Asphalt Controls

Our Asphalt product range and services deliver outstanding results.

Innovative Asphalt control solutions

Meet the 404 Family – an advanced, modular, integrated control system with advanced data-reporting capabilities.

Our 30+ years experience in Asphalt Controls has resulted the the 404 Family of Control Solutions. Each module is capable of seamlessly integrating with your existing systems to provide a powerful upgrade. As a complete solution, the 404 Family work together to deliver the most advanced Asphalt Control Solution available anywhere in the world. Each module of the 404 Family integrates with our advanced Cloud Storage Solution allowing your Plant Managers to remotely access comprehensive operational and performance information to ensure they are making data-driven decisions to improve efficiency, sustainability, safety and ultimately, profitability. Explore each module below or get in touch with one of our expert Asphalt Team to discuss the specifics of your Operation.

comprehensive product range

Five modules designed for each key area of asphalt manufacturing. The modules can be installed in isolation, or as part of a total plant controls upgrade.

MC404

Mix Controls

The new MC404 is designed to ensure you make great mix, every time, and has great reporting features to allow you to drive efficiency from your plant.

Features
  • It’s built on a modern software platform with easy intergration between other software, e.g. AC303, AC404, LC404, MC404, etc.
  • It has a more functional user interface for ease of display and operation.
  • Intuitive and fast access to station set ups, material set ups, mix designs etc.
  • Clear indication of out of limits or other alarms, with key operational information, including alarms, recorded to a database for reporting.
  • It has a built-in calibration mode for much easier calibration with no need to change start and stop delays.
  • Allowance for remote logging into PC to assist with problem solving
  • QA and Alarm database backed up to CATIE for remote access and graphing of process parameters
  • The software is branded with our customer’s logo.

All control modules come with full documentation including, where applicable, PLC code, functional descriptions, process flow diagrams, electrical wiring diagrams, commissioning sheets, and operational manuals.

AC404

Plant Control and Monitoring

Designed to not only control your plant operation, but to monitor and allow reporting on its key operational indicators.

Features
  • A PLC with a high performing CPU with best practice installation, and interfacing with propriety controls (e.g. burner etc)
  • The latest in safety interlocks
  • Sequencing starts
  • Sequencing stops
  • Mid-stream start/stops
  • Manual start/stop of motors/valves etc
  • All key operational information available at a quick glance
  • Recording of analogue values for QA
  • Alarm logging for QA
  • Allowance for remote logging into PC to assist with problem solving
  • QA and Alarm database backed up to CATIE for remote access and graphing of process parameters

All control modules come with full documentation including, where applicable, PLC code, functional descriptions, process flow diagrams, electrical wiring diagrams, commissioning sheets, and operational manuals.

AC303

Batching Control System

Smarter Batching with a Smarter Control System. Designed to transform productivity, product quality, and profitability with intuitive controls and better operational data.

It controls and monitors your conveyors, burner, drum, mixer, slats, running current, pressures, temperatures, blowers, gob hoppers etc. It also manages your mix designs, monitors and controls your hot bin, your weigh hopper, your bitumen and additive valves, mixing, and despatching from the mixer. All this in one package. The new AC303 is designed to not only ensure you make perfect mix, but to allow reporting on its key operational indicators to help managers drive efficiency through data driven decisions.

The AC303 utilises a propriety PLC for accepting all field instrument signals, loadcells, level switches, proximity switches etc, and control outputs i.e. motors, valves, rams etc. The PLC will be programmed based on our 30+ years’ experience in the asphalt industry. This experience ensures your plant has this expertise programmed into your plant’s operation. The HMI interface is designed on the latest windows’ platform, and has been designed on years of feedback from operators. It gives critical process information quickly and allows operators to manage their plant effectively.

Includes:

  • PLC with high performing CPU with best practice installation, and interfacing with propriety controls (e.g. mixer, loadcells, valves etc)
  • Sequencing starts
  • Sequencing stops
  • Manual start/stop of motors/valves etc
  • Built in safety interlocks
  • Easily customised to meet individual site’s characteristics
  • Real time display of weights
  • Smarts that compensate bitumen addition for actual dry mix weight
  • Automatic in-flight compensation for continuously accurate mix
  • Adjustable mix weight tolerance alarms
  • Two speed aggregate filling
  • Allowance for manual overrides and pausing of mix
  • Built recipes database with ability to easily add, change and load.
  • All key operational information available at a quick glance
  • Recording of process information for QA
  • Alarm logging for QA
  • Allowance for remote logging into PC to assist with problem solving
  • QA and Alarm database backed up to CATIE for remote access and graphing of process parameters
  • All control modules come with full documentation including, where applicable, PLC code, functional descriptions, process flow diagrams, electrical wiring diagrams, commissioning sheets, and operational manuals.

