Developed by Marini technicians to ensure maximum interoperability, Marini SMART Plant is the core of an interconnected network of plants that will leverage Artificial Intelligence (AI) and Machine Learning (ML) to assist operators in managing and maintaining plant efficiency.
Advanced technologies, such as Artificial Intelligence (AI) and Machine Learning (ML), are a fascinating and fertile territory, rich in potential, that are playing an important role in research and development across many sectors, including the production of bituminous conglomerates.
But which aspects of a plant's and a company's daily operations do these innovations impact, and to what extent?
The response of Marini's technicians and engineers, who are continuously engaged in developing new solutions to help customers manage and maintain the efficiency of their asphalt plants, will be officially presented at the Bauma 2025 event in Munich.
It’s the launch of Marini Smart Plant, a new software for data sharing between all plants installed in the field: an interconnected network of machinery, communication systems, and computing power that uses Artificial Intelligence and Machine Learning to analyse operational plant data, promote automated processes, and learn from experience—all with the goal of simplifying the operator's day-to-day management tasks.
Marini Smart Plant: Opening a Plant to the Outside World
In its traditional configuration, a bituminous mixture production plant operates as a closed system. All the data for the various recipes are integrated exclusively within that system, and there is no communication channel with other external systems; they can be transferred, but only internally.
Through data sharing , Marini Smart Plant has been conceived to overcome this limitation, offering maximum interoperability, with the primary goal of opening the plant to the outside world, transferring its data to the cloud, and enabling connections with data from other plants.
For example, in the case of a customer with multiple Marini plants active at different sites, or plants belonging to different customers but of the same type, Marini Smart Plant offers the ability to compare production data related to energy consumption per recipe, environmental conditions across different types of plants, and the varying levels of efficiency.
Three distinct technologies form the cyber-physical framework of Marini Smart Plant: Cloud Computing, Open and Smart Controller.
Cloud Computing
Cloud computing is at the heart of Marini Smart Plant: a hardware-based data storage platform where information is analysed using Artificial Intelligence (AI) and Machine Learning (ML) algorithms. These analyses drive the development of predictive maintenance applications (implemented with Siemens Edge technology), enable self-learning capabilities, and establish correlations between data from different systems, all of which are then made accessible to customer services.
Within this context, the most important aspects are a unique cloud environment designed to collect data from asphalt plants worldwide, their subsequent analysis, and the generation of system maintenance reports.
In collaboration with the University of Bologna, Marini's technicians have developed a predictive maintenance prototype that uses a Machine Learning algorithm to gauge the degree of clogging in the filtration system.
Open
Open is the system control software, which no longer merely controls the process, but becomes a reference point for receiving and sending information to and from the various cloud services.
There will be, for example, the possibility of connecting the plant with the programmes that manage activities at the construction sites, providing information on lorry locations, the quality and quantity of asphalt produced, any pending orders and modifications to be made.
Consequently, depending on the progress of on-site operations, it will be possible, when necessary, to directly notify the plant of the need to suspend production to prevent waste, or to report issues with temperature (e.g., too high or too low), mix quantity, or characteristics. This will allow the plant to receive valuable information that can improve production with each lorry trip or optimise material transport times.
Although making its world premiere at Bauma 2025, Marini SMART Plant has already been tested at one of Marini's customer’s plants in Italy in the months leading up to the launch. Marini SMART Plant has been designed to deliver scalable solutions that adapt to different market needs, and simplifying integration with existing systems. The operator or plant manager can also receive notifications and information from Cloud Computing to optimise the system’s efficiency.
Smart Control
This is the “intelligent” part of the system, equipped with a virtual maintenance assistant.
The use of Artificial Intelligence and Machine Learning on the data collected in Cloud Computing allows for the development of a range of innovative services, such as the enhancement of system control functions derived from data analysis and self-learning AI algorithms.
The virtual assistant is an application powered by AI algorithms, and implemented using chatbot technology.
The chatbot will be available for users to obtain possible solutions to a problem, guidance or advice on the best operating methods, or suggestions for resolving warning notifications.
In conjunction with Cloud Computing, the predictive maintenance function alerts the plant to the need for intervention in specific system sections to prevent production stoppages.
Finally, a custom Web-App has been developed, allowing users to access cloud-analysed data via a login page from a tablet or smartphone a login page, where they can connect to the desired asphalt plant and select the information they wish to view.
Dynamic RAP Recipe Programme
Another distinctive feature of SMART Plant is an important and innovative programme that serves as an assistant for preparing RAP (Reclaimed Asphalt Pavement) dosing recipes. This programme is already available and installed at the plants of several Marini client plants.
These dynamic recipes are loaded automatically, allowing the RAP percentage to vary continuously from 0 to 40% while maintaining the correct particle size distribution and ensuring the quality of the final asphalt.
The operator can use cold RAP in the mixer without activating the burner and dryer to heat the aggregates, relying on those already stored in the silos beneath the sieve.
Adjusting the percentage of cold RAP introduced into the mixer based on the actual temperature of the aggregates ensures proper management of the final asphalt's temperature.
Paving the Way to a More Efficient Future
Each of these solutions proposed by Marini is designed to create an environment that enhances process efficiency for our clients. This is achieved through improved communication between production managers, greater transparency across all stages of the process, and a system that reduces costs and downtime bolstered by the increasingly valuable support of AI.
Smart Plant technology will initially be available on the mid-to-high and high ranges of the Marini plant portfolio. At a later stage, it will be expanded to cover the entire range, including plants produced in China, India, and Turkey for local markets.
FOR FURTHER INFORMATION, PLEASE CONTACT:
Roberto Berardi, Marketing Manager, Fayat Mixing Plants Division
+39 3406799678
r.berardi@marini.fayat.com