Automated loading base management with ERP integration and multi-compartment truck handling.
Industry: Oil & Gas / Logistics
Quick Facts
| Attribute | Value |
|---|---|
| Scale | 84,284 tags, 3,576 communication points |
| Loading Bays | 30 bays |
| Screens | 79 displays |
| Servers | 3 (1 database/application, 2 redundant operation) |
| PLCs | NEXTO 3030 |
| Clients | 5 concurrent |
The Challenge
Challenge: Implement comprehensive loading base management to automate access control, manage loading operations with precision, handle multi-compartment vehicles, and provide real-time data with ERP integration.
Specific pain points:
- No integrated solution for loading diverse products (milk, chemicals, fuel, grains)
- Manual access control and bay assignment inefficient
- Multi-compartment tanker trucks require precise product-specific filling
- Lack of real-time operational data
- Disconnected systems between loading operations and ERP
Impact: Manual processes causing delays, errors in product allocation, and inability to track operations in real-time.
The Solution
Architecture
| Tier | Component | Capabilities |
|---|---|---|
| Field | Presets, TEDs, PLCs | High-precision milliliter meters, valve control |
| Central | 3 servers (redundant) | Database, application, operation |
| Integration | ERP connection | Order management, tracking |
| Clients | Web interface + 5 stations | Registration, configuration, operations |
Automated Workflow
- Orders inserted into system
- Truck arrives with barcode tag
- System reads barcode, assigns bay
- Multi-compartment filling (different products per compartment)
- High-precision metering (milliliter accuracy)
- Real-time tracking to ERP
Scale
| Metric | Value |
|---|---|
| Tags | 84,284 |
| Communication Points | 3,576 |
| Screens | 79 |
| Loading Bays | 30 |
| Clients | 5 |
Key Features
- Runtime mode allows adding screens and information without downtime
- OPC Server connected to PI system with auto-create tag functionality
- Web interface for registration and configuration
Key Enablers
FrameworX capabilities that made this solution possible:
| Capability | Application |
|---|---|
| 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 and ERP |
| Scalable Architecture | Redundant server configuration for operational continuity |
| Runtime Flexibility | Dynamic screen and information addition without downtime |
The Results
Fully Automated Operations — Established automated loading base managing 30 bays
Complete Traceability — Achieved end-to-end tracking from order entry to product delivery
Eliminated Manual Processes — Automated truck routing and product allocation
Real-time Visibility — Provided instant visibility of all loading operations with high-precision measurement
Scalable Solution — Delivered redundant, ERP-integrated system ready for expansion
Runtime Customization — Enabled operational changes without system downtime
This case demonstrates automated loading base management with barcode identification, multi-compartment handling, and ERP integration.