MA-ESTRO PRODUCTS AND SOLUTIONS Q-AUTOMATION THE AUTOPILOT OF YOUR CRUSHING PLANT.

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1 MA-ESTRO PRODUCTS AND SOLUTIONS Q-AUTOMATION THE AUTOPILOT OF YOUR CRUSHING PLANT

2 Q-AUTOMATION : THE BENEFITS AUTOMATION, COST REDUCTION AND RESPECT FOR THE ENVIRONMENT HARDWARE INSTALLATION MACHINE EFFICIENCY S INSTALLATION Q-AUTOMATION originates from the experience and expertise of MA-ESTRO. Being aware of the problems of a crushing plant, we have developed a smart automation system that controls the production flow at every moment. We do not just install the sensors and transmit data on screen, with the AFC function we transform a mere supervision system into an automated control platform. This allows to relieve the crushing plant of many of the problems that usually prevent the achievement of its true potential. A few examples are the extreme variability of the material, where AFC reaches its maximum potential, or the inexperience of an operator who, with AFC, becomes a supervisor. The immediate consequence is the reduction of the production costs and a better management of the resources. OPERATOR SOFTWARE INSTALLATION PRODUCTION INTEGRATION Q-AUTOMATION & AFC : AUTOMATIC FEEDER AUTOMATIC REGULATION OF THE FEEDERS DEPENDING ON THE ENTIRE PRODUCTION PROCESS Q-AUTOMATION is the automated control system of your crushing plant developed by MA-ESTRO. It consists of a central unit, similar to an artificial intelligence, and of a series of sensors installed on the crushing plant machines. It is a system that assists the operator in all control and adjustment phases, automatically processes all information received from the sensors and automatically adjusts the flow of material to the feeders in order to obtain the maximum in terms of production and to minimize waste and inefficiency. The automated adjustment process has the advantage of being able to bring a system to its fullest potential, which would be impossible to achieve with a manually regulated facility. AFC, a Q-AUTOMATION module, has been implemented to be usable also by an inexperienced operator, thus ensuring the maximum productivity and minimizing the downtimes. In addition to the control of the production process, AFC records the information concerning production, consumption, maintenance, and downtimes of your plant thus allowing you to know, in real time, the true cost per ton produced, and then to manage all the work phases. MAIN BENEFITS: Modular, customized, implementable Non-invasive installation Automatic material feeder regulation every 1.5 sec Real-time machine efficiency monitoring Automatic engine starting sequence management Automatic production report forwarding* Raw material variability self-adapting system Improved safety for operators working on plant Personnel management optimization Clear,intuitive and customized 3D view of machines on plant Sensors designed to operate in harsh environments Optimization of energy consumption per ton Production costs analysys: energy, maintenance activities, inefficiencies, plant downtimes* Crushing plant remote control* CO 2 emission reduction *paired with Q-PRODUCTION RETURN ON INVESTMENT GUARANTEED PRODUCTION COSTS REDUCTION MODULAR CUSTOMIZED IMPLEMENTABLE INSTALLABLE ON NEW OR EXISTING PLANTS PLANT REMOTE SIMPLE AND INTUITIVE USE

3 MACHINE EFFICIENCY S OPERATOR SOFTWARE As a result of our heavy investment in research and development, the customized MA-ESTRO sensors can control each area of the facility. Each individual machine can be paired with the right sensors and their related control software so that each individual setting can be controlled remotely. ENERGY COUNTER PRESSURE OBSTRUCTION SONAR TEMPERATURE BELT ROTATION These sensors are also developed and tested to work in harsh environments such as those found in a crushing plant. The data from the various machines is analyzed by the AFC that automatically adjusts the feeders depending on the entire production process CURRENT ABSORPTION POWER INVERTER CONVEYOR BELT SCALE SONAR/RADAR The AFC software is customized according to the needs of the specific crushing plant. The GUI is intuitive and easy to use, designed to be used also by operators with limited experience with computerized systems. The entire facility is represented by a custom, easy to read, 3D render, while the interface is touch screen and the system allows the setting of the regulation of the machine set points. The hardware infrastructure consists of an industrial PC with no moving parts, designed to withstand high temperatures and strong vibrations. The system operates on a Windows Embedded OS and is restored to its original version after every reboot. This feature makes the system more robust and capable of managing sudden shutdowns preventing any damage to both the hardware and the software. Moreover, the system in this configuration is protected from involuntary cancellations or computer viruses. PROBE ARTIFICIAL VISION SYSTEM FUEL PROBE MOBILE TERMINAL Touch screen display Machine efficiency trend analysis Automatic engine sequence management MA-ESTRO remote assistance service Flexible machine controls Setting detail Customizable set points Plant downtimes registration INTERMEDIATE HOPPER OPTIMAL CRUSHER VIBRATING SCREEN LOAD CONVEYOR BELT LOAD PRODUCTION DATA MANAGEMENT HYDROCYCLONE PRESSURE WASHING WATER PRESSURE HAMMER MILL POWER CONSUMPTION OPTIMAL CONE CRUSHER CONVEYOR BELT ROTATION AUTOMATIC FEEDER REGULATION VSI MILL AMPERAGE QUALITY ENERGY CONSUMPTION PLANT REMOTE MACHINE EFFICIENCY MONITORING

