ControlPro v3.3
Table of Contents
Introduction
ControlPro will automatically calculate the batch and sub-batch amounts automatically based on a plethora of data points. These default amounts can further be manipulated by the user if desired.
To configure a batch, start with the tickets themselves. On the Ticket Details screen, the values of the Total Amount and Estimated Loads fields will determine the default batch size when the ticket is included in a batch. Next, The Tickets tab of the System Details screen is where tickets are assigned and selected for a batch. Here, the batch amount can be refined by modifying the batched tickets themselves or the Total Batch amount field directly. Finally, the Batch tab of the System Details screens allows a user to manipulate the details of the batch as well as control how sub-batching will behave.
Understanding how batch and sub-batch amounts are limited and how they interact with each other can improve terminal throughput and reduce confusion.
How Tickets Settings Drive Batch Defaults
The Total Amount field of a ticket is the total amount requested. This is basically a sum of all the materials on the ticket.
Together with the Estimated Loads field, these values determine a ticket’s default batch size.
From the preceding screenshots, ticket 0632 will default to 2 batches of 6,000 pounds each, for a total of 12,000 pounds.
Configuring a Batch
Once assigned to a system, the defaults will show up on the System Detail’s Tickets tab. The requested amount from each ticket can be modified by typing directly into the grid cells for Batch Percentage, Batch Acres, or Total Batch [Amount*]. Modifying the ticket amounts will modify the system’s Total Batch amount.
*Note that the third column is based on the unit of measure of the system’s Primary Mixer Capacity Unit field, not the ticket itself.
Editable Columns
Some columns are conditionally editable (denoted by the Asterisks (*) in the headers). Values typed into grid columns are not committed until cell editing is complete. Once the batch has started, these values are locked in.
Batch Percent
The percent of the ticket to be ran in the batch. If Ignore Blend Ratio is enabled (more on this later), this field will be displayed as “--%“. This is because if the blend ratio is being ignored, the ticket percentage is largely meaningless.
Batch Acres
The number of acres to be ran in the batch. Similarly, if Ignore Blend Ratio is enabled, this field will also be displayed as “--“.
Total Batch [Amount]
The total ticket amount to be ran in the batch. ControlPro handles all unit conversions in the background. The units of the ticket, ticket materials, system, system materials, or any display units do not have to match.
Note: if mass to volumetric or vice versa conversions will be required, it is critical that the Density and Physical State fields on the materials be correct.
Batch Summary
The Total Batch field can be modified as the user sees fit. Modifying this amount will also modify the ticket amounts of batched tickets proportionally. The total batch delivered and remining amounts are also listed. Once the batch has started, the Total Batch amount is locked in.
Batch Preconfiguring Buttons
Below the ticket grid are three buttons that can preconfigure the batch for you.
An Example, consider ticket 0637 which has a previously delivered batch for 5,000 pounds, while the ticket as a whole is for 10,000 pounds total. This leaves 5,000 pounds remaining on the ticket. The ticket is supposed to be for a 50/50 blend of the two materials, but 3,000 pounds of Nitrogen and 2,000 pounds of Phosphorous were delivered (for whatever reason).
Remaining By Blend Ratio
The batch sizes of selected tickets are set to the remaining amount on the ticket as a whole, regardless of what actual material amounts have previously been delivered. The purpose of this button is to set up a ‘clean’ batch to finish off the ticket by its blend ratio.
Clicking this button would configure ticket 0637 to deliver 5,000 pounds of material; 2,500 pounds of both Nitrogen and Phosphorous. This sets up the ticket’s second batch to match its blend.
Remaining By Materials
This button enables the Ignore Blend Ratio option on the Batch tab and sets the batch amount to fulfill all the remaining materials on the ticket individually. The purpose of this button is to set up a ‘top off’ batch to finish off the ticket by individual materials.
Clicking this button would configure ticket 0637 to deliver 5,000 pounds of material: 2,000 pounds Nitrogen and 3,000 pounds of Phosphorous. This sets up the ticket’s seconds batch to top off its materials.
Note that if the ticket is deselected, the ticket will automatically be reset to default. This is because fulfilling this function requires settings that are on the Batch tab and is not wholly dependent on the ticket’s setup.
Reset to Default
This will deselect all tickets and reset their batcha amounts to default. Initially assigning a ticket to a system uses this function laity by default.
Since ticket 0637 is a 1 Estimated Load ticket, clicking this button would configure the ticket to deliver 10,000 pounds of material: 5,000 pounds of both Nitrogen and Phosphorous.
Configuring a Sub-Batch
The Batch tab on System Details contains all the specifics of how the batch will be delivered. In the upper left quadrant of the screen is the breakdown of the individual batch materials to be delivered. The upper left quadrant contains a few batch options and all the sub-batching options. The lower half of the screen has batch control options that are also present on the Tickets tab.
