MC 500

Control system for batching plants

Control systems for batching plants from Stetter

The optimal solution

for every batching plant
Stetter has wide experience gained over many years in the development of process control systems for concrete
batching plants, and has become a market leader in plant and control configuration for just this very purpose.
To protect the customer’s investment is our main duty and means that we at Stetter input a maximum in servi-
ceability, functional reliability and professionalism into our plants and our control systems. After all, customer
satisfaction is a premium and has been demonstrated in more than 1,000 installed control systems all over the
world.

Flexibility and security of investment

The architecture of the Stetter software, custom-developed in our own
R&D department, and the multiple configuration possibilities that arise
from that, make it an easy task to adapt a plant control system to any
existing production process. Circuit arrangements, switchgear cabinets
and the relevant circuit and wiring diagrams are all worked out in our own
engineering division and are optimally adapted to Stetter batching plants.
Our system flexibility even allows us to custom-build control systems for
use in other makes of batching plants.

Proven solutions for the concrete industry

The commercial industrial production of concrete calls for more than just
an elementary batching plant control system. A comprehensive package
to satisfy the concrete producer and his customers covers a series of
tasks ranging from the initial quotation to production planning, the pro-
duction of the concrete itself and the management of mixer and pump
fleets, right through to the issuing of the invoice for the concrete deli-
vered. In addition, the correlation of various statistics for production and
accounting management must be taken into account. For companies that
operate several batching plants in a company frame, it is essential to
have a network running on a common database that can provide instant
transparency for the management. This is exactly the point where Stetter
offers customized, but also standardized, solutions.

The optimal control for every batching plant Quality, reliability and safety
Every Stetter plant control system is available in your language. The When choosing hardware components, we select only proven and
MC 110 control system, for example, is the solution for plants with batch high-grade material that is reliable enough for our requirements. But
sizes up to 1 m3. For larger batching plants, networked plants, or plants whatever the brand or make of component, it must pass our stringent
with special requirements on delivery note printing and statistics, the QC testing simulations even during the development stages. Constant
MC 500 is the recommended control system. final acceptance tests are also essential for long-term product quality
and reliability, naturally always with ISO 9001 certification. Of course, we
comply with the Machine Directive IEC 62061 and ISO 13849.
 Electrics MC 500 Batching plant control system

Power unit
At Stetter, we develop and make our own HV modules in consideration of
all relevant international, national and safety standards.
Circuit and current-flow diagrams are generated on our CAD system and
are supplied as hard copy and in .pdf format.

Control with investment security

The batching plant controller program runs independently of the main
processor on its own PLC (programmable logic control). Such systems
have proven their value not only in the concrete industry but also in
many other industries. The clear separation of “jobs” makes it possible
to keep the systems easily “up to date” and make use of the latest
technological developments. The result is a family of hard-ware and
software that is on the one hand reliable and ro-bust, on the other easily
extendable to future needs.
Following our concept, the main processor runs only the backbone func-
tions of the plant. The “real-time” jobs are undertaken in the PLC which
is easily accessible but pro-tected inside the main switch cabinet. Stet-
ter control systems use exclusively the SIEMENS PLCs, thereby ensu-
ring a maximum level of quality in a state-of-the-art form and with easy
exchangeability. All for the benefit of the customer in long years of plant
op-eration.

Modular through the use of

industrial-ethernet
We make extensive use of BUS systems not only with comply to today’s
requirements, but also to maintain the flexibility required for tomorrow’s
tasks. The difference to other systems is that the BUS does not have each
signal line running from limit switches, etc., through the whole plant and
into the controller area. The BUS registers the signal on the spot and then
transmits through the main BUS line. That greatly reduces the comple-
xity and expense of the overall plant wiring system and therefore greatly
reduces the number of potential errors or faults that might occur. It also
allows easy upgrading and extension to cover more tasks.
Overview MC 500 Batching plant control system

