In the business of aggregate processing, keeping operations running smoothly is a constant challenge. Over time, control systems evolve, expand or are subject to piecemeal replacement due to growth or equipment failure. What once worked seamlessly may now struggle to meet today’s demands for flexibility, efficiency, and productivity. The result? Increased downtime, inefficiency, and higher operating costs.
The harsh conditions of aggregate sites often lead to quick fixes when equipment breaks down. But these sticking plaster solutions might be holding you back. Fortunately, there is a smarter way forward where you do not have to overhaul your entire operation in one go. Instead, a well-planned, staged approach to digitalisation can yield rapid improvements, driving down costs and enhancing performance, all without massive investment or extended downtime. But first, you need to understand where all the problems are.
Why Digitalisation?
Digitalisation provides real-time insights into plant performance, helping you see where inefficiencies lie and show you where to make improvements. It delivers full visibility of plant assets, from availability to overall performance, enabling predictive maintenance and real-time control strategies. These insights help increase production capacity, reduce waste, and prevent unexpected shutdowns. Furthermore, it also supports new techniques and technologies that are constantly improving aggregate processing, such as innovative aggregate conveyor health management.
Here at BPX, we have a proven history in helping plants like yours implement tailored digitalisation programs, regardless of the size of your operation, budget, or goals. The process begins by identifying key objectives, often focusing on reducing energy costs and preventing the loss of critical assets.
Start Small, See Big Results
One of the main advantages of digitalisation is that you do not need to upgrade everything at once. By targeting known problem areas and pinch points, you can quickly see a return on investment (ROI) with manageable outlays. Many modern automation devices already generate valuable data, from energy usage to performance trends. They enable predictive maintenance that protects vital equipment and keeps operations running smoothly.
For example, focusing on energy-intensive assets or unreliable equipment delivers immediate benefits, such as reduced operating costs and increased uptime.
The Key to Success: Visibility and Control
The real power of digitalisation lies in providing a clear view of your entire plant. Understanding asset availability, monitoring for early signs of failure, and optimising the utilisation of critical machinery are essential steps to cutting costs and boosting productivity. Connecting all assets through a reliable infrastructure makes real-time control strategies possible. Thus, enabling you to adjust operations on the fly to meet production targets and minimise waste.
Tailored Solutions for Aggregate Processing
We offer a comprehensive suite of automation solutions designed specifically for the aggregates industry. From energy-saving variable speed drives (VSDs) to intelligent PLCs and network solutions for control and data aggregation, we have the tools to help you implement a successful digitalisation strategy.
For example, take Mitsubishi Electric’s ICONICS GENESIS64 software suite, which provides advanced analytics, producing detailed insights that help you maintain predictive maintenance schedules, monitor plant performance, and visualise data across the entire plant or specific areas. Whether deployed in the cloud or on-premises, these solutions deliver the critical information you need to keep your plant running smoothly and efficiently.
Achieve More with Digitalisation
With the right digitalisation strategy in place, your aggregate processing plant can become more responsive, reliable, and cost-efficient. Our local support network and Mitsubishi Electric’s Drives Systems Centres ensure that you have the expertise you need, whether you are enhancing plant visibility, improving uptime, or increasing flexibility.
Even a modest initial investment in digitalisation can unlock significant improvements in plant performance and profitability. A clear, staged approach with defined milestones will allow any plant, regardless of size, to benefit from greater visibility, better asset management, and more efficient operations.
Ready to Take the Next Step?
Start your digital transformation today by evaluating your current automation infrastructure. Our Applications Support Team and manufacuring partners are here to help you craft a tailored solution that fits your needs, drives down costs, and enhances productivity. With digitalisation, the future of aggregate processing is smarter, more efficient, and more profitable.
BPX are proud Innovation Partners of Mitsubishi Electric, and since 1989, the largest independent technical distributor of Mitsubishi Electric automation equipment in the UK. Should you wish to discuss your aggregate processing needs with a member of our Application Support Team and a Mitsubishi Electric specialist, please don’t hesitate to submit our contact form below, and we’ll be in back in touch at the earliest opportunity.
