Case Study · SCADA + PLC

Concrete Batching Plant Automation

Full automation of a concrete batching plant with recipe control, weighing accuracy, and production reporting.

±0.5%

Batch accuracy

100%

Manual entries removed

Automatic

Report generation

35%

Downtime reduced

The Problem

What the plant was facing

The plant was running on manual switchgear with inconsistent batch quality, no traceability, and frequent rework. Operators had no live visibility into aggregate/water/cement dosing, and reports were maintained by hand — making audits and dispatch reconciliation slow and error-prone.

Our Solution

What we engineered

Designed a Siemens S7-1200 based PLC control system with load-cell weighing for aggregates, cement and water
Custom SCADA with recipe management, batch sequencing, and truck-wise dispatch tracking
SQL logging of every batch with material consumption, moisture correction, and operator ID
Weintek HMI for operator control with live schematic view, alarms and manual override
MCC + PLC panels with VFD-driven conveyors and safety interlocks

Tech Stack