Project NameAsphalt Batching Plant Automation System - 260 TPH
Case Study: Infrastructure / R&B
SCADA Automation for 260 TPH Asphalt Batching Plant - Real-Time Control, Batch Reporting & Truck Loading
End-to-end SCADA automation for a 260 TPH asphalt batch mixing plant - from cold aggregate dosing and dryer control to bitumen handling, fiber feeding, hot bin management, and automated truck loading.
Project Overview
Project Information
Hive Automation developed and implemented a fully automated SCADA-based control system for a 260 TPH Asphalt Batching Plant - one of the largest throughput capacities in road construction automation.
The system integrates real-time control, monitoring, and visualisation for the complete mixing process, from raw aggregate dosing through final batch delivery and truck loading.
The SCADA provides a centralised operator interface for all plant components - including motors, pumps, valves, heating systems, dryer burners, and weighing systems - with data logging for batch reports, truck counts, and daily production totals that enable production management and quality audit.
Project Details
Project Delivery Snapshot
Completion DateCommissioned
Scope of WorkPLC Programming | SCADA Development | Weighing Integration | Burner Management | Site Commissioning
LocationIndia
System Architecture
Technical Architecture
PLC-based control system with a SCADA operator station providing full plant visibility and centralised operation of the entire batch mixing process.
Weighing controller integration for gravimetric batch control across aggregates, bitumen, filler, and fibre dosing.
Burner Management System integration for the coal or HFO dryer burner with direct ignition control, plus data logging and batch report generation.
Delivery Scope
Scope of Work & Key Deliverables
- Cold aggregate dosing - graded aggregate proportioning with belt weigh feeder control
- Dryer and burner control - rotary dryer temperature, coal burner management with direct ignition and combustion air control
- Dust collection and cleaning unit - bag filter differential pressure management and automatic cleaning cycles
- Bitumen and filler handling - bitumen tank temperature, pump sequences, and filler dosing with weight control
- Mixing drum and hot bin management - hot elevator, vibrating screen segregation, and hot bin level management
- Fiber feeding and weighing - gravimetric fiber dosing integration into batch recipe
- Truck loading automation - loadout weigh bridge and truck count logging
Project Impact
Challenge & Outcome
Challenge
Automating a 260 TPH asphalt batching plant required tight synchronisation between multiple simultaneous processes - aggregate dosing, drying, screening, hot bin management, bitumen heating, and batch weighing - all with real-time weight control accuracy and a burner management system that responds to dryer temperature demand without flame-out risk.
Outcome / Result
The 260 TPH Asphalt Batching Plant SCADA system was commissioned and made operational with centralised plant control, automated batch reporting, truck loading, and real-time production data accessible from a single SCADA operator station.
Process Coverage
Processes Automated
- Real-time display of temperatures, weights, flow rates, and current batch size on SCADA mimic screens.
- Integration of bitumen and fibre dosing with precise gravimetric weight control for recipe consistency.
- Automated order handling where production orders trigger automatic batching cycle sequences.
- Centralised control of all plant components including motors, pumps, valves, heating systems, and instrumentation.
- Batch data logging with complete batch records for material weights, temperatures, times, and batch IDs.
- Truck count and daily production totals for shift-wise and daily production reporting.
I/O Summary
I/O Capacity & Configuration
Our Clients
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Frequently Asked Questions
Infrastructure / R&B Automation Questions, Answered
The system controls cold aggregate dosing, dryer and burner management including coal burner with direct ignition, dust collection, bitumen and filler handling, hot bin management, fibre feeding and weighing, mixing drum, and truck loading - all from a single centralised SCADA operator station.
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We develop SCADA automation for asphalt batching, concrete batching, and infrastructure plant applications - with batch reporting, gravimetric control, and truck loading automation. Contact us for a scope discussion.