MC 500 BATCH MC 500 DISPO MC 500 FMS MC 500 FAKTURA MC 500 SYNC

Dosing and Database-

Dispatching Fleet Management Invoicing
Batch Control Unit synchronization

Order Management Order Management Truck Tracking Invoices Synchronisation of

Production Production Planning Street Maps Offers Separated Databases
Statistics Truck Planning Route Planning Turnover Statistics
Pump Dispatching Navigation

MC 500 Base
Database, Data Management, Data Permissions, Basic Functions

The MC 500-family MC 500 in network

MC 500 is a family of software modules all built on the same software plat- MC 500 can be adapted to the user requirements either as a workplace
form and with a common operator interface. Features to which we have solution or in an integrated network. Networking of individual workplaces
attached priority importance to ensure perfect intercommunication perfor- is the solution to cope with increased workloads, or to connect several
mance. Each module is designed and keyed to fulfil the customer’s requi- batching plants from one management desk.
rements and according to the registered operator rights. The hierarchy of
operator rights determines who can view and process the operating data.
Data security inclusive
Each module can be run from any connected workstation to give optimum
flexibility in personnel deployment. Our professional client/server database is the foundation for a multi-net
and transparent data archive. Other than with expensive solutions ba-
sed on a central server, we install an individual database server on each
production PC. Such local data archives are essential when networking
several batch-plant control systems in a group management net.
In case of net failures (e.g. during servicing work) the production can still
continue, thanks to an intelligent synchronizing module that caters for
synchronization of the databases.

VPN / Internet

GSM-Provider MC 500-Batch MC 500-Batch MC 500-Batch

local database local database local database

MC 500 MC 500-Dispo MC 500-Faktura Sales Management

database-server Dispatching Invoicing
 MC 500 Batching plant control system

Availability always and everywhere Always in the picture

Our synchronization module uses a configuration table to determine Data from the selected record are shown immediately on the screen,
which data sets need to be synchronized with the connected databases. which saves tedious opening and closing of individual dialogs. In addi-
We have taken this “lean approach” because it is not always necessary tion, the data can be edited online. When workstations are networked,
to have all data available at each and every workstation. In this way, we any editing or change in data records is passed in real time to the other
reduce communication expenses to a bare minimum stations in the net. Free arrangement of the spreadsheet columns makes
it easy to match the tables to the plant’s requirements. Redundant co-
lumns in the sheet can be erased to give a clearer overview of essential
Recipe management information. Another feature of MC 500 is its universal search function,
The recipes contain all of the standard EN 206-1 required information. where each column in a data list can be used as a search criterion. Each
They are managed centrally in the network. A plant-specific modification input of a letter reduces the number of found records.
allows you to adapt to a single batching plant.
BATCH MC 500 Batching plant control system

Daily production Alternate silo

The day’s planned production is listed in a table that can be extended at As soon as a binder silo runs empty (during production) a mouse-click is
will or kept at just the one day. The same list is used as the basis for prin- all that is needed to call up the next (alternate) silo so that production of
ting delivery notes and can also serve to select the requested truck mixer, concrete can continue without any interruption.
the amount of concrete shipped out, or the amount of returned concrete.
Naturally, multi-mixer plants can run on parallel production of two diffe-
rent recipes. A great boost, especially when one mixer is occupied with Consistency control
special mix designs requiring extended mix cycles. The weighing system, Many applications, but especially prefabrication plants, require exact
however, will usually be free and can therefore be utilized by the second compliance to predetermined concrete consistencies. The Stetter soluti-
mixer. Production cycle commences as soon as a weighing system beco- on is to meter the consistency in the mixer at the very time of mixing the
mes available. If a mixer has two discharge chutes, a priority batch can concrete and to add additional water in small quantities up to the required
be mixed and loaded into a second truck mixer while the first one remains content.
in position under its chute.
That proves a great advantage in plants that produce for ready-mix and
for prefabrication plants.
 MC 500 Batching plant control system

Moisture measurement Maintenance function

Optional moisture probes monitor the surface moisture of gravel and sand MC 500-Batch records during production the operating hours and the
and compensate in real time and within the actual quantities of water to quantity produced for required maintenance. A list of overdue maintenan-
be added to the mix. The probes can be easily calibrated using the MC ce work can be printed. With a history function the com-pleted work are
500 software. documented. With this function, you can prevent effectively unexpected
failures of plant components.