Note: the Reset to Default button is similar to the button on the Tickets tab, but only affects the batched tickets, and does not clear the batch.
In the tab header itself is an icon the denotes whether the batch is valid or not. This icon will either be a green checkmark for a valid batch, or a red ban sign for an invalid or no batch.
Batch Materials
This grid lists the materials present in the batch. All materials that will be sent to the system for delivery will be bolded. For normal tickets, this will be all of them. However, multiple mix group (MMG) tickets and tickets that will be spread out over multiple primary/secondary systems (more on these later) will have some batch materials displayed in a normal font. In these scenarios, the materials with normal font will not be sent to the system at this time.
Editable Columns
Some columns are conditionally editable (denoted by the Asterisks (*) in the headers). Values typed into grid columns are not committed until cell editing is complete.
Batch Requested
Editable:
- Ignore Blend Ratio is enabled.
- Before the batch has started processing. (Ready state)
Modifying these amounts will modify the system’s Total Batch amount and ticket’s Total Batch [Units] amount, and vice versa. Once the batch has started, the material Batch Requested amounts are locked in.
Sub-Batch Requested
Editable:
- Ignore Blend Ratio is enabled.
- Sub-Batching enabled.
- Manual mode is enabled.
- Before the batch has started processing, or between sub-batches. (Ready or Waiting sates)
The amount of material requested in a sub-batch cannot exceed the total amount of material remaining in the batch.
Sub-Batch Delivered
Editable:
- While a sub-batch is in progress. (Processing sate)
- The material is a hand-add or the system’s PLC Type Manual.
Sub-batch delivered values for automated materials will be read in from the physical system and cannot be altered.
Batch Configuration Options
The three checkboxes in the upper right configure the batch as a whole.
Ignore Blend Ratio
When enabled, material requested amounts become disconnected from the blend ratio of the tickets in the batch. But any amounts that are defaulted will still match the blend ratio. This option is automatically enabled when clicking the Remaining By Materials buttons or multi-ticket batching MMG tickets with different blend ratios.
Ignore Mixer Capacity
Enabling this option will not limit the batch or sub-batch by the mixer capacity. Although, batches are still limited by the system’s Maximum Batch Size. The purpose of this option is to facilitate wholesale loading of dry systems when the mixer is being bypassed. If materials are loaded into the mixer, do not enable this option as the mixer will overflow.
Use Sub-Batching
Enabling this option will enable all the sub-batching options below. Without sub-batching enabled, the batch size will be limited to the mixer capacity. While enabled, the batch size will only be limited to the system’s Maximum Batch Size.
The sub-batching workflow will arm the system sequentially to deliver all the materials in the batch. Once all sub-batches are completed, ControlPro will sum up all delivered materials and create loads on the batched tickets.
Sub-Batch Configuration Options
On the right side of the panel are the workflow modes. On the left are the sub-batch recalculation modes.
Sub-Batch Workflow Modes
These govern how ControlPro will move from one sub-batch to the next, and how the batch as a whole will be completed.
Manual
Each sub-batch will need to be manually started by the user by clicking the Process button. The batch itself will only be completed when the user clicks the Complete button. If Ignore Blend Ratio is enabled, Manual mode allows the Sub-Batch Requested columns to be editable.
Automatic
Each sub-batch will automatically be started, and the batch will automatically be completed. No user interaction is required after the Process button is first clicked.
Continuous
Similar to the Automatic mode, but this option is used solely with systems that utilize profiles. If the profile is configured with multiple stages, multiple sub-batches will be in process simultaneously.
Sub-Batch Recalculation Modes
These option control how each subsequent sub-batch will be calculated. ControlPro will strive to fulfill a specific target condition to complete the batch.
Recalculate By Blend Ratio
ControlPro will use the Total Batch amount as the target. Each subsequent sub-batch will adjust the necessary amount to reach the Total Batch amount in it based on the batched tickets’ blend ratio.
Recalculate by Materials
ControlPro will use each batch materials’ Batch Requested as the target. Each subsequent sub-batch will adjust each batch materials’ Sub-Batch Requested amount to meet the Batch Requested amount as close as possible.
Recalculate Sub-Options
When either Recalculate By Blend Ratio or Recalculate By Materials is selected, these options will be enabled.
Equalize Sub-Batches
If enabled, ControlPro will try to equalize each batch as much as possible. If not, each sub-batch will be set to the Mixer Capacity, while the last sub-batch is a top-off sub-batch.
Mix Group Selection
This will only be enabled if the batched tickets are MMG. This dropdown will allow the user to select which mix group to run in the current sub-batch.