Includes:

  • Hardware can be either a remote IO from master PLC, or individual PLC.
  • Communicates to TC404 HMI software.
  • Built in interlocks for delivery, or dispatching of product.
  • Full integration with our other control modules.
  • Heating timers.
  • Remote alarm notification via SMS or cellphone.
  • Analogue readings, event logs, and alarm recording to database for QA purposes.
  • QA and Alarm database backed up to cloud for remote access.

TC404

Tank Control 

Safely Managing your Tank Operation.

The TC404 module is designed to control and monitor your bitumen storage and delivery. It puts safety first while also recording key operational parameters to drive sustainability and profitability.

It utilises a propriety PLC for accepting all field instrument signals and control outputs i.e. motors, valves, levels, temperatures. The PLC will be programmed based on our 30+ years’ experience in the asphalt industry. The HMI interface is designed on the latest windows platform and gives operators a quick and easy view of key operating parameters. It gives visibility and control over the bitumen tanks management and therefore significantly reduces H&S and operational risk.

The TC404 takes the manual process out of the tank operation and greatly increases safety. It also allows monitoring and control of key operating parameters to increase sustainability by reducing energy use, and boosting profit.

LC404

Loadout Control

The new LC404 not only manages the loadout of your products but also includes truck safety, job management and integration to 3rd party software to give greater efficiency to your plant.

The new LC404 not only manages the loadout of your products but also includes truck safety, job management, and integration to third party software for inventory management, invoicing etc. The smarts built into the LC404 allows for greater efficiency for your plant and thus profitability.

The new LC404 is designed on a modern platform with ease of use and functionality being the key features to the new design. It increases profitability by increasing efficiency and helping to reduce errors in recording loadout and has inbuilt flexibility for each site’s unique application.

The LC404 includes product database, customer database, and truck/driver database that can be altered remotely or manually. It also has additional features including truck safety i.e. building in safety interlocks that ensures the truck is at the correct hot bin, and the operator can’t open any other hot bin door. It also has a Job Management feature that records what has been delivered to what job, when, and includes default instructions e.g. delivery information etc.

Includes:

  • Easily integrates with our other newly released software modules
  • It has a very functional User Interface for ease of display and operation
  • Allows set up of individual truck/drivers for efficient entering of loadout information
  • Allows set up of individual products for efficient entering of information
  • Allows set up of individual customers for efficient entering of loadout information.
  • Allows set up of individual jobs for efficient entering of loadout information including auto-filling of customer, mix, and delivery details. The jobs allow for cumulative totalling to be shown on the individual dockets for each job.
  • Allows dockets to be printed as per customer’s layout/logo and design. Dockets can also be reprinted if necessary.
  • Allows option of Night weighing, which is the management of loadouts at an unattended site, but still allows for the existing safety interlocks, and recording of load outs.
  • Production of an End of Shift report that will display a summary of all loadouts during that shift and allow correction of entries if required. This report can be automatically emailed to a nominated email address or saved to a file.
  • Recording of process information for QA
  • Alarm logging for QA
  • Allowance for remote logging into PC to assist with problem solving
  • QA and Alarm database backed up to CATIE for remote access and graphing of process parameters
  • All control modules come with full documentation including, where applicable, PLC code, functional descriptions, process flow diagrams, electrical wiring diagrams, commissioning sheets, and operational manuals

 

CATIE

Cloud Based Solution

CATIE (Cloud Access Total Information Exchange) gives you the critical process information to make data driven decisions.

Each of our new generation Asphalt Control modules (MC404, AC303, AC404, TC404, and LC404) have the capability to securely connect to CATIE to allow the user-friendly display of the plant’s process information. It allows this data to be exported, cut, sliced and diced any way you like to identify how to drive the greatest sustainability from your plant. It allows you to show as many or as few parameters as you would like to display.

CAITE allows for full remote monitoring and storage of your operating data. You will be given a unique login that will give you access to current and historic plant information. This is perfect for enabling key plant operational information to be remotely monitored and allows managers to make data driven decisions to improve sustainability and drive profitability. This information is shown in either table or graphical format and can be exported for external reports. It also backs up all your key plant parameters ensuring calibration information is backed up.

CATIE utilises its own onsite cellular modem, independent of any other network, to transmit the package of data to its remote server. With a local database storing the plant information, it will ensure no disruption to the data being stored to CATIE in case of loss of connectivity.

CATIE, working with N2P Controls’ latest generation software, will give plant managers the tools to drive the greatest sustainability and profitability from their plant.

SERVICES

With 30+ years’ experience in asphalt manufacturing, we offer more than just world leading controls. We can assist with completing plant audits, safety audits, training, servicing, producing process flow diagrams, and updating documentation.

With the experience gained in being involved in over a hundred different asphalt plants, we can share this combined experience to help identify areas of improvement with your plant. We have several engineers that can come to site and complete a site audit to identify potential areas of improvement to help your plant be as sustainable and profitable as possible.

It’s the little things the keeps our customers coming back, and we pride ourselves on the extras.