Automation

Smarter control, better results

At the heart of the automation is a superior PLC+HMI that connects and controls every individual component and offers direct, user-friendly access to every part of the machine. The system has built-in alerts and alarm triggers which ensure safe operations. Smart cameras use image recognition to monitor feedstock infeed and pyrolysis inside the chamber. The cloud management platform stores historical data and provides remote access to the HMI, allowing global access.

The result is a smooth-running system where operators have complete visibility, issues are detected early, and performance is optimised - delivering greater reliability, higher throughput, and stronger financial returns.

20/20 Feedstock Vision

AI-equipped smart cameras installed at the feed hopper inspect incoming feedstock for particle size and moisture hotspots. Any deviation from the expected feedstock properties would trigger an alarm, thus preventing wrong feedstock from going in and avoiding damage.

IR cameras that view the entire pyrolysis chamber provide vision of the feedstock while being pyrolyzed, along with temperature hotspots. This allows for greater visibility and automated adjustments to ensure uniform pyrolysis.

Real-time Machine Status

The Unitronics PLC+HMI provides a user-friendly touch screen to view the status of the machine. The overall status page lists the running status of all the individual components (motors, fans, pumps) and sensors (level sensors, oxygen sensor, thermocouples) along with an alarm log.

Using Unicloud (Unitronics' cloud management software), this screen can be remotely accessed from anywhere across the globe on your laptop or mobile phone. However, it is securely encrypted so that only users with the right credentials and permissions can view and control the machine status.

Precise Control Of Every Component

Beyond the status page, operators can also access individual control screens on the HMI. While the entire machine runs fully on automated commands, you can also choose to run the machine on manual or timer modes depending on your requirements.

These control pages allow you to individually control the motors, valves, pumps and fans with super-intuitive buttons and textboxes along with help icons to explain what the functions of those commands are. You can use Unicloud to allow secure remote/role-based control access to these pages.

Smart Alarm Management

The system comes with in-built alarm functions that trigger on crossing the relevant thresholds. Furthermore, every alarm and event triggered from the PLC is timestamped and stored on the HMI and forwarded to Unicloud where alarm logic enriches it (severity, affected asset, batch id, etc).

Integration with SMS/email gateways and contact groups lets the right person be notified instantly and provides a full audit trail for each alarm and acknowledgement.

Data Analytics With Unicloud

All sensor streams, control actions, batch records and alarm logs are pushed to Unicloud as time-series data and stored securely with role-based access. That centralized historian supports downloadable reports, long-term trend queries, and export to other systems (ERP/QA), giving a complete record of machine performance and material inputs.

This data can be seamlessly connected to the dMRV system of your choice, making the audit calculations for biochar and carbon credit generation effortless.

API-Ready Data for MRV and Beyond

All machine and process data from CarboFlow is structured for interoperability. Whether it’s for MRV reporting, biochar batch traceability, or internal performance tracking, our data architecture allows standard, open APIs to seamlessly connect and pipe data in formats of your choice. This flexibility means your data flows effortlessly into your chosen systems, from verification platforms to in-house dashboards, without custom middleware or manual handling.