1. The Problem

The loading base facility needed a comprehensive system to manage and control the loading of diverse products (milk, chemicals, fuel, grains, etc.) across multiple loading bays. The facility lacked an integrated solution to automate access control, manage loading operations with precision, handle multi-compartment vehicles, and provide real-time operational data while maintaining seamless connectivity with the company's ERP system.

2. The Solution

The Loading Base Project was implemented with an integrated interface that manages all hardware, controls loading operations, and provides real-time data. The solution includes a WEB interface for registration and configuration of all process data and base customization.

The system automates the entire workflow: orders are inserted into the system, and from there, all access control and loading operations are automatic. When a truck driver arrives at the gate with a barcode tag, the system reads the information and directs them to one of 30 loading bays containing the required product. The system controls high-precision milliliter meters and manages multi-compartment tanker trucks, where each compartment can be filled with different products (gasoline, kerosene, etc.).

             [ERP System]
                     |
            [Application Server]
                     |
    ??????????????????????????????
    |                              |                         |                 
[DB Server]   [Primary Server]  [Backup Server]         
    |                              |                          |                 
    ??????????????????????????????
                     |
          [OPC Server → PI System]
                     |
        ???????????????????????????
        |                       |              |
  [NEXTO PLC]   [Presets]    [TEDs]
        |                       |              |
???????????????????????????
 |                           |                  |                      |               
 [30 Loading     [Flow      [Barcode          [5 Client          
    Bays]           Meters]    Readers]        Workstations]      


Technical Architecture:

  • Servers: 3 servers total - 1 for Database and application server, 2 for software operation and redundancy

  • Network Integration: Connected to presets, TEDs, and PLCs controlling various loading base processes

  • ERP Integration: Connected to company management system

  • Runtime Capability: Allows adding screens and information in runtime mode

  • OPC Server: Connected to PI system with auto-create tag functionality

  • System Scale:

    • Tags: 84,284

    • Communication Points: 3,576

    • Screens: 79

    • PLC: NEXTO 3030

    • Clients: 5

3. Key Enablers

  • Automated Access Control: Barcode-based truck identification and automatic bay assignment

  • Multi-Product Handling: Support for multi-compartment vehicles with different products

  • High Precision Measurement: Milliliter-level accuracy in product dispensing

  • Real-time Data Integration: Live connectivity between field devices, control systems, and enterprise applications

  • Scalable Architecture: Redundant server configuration ensuring operational continuity

  • Runtime Flexibility: Dynamic screen and information addition without system downtime

  • Comprehensive Integration: Seamless connection between PLCs, presets, TEDs, and ERP systems

4. Results

  • Established a fully automated loading base management system controlling 30 loading bays

  • Achieved complete traceability and control from order entry to product delivery

  • Eliminated manual processes in truck routing and product allocation

  • Provided real-time visibility of all loading operations with high-precision measurement

  • Delivered a scalable, redundant solution integrated with existing ERP systems

  • Enabled runtime customization capabilities for evolving operational needs

  • No labels