4 Q-AUTOMATION : MAIN S PRIMARY CRUSHING ZONE The main goal of our automatic control in the primary crushing zone is to identify and solve all the issues caused by the raw material variability. Thanks to a synergy of controls, Q-AUTOMATION can handle the material flow to the feed hopper accounting for and promptly adapting to all these factors, as highlighted in the example in the figure. Each single machine or component is controlled and managed similarly to how an experienced and competent operator would do, with the additional advantage of having an automatic control over the material feeder every 1.5 seconds, thus maximizing both the efficiency and the productivity of the initial part of the productive process. This allows the operator to work solely on the other parts of the production process or to intervene in case of technical problems. CONE CRUSHER FEED HOPPER CONE CRUSHER LOAD AMPERAGE OIL TEMPERATURE AFC FUNCTION: AUTOMATIC FEEDER INVERTER Thanks to an ultrasonic sensor the operator can decide the height of the material automatically loaded. The system will manage the power supply to keep the preset value by adjusting it constantly, so to avoid sudden power ups and shutdowns. In presence of storage hoppers, the system will be also able to automatically manage the shutdown and the power up of the machine in order to minimize the energy consumption. 1. HAUL CYCLE TIME ANALYSIS 2. FEED HOPPER 3. OPTIMAL REGULATION AT THE CRUSHER FEED OPENING 4. BEARING TEMPERATURE 5. ROTATION 6. AMPERAGE 7. BELT LOAD 8. AFC FUNCTION: AUTOMATIC FEEDER HAMMER MILL 1 2 VSI MILL STORAGE HOPPER BLOCKAGE AMPERAGE BEARING TEMPERATURE ROTATION SPEED The power is automatically adjusted by the current control and by a special software algorithm. The operator will only have to define the maximum energetic absorption of the machine, and the system will automatically adjust the material. The software filter controls all data received by the absorption control and reprocesses the information to properly adjust the machine in order to avoid constant up-and-down adjustments BLOCKAGE AMPERAGE BEARING TEMPERATURE Also for the VSI mills the power is automatically managed by the current control and by a special software algorithm. The operator will only need to define the maximum energy absorption of the machine and the system will automatically adjust the material. The software filter controls all data received by the absorption control and reprocesses the information to properly adjust the machine in order to avoid constant up-anddown adjustments 8 SCREEN 6 7 SCREEN BLOCKAGE AMPERAGE BEARING TEMPERATURE Screening control is ensured by a careful analysis and interpretation of the energy absorption; the developed software allows to process all the data and determine the status of each screen. This control allows us to determine the actual screen load and any anomalies in its operation; it also allows to avoid any machine overloads or downtimes.

5 CONVEYOR BELT MUD TREATMENT ARTIFICIAL VISION SYSTEM FOR RECOGNITION METAL DETECTOR AMPERAGE BELT SPEED WEIGHING SCALE SYSTEM The conveyor belts can be equipped with multiple controls. For example it is possible to keep the speed of the belt itself under observation, or to install various controls such weight sensors in order to regulate the production, anti-swerving sensors, ultrasonic sensors to keep critical points under observation and even metal detectors to identify any foreign metallic object MUD PRODUCTION CLEAN WATER CONSUMPTION AMPERAGE AFT allows to manage external notifications such as, mud treatment plants. Moreover, additional system can be installed to monitor the mud production HYDROCYCLONE TRUCK LOADOUT AUTOMATION SYSTEM PRESSURE TO AVOID ANY SAND LOSS VIBRATORS AMPERAGE PUMP AMPERAGE The continuous control of the hydrocyclone pressure allows a very close monitoring and optimizes the production process. A low pressure reading usually is a symptom of a machine overload and could cause sand leaks that may end obstructing the drain pipes with severe downtimes of the machine itself. The pressure sensor, installed at the top of the hydrocyclone cone, is protected by a membrane that prevents any water or sand from compromising its performance EXTERNAL DISPLAY FOR MONITORING MONITORING AUTOMATIC DISCHARGE MOUTHS MANAGEMENT DISCHARGED DATA REGISTRATION The ability to remotely control dump operations and actual load of the storage sites, gives the opportunity to ensure the maximum efficiency in one of the weak spots of many facilities. WASHING DRUM ENERGY AND FUEL GENERATOR BLOCKAGE AMPERAGE ROTATION The system allows to manage the load of the drum washers: the machine load is automatically determined and the material load is adjusted accordingly. Potential machine stops and anomalies are managed by the system itself. ELECTRICAL NETWORK ANALYSIS GENERATOR ISSUES ANALYSIS FUEL FUEL CONSUMPTION Thanks to the pairing of the AFC system and the innovative production control we can guarantee the monitoring and recording of all energy consumption sources; moreover by automatically combining these data with the real production capacity of the facility it will be possible to evaluate potential variations in the usage of the facility itself. SAND RECLAIMER OTHER MACHINE ROTATION AMPERAGE AUTOMATIC SPEED REGULATION The system allows the management of the drum washers and of the sand reclaimers load: the machine load is automatically determined and autonomously managed by the AFC system FUEL CONSUMPTION TRANSPORT TIME REGISTRATION TRUCK WEIGHING MAINTENANCE MANAGEMENT PLANT REMOTE FROM MOBILE DEVICE (TABLET) A radio controlled industrial tablet can be installed directly into the operating machines. This allows the control of the entire facility by a single person and with the maximum safety conditions. By monitoring energy consumption, time & maintenance schedules, truck loads, etc.it will be possible to have a clear vision of the actual productivity of every machine working in the plant.

