We’ve delivered comprehensive automation solutions for the refractory industry, covering everything from raw material handling to kiln control. These environments demand durable automation that works reliably in dust-heavy, heat-intensive, and batch-sensitive conditions — and that’s exactly what we built.
Raw Material Handling
We automated the movement of powder-based inputs using silos, feeders, elevators, and conveyors — all synchronized via interlocks, level sensors, and timers to minimize material loss and ensure continuous flow.
⚖️ Batching Units
Accurate batching is key to product strength and consistency. Using load cell-based weighing systems, we deployed recipe-driven control logic for multi-material dosing, tailored for bricks, castables, or custom mixes.
️ Dryer Automation
Dryers were equipped with PID-controlled temperature loops, airflow control, and cycle timers. The system maintained drying curves based on material type, while safety logic handled blower interlocks and over-temp trips.
Kiln Control Systems
We provided logic for burner control, temperature ramping, and soak time management, fully customizable per batch. Safety interlocks, logging, and automatic shutdown logic were integrated.
Energy Recovery Integration
To improve energy efficiency, we implemented waste heat recovery systems:
- Hot air or flue gas redirection from kilns to pre-dryers
- Heat exchanger logic controlled via temperature feedback
- Interlocks to protect equipment and maintain stable operating ranges
- Monitoring of energy savings and outlet/inlet temperatures on HMI
This allowed re-use of thermal energy, reducing fuel consumption and supporting sustainable operation.
Platform Flexibility
Depending on plant size and customer preference, we implemented control using:
- Siemens PLC + HMI/SCADA
- Allen-Bradley (AB) PLC for North American systems
- Delta PLCs for compact and cost-sensitive solutions
For most stations, an HMI was sufficient for operation and diagnostics. In larger, multi-zone systems — such as kilns and dryers with batch tracking — we deployed SCADA systems for centralized monitoring, recipe handling, and historical trend logging.
✅ Project Outcomes:
- Consistent batching and quality output
- Lower maintenance and manual intervention
- Greater control over drying and firing processes
- Scalable architecture, from standalone HMI to full SCADA-based control
This work reflects our ability to automate harsh industrial processes using the right hardware and control philosophy — whether it’s a compact machine or a full plant.