Vardan · for plastic recycling plants
The whole plant in one system.
Old and new machines speak one data language, every unit's electricity is metered separately, stock and cost are calculated in the ERP, and the result reaches accounting on its own.
- Machines
- Energy
- Stock
- Cost
- Carbon
This page describes the scope and architecture of the system. Values in the scenes and the dashboard are samples, not measurements.
From raw material to granules, every step is measured.
As material moves down the line, the sensor and energy meter at each unit are read. In the scene, the left line carries energy and the right line carries sensor data; both meet in the hub and go on to the ERP, accounting and the carbon calculation.
The scope is the whole plant: pre-process preparation, old and new platforms, old and new Sortex optical sorters, conveyors and elevators, screen, extruder and granulation unit, labeling, compressors and solar panels.
- Raw material intakeWeighbridge and batch record: kg in, material type (PET, PE, PP).
- Conveyor and elevatorMotor energy, run and stop time.
- Washing tankPump and motor energy, water temperature, run time.
- DryerHeater and fan energy, temperature.
- ScreenVibration motor energy, run time.
- Sortex optical sorting, old and newSorting data from the machine or weighing of rejected material, air consumption, energy.
- Extruder and granulationScrew motor and heater energy, melt temperature, kg out.
- Labeling and dispatchBag weighing, batch label, entry into stock.
Different machine generations, one data language.
New and old Sortex machines, old and new platforms, elevators, screens, labeling and compressors connect to the same system. New machines report over the network; on older machines without a network connection, run, stop and fault signals are picked up with added sensors and meters.
All signals are translated into one shared format through open industrial standards such as PLC, Modbus and OPC UA. Which path suits which machine is decided during the site survey, based on the machine's own interface.
- The same fields for every machine: state, run hours, output, energy.
- Stops and faults are flagged as they happen and their duration is logged.
- An old machine can be measured from outside without replacing it.
Every unit's electricity is metered separately.
Separate energy meters are installed for conveyors and motors, the washing tank, the dryer, the extruder and granulation unit, the screen and Sortex machines, and the compressors. The plant's total bill becomes readable unit by unit.
On the solar side, metering devices connected to the inverters read production and efficiency. Energy produced and consumed is balanced on the same screen: what came from solar, what was drawn from the grid, and what each unit used.
Stock, cost and efficiency in one calculation.
The ERP layer covers not only the production line but also the steps before it: raw material intake, sorting and preparation before washing. Material in, out and rejected is tied to the batch; the batch's energy is summed from the units' meters.
- Energy per kg of granules
- Total kWh of the batch ÷ kg of granules out. Pre-process units are included.
- Cost per kg of granules
- (Energy + raw material + other plant costs) ÷ kg of granules out. Energy cost is tracked per unit, with grid and solar kept apart.
- Reject rate
- (kg in − kg out) ÷ kg in. Material removed in sorting, screening and washing is shown separately.
- Stock
- Raw material, intermediate and granule stock updates itself from weighbridge and label records.
Accounting sees plant costs without re-keying.
The algorithm merges machine, sensor, energy and stock data by batch, shift and day. It flags missing or inconsistent readings and checks them before they enter any calculation.
At the end of each period, a summary of plant costs (energy cost per unit), reject and efficiency is sent to accounting automatically. The transfer uses whatever the accounting software accepts: a file (CSV, Excel, XML) or the software's API.
Scope 2 emissions from electricity.
Because the plant's electricity is already metered unit by unit, emissions from purchased electricity (scope 2) are calculated directly. Solar power used on site reduces the share drawn from the grid; carbon per kg of granules comes from the same data.
kWh drawn from the grid×official emission factor=scope 2 (t CO₂e)
The factor is the yearly Türkiye electricity generation and consumption point emission factors published by the Ministry of Energy and Natural Resources of Türkiye (page in Turkish); it is chosen by the line the plant is connected to (transmission or distribution) and updated every year. No factor value is given on this page; the official value in force is entered at commissioning. If the dryer runs on a fuel such as natural gas, meter data can be added to cover scope 1 as well.
The plant on one screen.
Live plant view
Sample data · simulation- Total consumption
- 508kW
- Solar output
- 142kW
- From the grid
- 366kW
- Production
- 1.10t/h
- Reject
- 6.8%
- Energy per kg
- 0.46kWh/kg
- Electricity cost per kg
- 1.30TRY/kg
- Carbon, scope 2
- 183kg CO₂e/h
| Unit | Now kW | Today kWh |
|---|---|---|
| Conveyor and elevator | 24 | 190 |
| Washing tank | 86 | 702 |
| Dryer | 118 | 951 |
| Screen | 8 | 61 |
| Sortex, old and new | 19 | 149 |
| Extruder and granulation | 212 | 1,684 |
| Compressors | 38 | 297 |
| Labeling and dispatch | 3 | 22 |
| Total consumption | 508 | 4,056 |
| Solar output | 142 | 1,020 |
| Drawn from the grid | 366 | 3,036 |
These values are not real measurements. They are sample data generated to show what the dashboard looks like, and they are regenerated every few seconds. Cost uses a sample electricity tariff (3.90 TRY/kWh) and carbon uses a round, unofficial sample factor (0.5 kg CO₂e/kWh); the real tariff and the official factor are entered at commissioning.
From site survey to reporting.
Site survey
We walk the plant and list the machines, panels, existing meters and each machine's data interface.
Sensors and meters
An energy meter for every unit, sensors where needed, and a metering device connected to the inverters on the solar side.
Integration
Old and new machines are connected to the shared data language; the ERP and accounting transfer are set up.
Commissioning
Readings are checked against weighbridge and invoice records; the tariff and the official emission factor are entered.
Reporting and training
The dashboard, period reports and accounting reports go live; the plant and accounting teams are trained to use them.
Let's talk about your plant.
Write to us with your machine list and energy setup, and we will get back to you about a site survey.
iletisim@vardansistemler.com WhatsApp +90 544 673 50 67