Consistency record
The consistency of each mixer batch is shown in a different color. The
calibration of consistency depends on the mixer or of the recipe.

Raw material stocks

The graphical display allows level comparing measured and calculated
silo stock. The measured level is available only for silos with integrated
level measurement.

Manual operation (optional) Manual operation per mouse click

Of course, additional material can be dosed via a manual operating level. With the detailed and animated process visualization, the mixing plant
MC 500 registers each a weighed material and designates in the produc- can be controlled manually.
tion protocol and in the consumption statistics the weighed components
and quantities. So you do not lose any material.
BATCH MC 500 Batching plant control system

Sampling schedule
The European standard EN 206-1 stipulates precisely when concrete
samples are to be taken and the number of samples required for a parti-
cular concrete family.
MC 500 gives the operator a message that a sample needs to be taken.
The message is generated from a background program that is continually
updated after every single production and is therefore permanently up-
to-date. Such a facility is usually part of a separate laboratory software
package, but with MC 500, it is already on.

Timing diagram
A graphic display showing the step-by-step processes with the batching
plant running in operating mode is especially useful during commissio-
ning and when fine- tuning the plant’s performance
On demand, MC 500 records the process chain and maps them in a
timesheet form. With this information parameters can be optimized.

Production logbook
Material Management (if required)
Every stage of production and any fault or failure event is strictly regis-
tered in the logbook to allow a detailed production analysis at any time. The host computer controls of the filling of aggregate or binder silos. If
additional external storage silos are available, then it makes sense to fill
the main silos automatically.
Delivery note
The delivery note is printed to your specifications, as well as on demand a
calibrated delivery note reprint. For different order types (concrete, mort-
ar, etc.), you simply define your own forms.

Grey water consistency

Optionally, you get a gauge for determining the slurry water density. De-
pending on the density of the slurry water the fines (cement) is automati-
cally detected and corrected for each batch. Alternatively, enter the slurry
water density manually.

Barcode Scanner for recording

Self-learning in-air compensation deliveries of material (optional)

The last runnings of material depend firstly on the material itself and Optional delivery notes of incoming material deliveries can be recorded
the degree of filling of the aggregate or binder scales. Our MC 500 has with a barcode scanner. All necessary information, such as supplier, type
a self-teaching program that registers the overrun for each silo and for of material, quantity and delivery note number will be read and stored in
three different scales fillings. the system. The silo to be filled is then automatically selected. A wrong
silo selection is thus prevented. Talk to us, we have ready-made solutions
at hand.
MC 500-Disposition Graphically planning of deliveries
MC 500-DISPO is the answer to production planning problems. When the In the graphical overview you can see at any time the planned produc-
order is accepted, you determine which plant has to carry out the produc- tions. The automatically created plan can of course be modified using the
tion. The color display of orders will help you to keep track. With the ability mouse. A simple movement suffices.
to split single jobs on different plants, may be provided for a uniform uti- If a plant is congested at a certain time, then a delivery or a complete job
lization of the plants. The scheduling of the trucks is done automatically. can simply be assigned to another plant.

„No-Go“ mixers Integrated pump fleet dispatcher

The database automatically rules out truck mixers that are not suited to MC 500-DISPO not only acts as a plant and truck mixer manager. It can
certain job sites. And it takes the drivers’ working hours into considera- also be used as dispatcher for truck-mounted concrete pumps.
tion as well. Pump orders can be booked individually or together with a job to deliver
concrete. Any changes in mixer delivery schedules are immediately re-
flected in the time booked for the concrete pump.
Fleet Management System MC 500

