Building Products Process Control System

Minimising Downtime

Imperium4Batch is an advanced process control system built on Industry 4.0 principles, designed to handle the diverse demands of construction materials manufacturing. Its versatility makes it ideal for managing both bulk and liquid blending applications across multiple plants.

By using recipe-driven steps, Imperium4Batch automates sequential production actions, offering far greater flexibility than traditional ingredient-based systems. With its user-configurable functionality, new steps can be easily created and integrated into the process, allowing manufacturers to quickly adapt to changing plant requirements and production needs, ensuring precise control and operational efficiency.

Imperium4Batch Logo | Process Control System

Imperium4Batch Overview

  • Overview

    Imperium4Batch is a process control, planning and information system that is designed for specialist batch manufacturing plants in various industries such as asphalt and aggregates.

    Imperium4Batch is simple and intuitive to operate. It provides highly sophisticated techniques to optimise production and allow unmanned operation where possible.

    Imperium4Batch is fully user-configurable and built from a number of modular blocks to control your plant. This includes the intake of raw materials, blending, grinding and mixing of batches, Machine control and bulk outloading / packing.

    The system is fully scalable and can be configured for all batch processes, from the smallest to the largest of plants. It may be used to control one area of a plant initially and then be extended as circumstances permit. Many modifications can even be made to the system even while production is running.

  • Front to Back Control

    Imperium4Batch may be used to control:

    Weighbridge in, intake/receiving, weighing and batching, hand weighing, disperser control, mixing with liquids control, routing to finished product vessels, filling/packing machines, bulk out loading, packing, warehouse, weighbridge out.

    Imperium4Batch has a built-in simulation system which is a useful testing and training facility.

    When the system is configured with real-time simulation parameters, it can be used to help engineers redesign a plant and identify potential bottlenecks.

  • Standard Hardware & Mobile Control

    Imperium4Batch is based on one or more standard Microsoft Windows PCs and readily connects to most common PLC and Input/Output systems e.g. Allen Bradley, Mitsubishi and Siemens. This allows competitor or legacy process control systems to be economically upgraded with minimal disruption and wiring changes by reusing the existing PLCs.

    Windows server may be used for larger systems with Thin Client PCs used for operator workstations. Thin Client computers are suitable for industrial environments as they do not have a hard disk. This makes them easier to set up and they are more rugged and more reliable.

    Imperium4Batch’s software is a mature and well proven system with many installations across the world. Imperium4Batch has an secure menu system that prevents unauthorised access. In the unlikely event of a serious fault with the control server, a standby server can take over to minimise downtime.

    A rugged PC that has been installed with Imperium4Batch, allowing operators and maintenance staff to go about their tasks without having to be tied to a workstation. All the facilities of Imperium4Batch are particularly useful when you are on the move.

     

     

  • Logging & Reporting

    Imperium4Batch will log all intake transactions, batch records, stocks audits/alarms, usages, production, pellet press/extruder runs and outloading transactions. This data is stored online for up to seven years and can be viewed with Imperium4Batch’s simple-to-use facilities. This satisfies most site requirements and helps mills to achieve the required quality standards and approvals. Data may be printed and can be exported to a spreadsheet of another computer system.

  • Intergration

    Imperium4Batch has facilities to integrate with a wide variety of IT, ERP and formulation systems in the following areas:

    Intake/Receiving

    Order and production

    Batch production details

    Truck operations

    Bin/Silo contents

    Recipe, declaration and product information

    Imperium4Batch has been successfully integrated with Format International, Microsoft Dynamics, SAP, SAGE, Plex in addition to many bespoke and local systems.

  • Minimalist clock design with orange concentric circles on a black background

    24/7 Support and Built-in Redundancy to Minimise Downtime

  • Graphic of a finger pressing a red target on a black circle

    Browser Based User Interface

  • Two red gears in a circular outline

    User Configurable

  • Infinity symbol with concentric circles

    Software For Life

  • Icon of a stack of books outlined in orange within a black circle.

    Reduces Operator Workload

  • Expandable For Any Future Plans

Integrated Modules

OEE4Imperium Logo | Process Control System

OEE4Imperium is a web-based performance monitoring system designed specifically for feed and grain plants. The system collects data from the Imperium4Batch local control system and displays OEE (Overall Equipment Effectiveness) and KPIs (Key Performance Indicators) on a web page. The data can be drilled down to reveal more detailed data. The web page can be accessed on a local intranet or exposed to the internet for global access. The system can be set up with user security to prevent unauthorised access.

CMMS4Imperium Logo | Process Control System

CMMS4Imperium provides a method of recording information on all site equipment which may be used as an aid to planned and unplanned maintenance. It also provides a means of storing supplier information and sub-assemblies in stores. If linked to an Imperium4Batch control system, equipment run times and other totals such as the number of times a certain item has been started are updated automatically; therefore maintenance schedules are automatically updated too. Equipment faults can be reported by the operator by clicking on the item which in turn automatically creates a maintenance task.

Plan4Imperium Logo | Process Control System

Plan4Imperium is designed to simplify the process of scheduling orders for production by visually displaying the production program on a timeline and highlighting any potential problems. Plan4Imperium makes scheduling and planning simple and quick, prevents scheduling mistakes, warns of orders which are going to be late and minimises flush batches and die changes.

Logo with text "WMS4Imperium" featuring a geometric design."

The Warehouse Stock Tracking option is simple to operate and yet provides substantial benefits. Every time a pallet is produced, a barcoded ticket is printed and stuck onto the pallet. When a truck arrives to collect a delivery, a wireless tablet PC is used by the forklift truck (FLT) driver.

After entering the order number, the FLT driver wands the barcode of the pallets or part pallets collected. Codes and stock levels are instantly checked, preventing incorrect operations such as shipping the wrong pallet or missing items.

A complete and accurate stock record is always maintained, and details of all deliveries are logged. A variety of reports and printouts are available as standard. The system works with pallets of small bags, big bags, raw materials, finished products, packing materials and consumables - whatever you have in your warehouse.

Logo of Insight4Imperium company

Insight4Imperium is an online report viewing portal where your process data is exposed in the form of configurable dash boards, allowing you to gain insight to your factory's analytical data for continuous improvement of your process. Data Usage - Data is accessed from your Imperium4Feed system stored on the SQL database. Most dashboards have multi-tiered data - high level data that can be viewed with the option to dive deeper into additional details.

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