Auto-Increment Mix Groups
This will only be enabled if the batched tickets are MMG. If enabled, ControlPro will auto increment from one mix group to the next. When used in conjunction with Automatic mode, the user will only be required to click the initial Process button and the batch will proceed without user interaction.
Fixed & Repeat
If enabled, each subsequent sub-batch will not be recalculated. The size of each sub-batch will be a fixed amount. When using Fixed & Repeat and prior to the batch starting, any modifications to the system’s Sub Batch amount will modify the system’s Total Batch amount and the batched tickets’ Total Batch [Amount], and vice versa. Once the batch has been stated, all these values are locked in.
Remaining Repeats
Before the batch has been started, this is the total number of sub-batches that will be ran. Modifying this will modify the system’s Total Batch amount and the batched tickets’ Total Batch [Amount]. Once the batch has been stated, all these values are locked in.
Sub-Batch Summary
At the bottom of the panel is a summary of the sub-batch. The Sub-Batch total requested is first. This can be edited between sub-batches if Manual mode is selected. Next are the amounts delivered and remaining in the current sub-batch. Below, the total counts of tickets, dispatches, and loads are listed.
Batch Control Buttons
These buttons control both the batch and the physical system.
Clear Button
This clears the physical system, the batch, and any batch tickets that may have gotten ‘stuck’ if ControlPro has gotten into an odd state. The Clear button is only enabled if there are no non-hand-add delivered amounts present in the batch.
Abort Button
This is a last-ditch emergency option. Aborting a batch is for when something has happened, and the batch needs to be completely thrown out. An abort ticket will be created with all delivered materials on it. This will keep inventory correct and provide a record of the aborted batch. The batch will be backed out and all batched tickets will be unaffected. Although, audits of the action will be added to both the system and the batched tickets.
Complete Button
Clicking this will complete the batch. This button can be clicked at any time, even in the middle of a sub-batch.
Process Button
Click this button to begin processing a batch. If in Manual mode, this button will need to be clicked to begin each sub-batch as well. The count of tickets in the batch is displayed on the button in parenthesis.
System Configuration
There are multiple settings and options on the system that affect batching.
Details Tab
These settings control limitations of the physical system as well as workflow limitations.
Primary Mixer Capacity & Alternate Mixer Capacity
The Primary Mixer Capacity and Alternate Mixer Capacity work together to ensure that the mixer does not overflow. One will be a mas amount and the other a volumetric amount.
Maximum Batch Size
This is the maximum amount that is allowed to be delivered in a single batch.
Minimum Batch Size
This is the minimum amount of material necessary for the proper operation of the physical system. When recalculating a sub-batch, if less material is left than the minimum allowed, the sub-batch will not begin. If using Automatic mode, the batch will automatically complete.
Options Tab
Most of the options on this tab are just how the batch and sub-batch options will be defaulted when configuring a new batch.
Although, there are some workflow options relating to hand-adds.
Ignore Hand-Adds
If enabled, hand-add materials will never be included in a batch. This option is primarily used for secondary systems.
Auto-Deliver Hand-Add Amounts
If enabled, hand-add material Sub-Bach Delivered amounts will be automatically populated with the Sub-Batch Requested amounts when the sub-batch is begun. Although, delivered amounts can still be edited manually as normal.
Other Configurations
Oher parts of ControlPro also have an impact of batches.
Global Settings
The Max Gross Weight controls the maximum allowable weight of a loaded truck. This is controlled by state law.
Equipment
The equipment’s Tare Weight, Capacity, and the Compartments checkbox impact how much is allowed to be in each batch. If a batch is assigned equipment with compartments, sub-batching is automatically enabled, even if the amount to be delivered does not exceed the mixer capacity.
Limiting Factors
To bring it all together, here are the factors that make up how batches and sub-batches are limited.
Batch Limiting Factors
The batch size and ability to process will be limited by these factors.
- System’s Maximum Batch Size
- Equipment’s Capacity
- Equipment is in use
- ControlPro’s Maximum Gross Weight minus the equipment’s Tare Weight
- Material Store’s Available Amount (if utilized)
Sub-Batch Limiting Factors
The sub-batch size and ability to process will be limited by these factors.
- System’s Primary Mixer Capacity
- System’s Alternate Mixer Capacity
- System’s Minimum Batch Size (sub-batch too small)
Multiple Mix Group (MMG) Tickets & Primary/Secondary Systems
Both these workflows are similar in how the batched materials are displayed in the grid. As mentioned earlier, materials not in the current sub-batch as displayed in a normal font, while batch materials in the current sub-batch are bolded.
Mix Group 1:
Mix Group 2:
This same paradigm is used for batch materials on primary and secondary systems, as well as system where had-adds are being ignored. It is important to note that even though the ignored materials are not deliverable in the current batch or sub-batch, their requested amounts are still used in the calculation of the Total Batch amount.