MC 500-FMS Close as necessary with the map view

A useful extension of the MC 500-Dispo is the fleet management system Mit Hilfe von Zoom- und Verschiebefunktionen können Sie den optimalen
MC 500-FMS. Here your vehicles are equipped with an on-board pro- Kartenausschnitt wählen. Auf einfache Weise können Sie verschiedene
cessor for satellite navigation. Depending on the version, various sensors Kartenausschnitte hinterlegen und mit einem Mausklick darstellen. Bei
can be connected. der Positionsabfrage eines Fahrzeugs wird der Kartenausschnitt so geän-
All the relevant status messages (Arrival construction site, beginning dert, dass das Fahrzeug sichtbar wird. Ein zusätzliches Ausschnittfenster
discharge, leaving construction site, arrival work, etc.) are automatically hilft den Überblick zu behalten. Es dient Ihnen einfach als Navigations-
without manual intervention by the driver, generated. hilfe. Notwendige weitere Informationen wie Fahrzeugliste und Auf-
Your benefits: a real overview of the status with a mouse click and no tragstabelle stellt MC 500 Ihnen ebenfalls zur Verfügung.
training for the driver.

Route planner
Mit dem integrierten Routenplaner wird der Weg zur Baustelle sichtbar.
Der Kartenausschnitt wird automatisch an die Route angepasst.
 FAKTURA MC 500 Batching plant control system

MC 500-Faktura Invoicing
MC 500-Faktura has been developed in cooperation with some of the There are a multitude of ways to determine the terms and conditions for
leading suppliers in the ready-mix concrete industry. The result is a tool job sites and customers. Invoices can be compiled either singly or com-
that is proven in practice and that reflects all of the day-to-day invoicing bound, depending on your customers’ requirements.
requirements of companies involved in the supply of ready-mix concrete There is also the means of issuing invoices for deliveries of concrete and
and relevant concrete pump service for pump services either singly or compounded.

Quotation management The fully integrated solution

Quotation Management is an elementary tool to compile and follow up MC 500-Faktura is an optional add-on module to the MC 500 package.
quotations. It involves a complete chain of processes from quotation, th- Because of its full integration, data-sets do not need to be imported or
rough production to the delivery note and finally the invoice, taking the exported from allied modules. Everything runs automatically.
customer conditions and terms into consideration at all steps. Once prices and conditions have been established and archived, they are
available to each and every workstation in the company net and can then
be used by all of the authorized operators.
Technical Data MC 500

MC 500- Database MC 500- Order Processing

• Backup of all data on a DVD, a USB flash drive, an external hard drive • Arbitrary sorting of order
or on a network computer • Display of total production for the current day
• Free selection of data to be printed • Order preparation for the next and the following days
• Free arrangement of columns in overview lists • Order creation from the address list
• Automatic width adjustment of the columns in overview lists (distributors, customers or construction sites)
• Each column can be defined as a sort criterion. • Printout of the delivery ticket depending on the order
• All editing functions saved with operator name, date and time • Recipe modification order and delivery based (additional cement, additives
• Logbook function for operator inputs and water) with input limits, which depend on the user group
• Export of displayed records as an Excel file • Combination of several orders to one production order
• Automatic planning of the productions
MC 500- Master Data • Preprint and reprint of delivery notes
• Input of dealers, customers, job sites, salesmen, trucks, subcontractors, • Parallel production of 2 orders with different recipes and different
drivers, texts, plant data, etc. prioritization (at concrete mixing plants with 2 built-in mixers)
• Cross-reference of customers to dealers • Pump orders (singly or assigned to a concrete order)
• Cross-reference of job sites to customers
• Cross-reference of customers to salesmen MC 500- Mix Design Management
• Display of deliveries to dealers, customers and job sites • Free selection of dosing sequence for aggregates, cement, additives
• Erase dealers, customers and job sites after day of last delivery and water
• Warnings or locks for dealers, customers, job sites and mix designs • Volumetric calculations
• Determination of travel times from plant to job sites • Calculation of aggregate quantities depending on a selected grading curve
• Determination of not possible truck mixers for particular job sites • Plant dependant adjustments to the mix design
• Determination of priority truck mixers for particular job sites • Arbitrary pre-mixing times for aggregate, cement, admixtures and water
• Simple transfer of the address data from the customer data • Data for DIN ENV 206-1
for a construction site • Recipe families
• Comprehensive import and export functions
• Maximum number of components for the production depending on the
MC 500- System Data concrete mixing plant
• Preparation of plant configuration data Aggregates: 8 of 20 Components (Dosing system 1)
• Arbitrary names for the scales, types of materials, types of vehicles, etc. Aggregates: 8 of 10 Components (Dosing system 2)
Aggregates: 4 of 10 Components (Dosing system 3)
MC 500- Report Lists Aggregates: 2 of 10 Components (Dosing system 4)
• Determination of the desired reports (lists, statistics, etc.) Aggregates: 2 of 10 Components (Dosing system 5)
that are printed regularly Aggregates: 2 of 10 Components (Dosing system 6)
Binders: 6 of 10 Components
MC 500- Texts Water: 4 of 10 Components
• Input of units (kg, etc.), price and booking code for special services Admixture: 5 of 20 Components (Dosing system 1)
• Input of special services, adverts, notes, warnings, etc. 5 of 10 Components (Dosing system 2)
Color: 2 of 10 Components
MC 500- User Management Ice: 1 Component
• User and user group management with password assignment Silicate: 1 Component
• Any number of user groups Steel fiber: 1 Component
• Any number of users
• Determination of access rights for user groups • Optional: concrete sampling schedule
• Optional: automatic message for required concrete sampling
• Optional: calculation of warm water quantity or quantity of ice depending
on the current temperatures of the materials used (requires an automatic
temperature measurement for each material)
 MC 500 Batching plant control system

