AUTOMATION SYSTEM

Automation systems play an equally important role in efficient asphalt production as the mechanical design and quality of the plant. At Sigma, we recognize the significance of a reliable and advanced automation system. Our state-of-the-art automation system is designed to ensure safe and efficient plant operation, while maintaining production capacity, optimizing energy consumption, and minimizing environmental impact. Let us now explore the unique features and capabilities of the Sigma automation system, which distinguish it as a cutting-edge technology for precision control and management of all production stages.

The system is designed to control all functions and production stages of the plant automatically which allows fully automatic operation of the plant without the intervention of the operator, provided that the material fed into the plant is in line with the set recipe and specifications of the plant. This makes the operation of the plant more efficient and less labor-intensive. Operators can also easily switch to manual mode if they prefer to.

The user-friendly software and programmable logic control system of the Sigma automation system allows for easy and intuitive control and management of the plant’s functions. The system provides the operator with an interface that is easy to use and understand, with all the necessary information and controls clearly displayed on the monitor. This ensures that the operator can easily monitor and control the plant’s functions, and make adjustments as needed.

The Sigma automation system has the ability to store a minimum of 100 different mix recipes and store and optionally print all batching data. It controls all functions of the plant, including metering at the prefeeders, control and display of the dryer and burner functions, control of the bag filter, temperature control and automatic adjusting, continuous control of aggregate levels at the hot silo, batching of aggregate-filler-bitumen into the mixer, and discharge of the hot-mix into the selected product silo section. The system also provides continuous online display of the production process and plant status, combustion data, and sensor data on the monitor.

The safety of the staff working at the site is a top priority for Sigma. Sigma automation system has been designed and tested according to EN IEC 62061:2015 standard, in order to ensure that any hazards are identified and eliminated before they can cause harm. All safety precautions have been implemented in the Sigma automation system at SIL 3 (Safety Integrity Level 3), which means that it has a very high level of reliability in ensuring the safety of the plant and the staff working on-site. The SIL 3 system achieves this high level of reliability through various safety features, such as redundant sensors and control systems, as well as fail-safe mechanisms that prevent any hazards from occurring. This level of reliability gives the operator and the staff working on-site the peace of mind that they are working in a safe and secure environment. Additionally, the SIL 3 system ensures that the plant is operating at its optimal level, with minimal downtime and disruptions due to safety issues.

The Sigma automation system is also designed to protect the plant by displaying warning messages to the operator whenever an inspection or intervention is needed, and to automatically stop the system in case of a failure to prevent any damage to the mechanical and electrical systems of the plant.

The control cabin of our Sigma asphalt plant has been meticulously designed to endure harsh environments and withstand various weather conditions. Built with insulated walls and equipped with air-conditioning, our control cabin ensures a comfortable and conducive working environment for the operator.

Taking ergonomics into consideration, the interior design of the cabin adheres to European standards, providing a seamless and user-friendly workspace. This focus on ergonomics enables the operator to work with ease and increased efficiency, contributing to the overall productivity of the plant.

At the heart of the Sigma control system are globally available top-quality European electric and electronic components. These components have been chosen for their proven reliability and durability thereby minimizing the risk of failures and ensuring uninterrupted operation of the plant.

The Sigma automation system is designed in-house by Sigma specialists, allowing any modifications to be implemented according to the clients’ specific requests. This ensures that the system is tailored to the client’s requirements, making the operation of the plant more efficient.

If requested, Sigma specialists can also access the plant’s control system remotely to analyse, identify and help with any issues that the operator may need assistance with. Our instant online technical service prevents unnecessary service trip costs and waiting times, saving valuable time and money for our clients.