Asphalt Plant Reduces Fuel Costs by 15% with Galileosky Trackers

Background

The full-cycle road construction company approached the task of simplifying and making fuel control transparent, given their monthly consumption of 150-200 tons. Daily, a tanker truck delivers 25 tons of diesel fuel to the asphalt plant. However, there was no clear understanding of how to account for and write off the fuel after delivery. The company suspected theft during transportation and storage in multiple containers due to chaotic recording by drivers operating excavators and dump trucks through tank openings. Additionally, downtime occurred due to late or excessive fuel deliveries that forced storage in barrels. Another issue was calculating product costs for clients.

Project tasks

1. Calculate actual diesel consumption per ton of asphalt mix.
2. Eliminate fuel theft.
3. Determine actual consumption by multiple users simultaneously.
4. Record emergency withdrawals from tanks.

Solution

The asphalt plant has two diesel consumers:

• Bitumen Department: Used for heating bitumen with a monthly consumption ranging from 1 to 3 tons depending on asphalt production volume.
• Drying Apparatus: Used for drying incoming inert materials; its monthly consumption exceeds 100 tons.

Initially, average coefficients were used in calculations due to lack of precise measurement tools on large storage tanks.
For project implementation, consumers were divided into two sections because the Bitumen Department involves both direct and reverse flow while the Drying Apparatus only involves direct flow.

During design phase challenges arose connecting individual elements to terminals; it was determined that Galileosky 7x fit perfectly due to its advanced configuration options and Easy Logic technology.

An alert algorithm was developed using EasyLogic: when opening tank lids blocks fuel supply (as this could indicate unauthorized refueling), sends an SMS alert allowing responsible personnel to activate alarms if not notified about access attempts during non-working hours when high usage makes tracking difficult56.

Result

• Reduced average fuel consumption by at least 15%.
• Determined precise figures for each consumer.
• Completely eliminated unauthorized access.
• Automated financial department data entry daily for cost calculation purposes.
• Accurately tracked remaining fuel levels reducing indirect logistics costs by reducing tanker deliveries by about 10%.
• Reduced personnel expenses by approximately 25% while eliminating paper-based records