MC 500- Raw Material Management MC 500- Statistics

• Input of material designation and article number • Archive (delivery notes, batch data, production logbook, etc.)
• Input of material density (for volumetric calculation) of all data to allow statistics to be generated over any relevant time period.
• Determining the moisture content of admixtures • Production statistics with details of average plant output
• Manual determination of the moisture of aggregates • Dealer, customer, customer mix design, truck and mix statistics possible
with printout of all deliveries
• Input of grading curve data for mix design calculations
• Production statistics for day, week, month, year or any other time-frame
• Determination of material - silo assignements
• Number of trips for each truck mixer in respect of a set time frame,
• Determination of alternate silos
including average load
• Limit points coarse/fine
• Target / actual consumption with calculating the deviation in %
• Determination oft he tolerance limits and in tonnes
• Automatic calculation of the quantity of retarder for required retarding time • Material consumption over any period
• Supplier and material management • Material consumption via manual operation
• Optional: Recording deliveries of material with a barcode scanner • Delivered quantities to dealers, customers, job sites, truck mixer, etc
• Special statistics on request
MC 500- Dosing Program
• Production logbook (incl. all messages send and received during MC 500- Available Languages
production)
• English, German, French, Russian and Chineese
• Automatic determination and calculation of the amount of solids in others on request
the sludge water and taking them into account during production
• Alternate silo switchover
MC 500- Option
• Automatic control of scales
• Manual operating tableau
• Mixer double-filling protection
• Extension to four monitors
• Automatic, self-teaching in-air compensation
• Remote service (assistance in the operation, adjustments are made via an
• Batch optimisation
Internet connection. Thus, a fast response time during maintenance and
• Shutoff flap monitoring service tasks is possible.)
• Automatic skip pre-start calculation
• Moisture metering of up to 6 components with sand moisture correction
• Air blow-out of additive lines
• Water pre-dosing
• Consistency graphic on display
• Monitoring of continuous silo levels
• Parallel production with prioritization
• Archiving of delivery data and batch records as a PDF file
• Up to 15 scales
• Optional: maintenance function
Technical Data MC 500

