Focused on hot mix asphalt.
Our work centres on hot mix asphalt plants — cold feed through truck loadout. The principal's background is in this space, including time at Astec developing the flagship PM3 system, and most projects since have been asphalt projects.
Continuous Drum Mix.
Each plant has its own character. The work generally covers these configurations:
Vendor-agnostic.
We're familiar with control systems from the manufacturers below — the exact level of experience varies by platform.
Subsystems we can help with.
A typical scope picks a subset; full plant retrofits cover most of these.
Cold feed
Volumetric or gravimetric blend control, bin levels, no-flow & low-flow detection, bin-empty warning routing into the recipe.
Drum & Burner
Drum variable speed control, burner sequencing, temperature setpoint PID control, exhaust gas, flame safeguard interfacing.
Baghouse
Differential pressure trending, cleaning cycle, fines return, EPA-friendly stack logging.
AC Metering & Tank Farm
Pump-pushing-pump system with encoder feedback or Micro Motion flow meters, tank level/temperature, automatic tank valve controls.
RAP system & Additives
Volumetric or gravimetric blend control, bin levels, no-flow & low-flow detection, bin-empty warning routing into the recipe. Bin-on-load-cell featrues. Drum entry sequencing. Fiber, lime, fly ash, polymer, anti-strip metering.
Silos & loadout
Silo filling, level and inventory display, transfer conveyors, drag slat conveyor, truck-under-silo detection, sequenced batch drop.
Truck scale
Ticketing integration, tare/gross capture, dispatch interface (Libra, JWS, WM2000).
Mix recipes
Live recipe editor, version history, role-based approval, by-mix totals.
Reporting & KPI
Shift, daily, job, monthly reports. Tons, fuel, downtime, AC usage, RAP %.
A few things that tend to make a real difference.
- Recipe changes without cumbersome click-throughs
- Totals and production data log exportable to CSV
- Alarm rationalization aligned with ISA-18.2
- Calibration handled on the HMI rather than a clipboard
- Stack and burner logging suited to environmental reporting
- Mix tracking exports for state DOT or Ministry requirements
- Optional cloud KPI views for off-site visibility
- Secure remote support over VPN
Designed to work alongside the rest of your stack.
Common interfaces and databases used by dispatch, lab, and accounting:
- WM2000, Libra Systems / JWS / Command Alkon dispatch
- SQL Server, MySQL, PostgreSQL
- PROFIBUS, PROFINET, OPC UA, Modbus TCP, EtherNet/IP
- AWS, Azure, or on-prem deployments
Quick scoping checklist
Bring this to your next operations meeting:
- What plants and capacities (t/h) are in scope?
- Current PLC platform and rough age?
- How many operator stations / HMIs?
- Dispatch and ticketing system today?
- Cutover window — winter shutdown or rolling?
Tell us about your plant.
If a controls project is on the radar, a short note is enough to start the conversation.
Get in touch