Inventory monitoring
Every silo at a glance
For each silo you immediately see the material, bulk density, fill percentage and current inventory in tonnes — including the next scheduled delivery.
02 / Material
Material conveying, silos and inventory.
Control systems for material handling, central material conveying systems, dryers, valves, silo measurement and alarm notifications — so the right raw material is always in the right place.
Reliable production starts with a reliable material flow. Prime Solutions builds the control systems that move your raw material automatically and in a controlled way from silo to machine. From central material conveying systems and vacuum conveying to dryers and valves: everything is operated from one clear installation control system.
With silo measurement and inventory monitoring you keep continuous track of your stock levels and material consumption. If a silo is about to run empty or a fault occurs in the conveying system, an alarm is triggered immediately — so you can intervene before production comes to a standstill. We also include the control of silo discharge equipment in the design.
Silo measurement with its own management system.
The silo management system by Prime Solutions continuously measures the level of each silo and translates it into inventory in tonnes — locally on the touchscreen and, if desired, connected to Prime Control.
Level measurement
Inventory as a bar chart
All silos side by side in tonnes: at a glance you see which silo needs attention and when a new delivery should be scheduled.
Configuration
Silo geometry and sensors
For each silo, shape, height and diameter are configured for an accurate volume calculation, complemented by rotary paddle sensors for full, mid and empty detection.
Material management
Raw materials and batch numbers
Raw materials are managed centrally with bulk density and supplier, and assigned per silo — including batch numbers for traceability.
Trend & monitoring
Weight trend per silo
Each silo has its own detail screen with weight trend, full, half-full and empty monitoring, dryer alarm and the current supplier and batch data.
Controlled filling
Filling without surprises
The filling couplings are mechanically locked. Only when the warehouse operator selects the correct material in the system — matching the contents of the silo in question — is the coupling released. This makes it impossible for the wrong material to end up in the wrong silo. Every delivery is registered with batch number and weight, and the system monitors how much capacity remains.
Material conveying system with web-based control.
Prime Solutions developed its own web-based control system for central material conveying systems: up to 40 hoppers per group, with multiple groups possible. Operable from any PC or tablet in your network and connectable to Prime Control. Also available as a replacement for the existing PLC control of your current conveying system.
Smart queue
Priority determines who conveys first
The queue is processed by priority and waiting time — critical machines first. Deviation detection flags hoppers with intake faults before production is affected.
Up to 40 hoppers per group
Every hopper tracked in real time
Who is conveying, who is requesting, who is in fault — plus conveying cycles and intake time per hopper. So you see which machines consume the most material.
Central vacuum pump
Frequency-controlled and energy-efficient
The right pump speed per hopper, adjustable ramp-up and run-on times, and a timeline that shows where energy can be saved.
This web-based control works alongside the HMI on the installation — an HMI is always present — and runs in any modern browser. The system status can also be displayed live on shopfloor screens in production, and the whole can be connected directly to Prime Control for inventory monitoring and reporting.
Coupling station control.
The coupling station determines which material line is connected to which silo, dryer or machine — and that is exactly where things often go wrong in practice.
With a coupling station control by Prime Solutions, every connection is monitored and registered. Conveying is only released when the correct line is actually coupled — preventing material cross-contamination, contaminated batches and unnecessary downtime. Every change is logged, so it can always be traced afterwards which material followed which route.
- Position detection per coupling — no release without the correct connection
- Alarms for an incorrect or missing coupling
- Registration of material routes, connectable to Prime Control
Ready to make your installation smarter?
Discuss your control system, retrofit, central material conveying system, silo measurement system or Prime Control integration with Prime Solutions.