according to the order created with the production planning feature, without the need for any additional approval.

Fast Communication

High speed monitoring, control and logging capability thanks to its Ethernet based communication architecture. With digital indicators instead of traditional analog weighing indicators, max. accuracy is provided. Indicator calibration possibility via SCADA and HMI PANEL.

OPTIONAL MODULES

WEB MONITORING MODULE

Production, orders and reports can be viewed by entering the web page from PCs or Android supported Mobile Devices.

ERP/ACCOUNTING PROGRAM INTEGRATION

Data exchange such as current account, dispatch note, raw material, recipe, order and stock can be performed with the ERP / Accounting program.

E-SHIPMENT with QR Code Module

E-Waybill can be prepared in accordance with the legislation and transferred to the relevant institutions online. (only in Turkey)

Field Feasibility Study

Pro-4 enables Feasibility Studies in line with your Requeirements of your Projects to provide Complete Solutions. In order to provide the optimum Cost, max Quality and Reliability in your Projects, all Details including Hardware, Software, Design, Production and Assembly are taken in to consideration.

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