6 Q-AUTOMATION & Q-PRODUCTION CUSTOMER CARE & SERVICES THE SYNERGY OF MA-ESTRO SYSTEMS TO LET YOU TAKE TOTAL OF YOUR CRUSHING PLANT Q-PRODUCTION is the ultimate automated production & energy consumption control system for your crushing plant. The system provides all the necessary data and statistics so that you know the real production costs. It identifies any issues, improves the production processes and reduces the costs per ton. By installing a few electronic components connected to an energy counter, and some conveyor belt weighing scales, our system will automatically register and monitor all production data. Its web portal will allow you to keep under control every detail of the production process in real-time and in a clear, intuitive way. CONSULTING SERVICES We identify the inefficiencies of your facility and, for each one, we determine the best solution. We can guarantee concrete answers by conducting detailed technical and global surveys on the operations of the crushing plants. REMOTE & ASSISTANCE One of our technician will be always available for any information or help. All the software settings can be managed remotely and in real time. Small repairings and replacements can be handled locally by trusted electricians under the remote supervision of MA-ESTRO. WEB PORTAL MAIN FEATURES: Automatic production registration Automatic fuel consumption registration Automatic energy consumption registration Production run-time and stop-time registration Plant downtimes registration Production data historicization (on database) Automatic report generation (daily or for working shift) Production trend monitoring Non-conforming raw material registration Maintenance management (optional) Multi-format data export ( Excel, PDF, CSV) SPECIAL ASSISTANCE In case of specific emergencies that cannot be handled remotely, one of our specialized technicians will come to the facility to solve the problem. Further personalized assistance plans are available at an annual flat rate, after agreement is reached with the customer. COMPLETE TURNKEY SOLUTIONS We can provide turnkey solutions for our customers, also in terms of any possible electrical intervention on existing hardware OPERATING LEASE PLANS Thanks to our partnerships with specialized institutes we can provide operating lease agreements that allow a return of investment while the system is operating. ENVIRONMENTAL CARE: MA-ESTRO is a company born at the foot of the Dolomites, in a territory where the respect for our environment is of the utmost importance. Our systems are designed so that efficiency and energy saving contribute to reducing the environmental footprint of the production process. Specifically, the use of AFC on average results in: MACHINE EFFICIENCY MONITORING Express the real potential of your plant maximizing the efficiency of every machine involved in the production process. Being able to obtain real time information on the efficiency of each individual machine, and to intervene directly on their settings, results in an increased efficiency for both processes and resources, but also an enhanced management of your facility UP TO - 20% CO 2 EMISSIONS UP TO - 15% WATER CONSUMPTION UP TO - 30% ENERGY per ton

7 DISCOVER THE OTHER MA-ESTRO PRODUCTS ON Q-AUTOMATION Q-PRODUCTION QUARRYING, MINING & RECYCLING PLANT AUTOMATION SYSTEM QUARRYING, MINING & RECYCLING PRODUCTION SYSTEM Q-TRANSPORT Q-FUEL TRANSPORT EFFICIENCY MONITORING AUTOMATED FUEL MANAGEMENT SYSTEM Q-MAINTENANCE PFREUNDT MAINTENANCE MANAGEMENT SYSTEM WEIGHING SYSTEMS MA-ESTRO S.r.l - Viale Caproni 11/e Rovereto (TN) - Italy Tel: Fax: P.IVA: info@ma-estro.com Web: IN PARTNERSHIP WITH