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Process Blending

Process blending components developed for hot mix asphalt plants: mix overview, mix-by-mix popups, totals, recipe editor, calibration, alarm banner, and a role-based login flow. Used as a starting point for plant-specific deployments.

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The HMI screens below are conceptual mockups for illustrative purposes only. They are not real-life screenshots from a live customer system or deployed plant HMI.

RUNNING ▶ MIX OVERVIEW LINE 1 · Operator L2
ORDER
93.4%
OEE
CYCLE
RATE
312t/h
DRUM
158°C
AC
5.1%
RAP
22%
SILO 1
112t
SILO 2
88t
SHIFT
1,148t
JOB
9501-B
OP: J.CARTER · L2AUTO▶■Ⅱ
RUNNING ▶ RECIPE EDITOR · 9501-B APPROVED · K.NGUYEN
GOOD PRODUCTION
1,257/ 1,500 t
REJECT
7.6%
VERSION
v12
MATERIAL%±
3/4" stone32.00.5
3/8" stone22.00.5
Sand28.00.5
RAP22.01.0
AC binder5.10.1
Recipe locked by supervisor roleREVSAVE
Components

What's included.

Plant Overview

3D view of your actual custom plant layout, designed to optimize the balance between accurate equipment footprint and pragmatic automation requirements. Perspective from 3 camera angles/views included.

Materials

Start-Stop controls for VFDs; production data - channel, mix point, reject chute; materials definitions and properties; types - AGG, REC, ASP, ADD, DUS, FIL; trending of pertinent information for quality control.

Totals & Reports

Plant totals report; breakdown by mix, shift, day, week, month and year; PDF report preview and print, CSV export; data logging to capture production trends.

Alarm banner + history

Alarm banner aligned with ISA-18.2, filtered history grid, CSV / PDF export; buffered and sequentially annunciated to avoid a simultaneous dump of alarms; integrated built-in text-to-speech feature with configurable voice options at the OS level - let you HMI speak to you.

Calibration

Per-channel calibration for all ingredients and belt scales; aggregate, recycled asphalt, virgin asphalt, dust, and filler; Multiple calibration modes to accelerate the process. Optional asphalt pump calibration to flow meter readings (Micro Motion).

Role-based login

Operator / Quality / Service / admin roles, inactivity timeout.

PLC integration

Works with YOUR plant.

We're built to intergrate with your plant - brownfield retrofit or a greenfield! Plants we're familiar with include:

Astec ADM Gencor Marini CMI Stansteel Custom rebuilds
Data & cloud

Data goes where it needs to go.

Local SQL Server for the historian, optional cloud-based integration for dashboards, integration via API where needed.

  • SQL Server / Express historian (on-prem)
  • AWS, AZURE (optional)
  • REST API for dispatch / lab / accounting
  • Scheduled exports to CSV, PDF, or email
Summary

One-page overview, on request.

A short PDF summary with a component checklist, supported PLCs, and deployment options is available on request.

Request the summary

Typical engagement deliverables

  • Custom HMI & PLC configured and deployed binaries
  • OPC UA tag map starter pack
  • SQL schema and stored procedures
  • Operator training, scope agreed up front
  • Post-cutover tuning window, and remote support

Want to talk through the components?

Happy to walk through what's included and discuss whether it's a fit for your plant.

Get in touch