Intelligent bulk silos prevent downtime and promote efficient logistics

Construction is digitizing and industrializing. As early as 2006, Weber Beamix introduced a first application of Electronic Silo Management (ESM) for masonry and screed mortars that continuously measures and calculates the current silo contents. With ESM version 2.0, Weber Beamix goes one step further and can even determine the content of bulk silos containing grout mortar, an extremely fine and dry substance. A welcome addition for foundation specialists, such as High 5 Solutions, to avoid downtime or overkill.

The ESM system communicates current data from the silo at the construction site, such as energy consumption, any problems preventing the process, as well as current contents. "The system has existed in the base for almost seventeen years and was initially developed to properly coordinate color determinations and contents of masonry and permeable mortars with customers," says Edwin de Blois, key account manager at Weber Beamix. "We are a company that listens to the needs of our customers and innovates constantly based on that. In discussions with foundation specialists, it became clear that they too needed up-to-date information on silo contents. But the fine and dry grout they use to make the grout mixture was difficult to measure until recently. With ESM version 2.0, that is a thing of the past."

Estimating consumption

The consumption of grout mortar is also difficult to estimate, according to Udo Snijer, product manager for concrete at Weber Beamix. "Foundation companies never know in advance how much material it will take to turn down the facing. It's impossible to predict. Then again, if you don't have an exact picture of the volume of the bulk silo, the situation becomes dire at some point. You don't want such a huge foundation machine to break down. After all, that would cost a lot of money. So what often happens now is that an extra load of grout mortar is ordered as a 'precaution', so that they can be sure that, for example, those last three piles can be made. Afterwards, it turns out that they could still manage with the remainder in the silo. In short, not exactly efficient, let alone sustainable because of the unnecessary loads. Moreover, the tons that have been called out also have to be paid for."

2-line control

ESM 2.0 monitors the current content of the bulk silo. "Based on a set limit value, a signal can be automatically sent out to the work planner or foreman. But the system is so intelligent that we can also proactively anticipate consumption." Arie van Vliet of High 5 Solutions can confirm this, saying, "Our guys on the construction site have a pretty good idea of when to call in a silo fill, especially since our mixing plant is equipped with its own weighing system. With ESM 2.0, we actually have double assurance of consumption, and that benefits quality. It allows us to control what we are doing even better and that is very valuable. It is also very pleasant that a party like Weber Beamix thinks proactively about transport planning in order to work together towards an optimum."

"Also at Weber Beamix, we get a better idea of what we can expect on a daily or weekly basis, so that we can adjust transport and logistics on the construction site more efficiently accordingly," says Snijer. "After all, a truck coming to load and unload always causes inconvenience. You want to limit that as much as possible. So with ESM 2.0, we are making a huge efficiency improvement and preventing failure costs due to equipment that falls silent. We are going to roll out the system more widely early next year, also for other product groups with a high throughput."