An automated Genius: Gordyn & Palmer

, Gordyn & Palmer Genius Batch Weighing System — The Genius Batch Weighing System provides feedback on traceability, batch data, cloud reporting and more.

Gordyn & Palmer’s technology is providing a “Genius” solution for asphalt plant automation. Director George Boloutis explains.

Gordyn & Palmer has always considered itself as being at the forefront of asphalt batching technology.

Based on more than 40-years’ experience in the weighing industry, Gordyn & Palmer developed the Genius Batch Weighing System, a computerised and automated technology, capable of providing accurate plant operation and monitoring.

George Boloutis, Gordyn & Palmer Director, says the Genius Batch Weighing System, first designed in the late 1970s, is renowned in the industry as reliable and trusted software.

“We do turnkey projects, right from the initial concept and design to the electrical engineering, switchboards, control cabinets, all the automation software, site installation and commissioning,” Boloutis says.

“The Genius software has been developed in-house so it’s been upgraded and updated to keep up with the latest technologies.”

The Genius system helps to increase the productivity and profits of asphalt production plants, by providing accurate and real-time feedback.

Batch data, full traceability, Cloud reporting, downtime summaries and plant monitoring can all be viewed via a mobile or tablet interface. The system is designed with standard PC hardware, enabling it to be implemented seamlessly into existing plants.

“Every batch is fully traceable. So, you have comprehensive reporting of materials that go into the system, and also the finished product,” Boloutis says.

The Genius system also has a seamless interface, meaning it’s compatible with Enterprise Resource Planning and other software packages. Boloutis says that the Genius system is also S88 compliant (ANSI/ISA-88 standard addressing batch process control).

“It offers comprehensive reporting and it’s flexible, so it can talk to external systems. Whether it needs to be used just for batching or blending, it’s capable of taking care of the whole plant,” he says.

“Diagnostic features are also built into the system. So, if something goes wrong, the Genius identifies it and takes the necessary measures.”

The Genius process

Before installing the Genius system for a prospective customer, Gordyn & Palmer follows a thorough scoping process to identify the client’s needs well before equipment is erected on-site.

Boloutis says this initial planning helps to ensure that the customers’ needs are realised.

“We’ll have a look and discuss the options with the customer to get a feel of what their needs are, and try to address their requirements. After that, we’ll form a changeover plan,” he says.

“The changeover is paramount. We want to make sure that production is not affected in any way. We set a realistic changeover time frame to make sure it works with the customer.”

After the system has been installed, the support and service doesn’t end there. Gordyn & Palmer offers assistance for operators with minimal experience.

“Once they are up and running, we’re there to train them and support them until they’re familiar with a system, but the Genius is very easy to use,” Boloutis says.

Deploying the Genius

Sunstate Road Services, which forms part of Colas Australia, had previously used an older control system from overseas, at its Maryborough plant in Queensland. When that system was no longer easily supported in Australia and became a business risk, Sunstate looked to Gordyn & Palmer for an upgrade based on modern and off the shelf hardware.

As Boloutis explains, upgrading to the Genius software averted any potential “catastrophic failures” caused by the previous control system.

“They had a system on site which wasn’t locally supported. So, they had a huge risk of the system going down. As they are a production site, where they have orders to deliver daily, even the smallest amount of downtime would have resulted in significant financial losses,” he says.

“We had a window of opportunity when the plant was down to install the upgraded Genius system, allowing Colas Australia to go back into full production seamlessly, to satisfy their orders and demands.”

Joel Cowen, Colas Australia Group Asphalt Industry Asset Manager, says he was impressed with Gordyn & Palmer’s “end-to-end service”.

“They provided the full scope of works, which included electrical engineering, wiring schematics, control system for the total plant, site installation and commissioning,” he says.

“Their service effectively removed the risk of the old system failing. Now we have better reporting capabilities and visibility of cost to assist with supporting and driving our sustainability ambitions.”

Boloutis says the feedback from Colas Australia has been “overwhelmingly positive”. He attributes the Genius’ success to Gordyn & Palmer’s “wealth of knowledge” in control systems and industry knowledge.

“It’s a proven system in the industry. We have a lot of in-house knowledge on asphalt plants, how they work and what their requirements are,” he says.

“One of the biggest benefits of our system is that we’re a local manufacturer, based in Victoria. We can service and support our customers with local parts and repairs, and they can always get hold of us.”

This article was originally published in the August edition of our magazine. To read the magazine, click here.