MC 500-Dispo – Order Management MC 500-FMS

• Determination of production plant • GPS truck tracking with map display
• Splitting of orders over several plants • Display of plants, job sites and trucks on maps in a freely selectable
• Automatic planning of the productions scale and map area
• Material requirement calculation • Storing frequently used overviews
• Exchange of orders between plants without central server • Print out the current map section
• Considering blocking times of vehicles and drivers • Fully automatic transmission of truck status
• Trucks and truck groups can be blocked for job sites • Display of trucks with actual status
• Considering the maximum permissible total weight at the job site • Display of routes travelled in time-frame by particular trucks
or on the route • Automatically search the job site address with correcting the GPS
coordinates and address data
• Storing the status data with the exact time to update planning data
MC 500-Dispo – Disposition
• Interpretation of truck position with signals “arriving job site”,
• Graphical display of deliveries for one or all connected concrete plants “starting unload”, “leaving job site” and “return to plant”
• Free planning by simply moving the deliveries with the mouse. In a simple
way, a delivery can be assigned to a truck in the same or in another plant.
• Plant utilization MC 500-Sync – Database Synchronization
• Truck utilization • Freely configurable, it is determined which data is exchanged
with which plant
• Display of time until required start of production
• Minimal traffic, because only the changed fields are transmitted
• Integration of a truck tracking via GPS
(requires MC 500-Map) • Exchange of data between the plants without a central server
• Manual status editing of truck mixers • Easy linking to further plants at a later date
• Automatic updating of travel times to job sites and plants
(requires MC 500-Map)

MC 500-Dispo – Pump Disposition

• Management of pump orders and pump delivery notes
• Interlinking of concrete deliveries and pump orders
 MC 500 Batching plant control system

MC 500-Faktura – Base Data MC 500-Faktura – Delivery Note Editing

• Management of price lists and payment terms • Correction of special service, waiting times, concrete returned to plant,
• Dealers, customers, job sites and plants with its own price lists additional cement and admixture quantities
• Dealers, customers and construction sites with general discounts • Creation of pump delivery notes
on the standard price list and with individual product prices • Optional: Import delivery notes (on request)

MC 500-Faktura – Pricing MC 500-Faktura – Invoicing

• Price lists include recipe prices, prices for special services, prices for • Collective invoices
delivery zones, material prices and pump prices • Customers with optional invoice per job site
• Free selection of price lists to dealers, customers, job sites • Individual job sites may be excluded from the collective invoice
• Free selection of conditions to dealers, customers, job sites • Considering the discounts of dealers, customers, construction sites
• Free assignment of discounts for selected articles to dealers, • Considering the price lists
customers and job sites
• Alerting when the validity date of the price list has been exceeded
• Pumps with basic price, minimum price scale prices at the time of invoicing
• Free assignment of pump prices and discounts to dealers, customers • Invoice printout (printer, preview or PDF file)
and job sites
• Optional: Creating an export record for transmission to a financial
• Discounts for dealers, customers, and sites with a validity date accounting software (DATEV, custom format)
• Automatic calculation of production costs of the recipes • Credit notes
• Transport costs depending on the truck and the distance • Sale of raw material
• Pump invoicing
MC 500-Faktura – Quotation • Other type of invoicing
• creation of quotations
• Determining the validity period for quotations MC 500-Faktura – Statistics
• Automatic Resubmission • List of issued invoices
• Creation of orders from quotations with cross-reference to agreed • m3, turnover per dealer, customer, job site, etc.
discounts
• Further statistics on request
 SCHWING-STETTER
ALWAYS CLOSE TO YOU

Parent plant
Production subsidiary
Own/independent sales
and service company
10312069.03.2016

SCHWING GmbH Stetter GmbH

Heerstrasse 9-27 · 44653 Herne, Germany Dr.-Karl-Lenz-Strasse 70 · 87700 Memmingen, Germany
Fon +49 23 25 - 987-0 · Fax +49 23 25 - 72922 Fon +49 83 31 - 78-0 · Fax +49 83 31 - 78 275
www.schwing-stetter.com · info@schwing.de www.schwing-stetter.com · info@stetter.de

Subject to technical and dimensional modifications. Illustrations are non-binding. The exact standard specification, the scope of delivery and the technical data are detailed in the offer.