Run the Whole Quarry from One Screen.
One AI-powered platform for the pit, the plant and the stockyard: live readings, predicted failures and every limit checked.
The Numbers That Run a Quarry.
Every Stage, from Blast to Delivered Load.
All Solutions
Crushing and Screening
Tonnes per hour and power per tonne on every line.
Dust, Noise and Water
Stay inside the limits, and prove it.
Stockpiles
Tonnes, days of cover and survey drift, by product.
Asphalt Plant
Fuel per tonne, mix temperature and baghouse health.
Weighbridge and Delivery
Every load, from the gate to the paver.
From Sensor to Decision.
Sense
Sensors and cameras on the crushers, belts, piles, ponds and the boundary.
Connect
One mast covers the pit, the plant and the stockyard, over LoRaWAN and 4G, and a Linux gateway reads Modbus plant equipment.
Decide
AI Quarry turns the readings into alarms, work orders and the daily report.
One Live Picture of Every Site.
Seventeen modules, one sign-in. Group, region, site and plant views, scoped to what each person is allowed to see.
How It Works
From the Tank to the Phone, in Eight Steps.
A real quarry story: a bitumen tank runs hot and AI Quarry handles it from sensor to fix. Watch it play, or pick a step.
Install and Pair
$ curl -fsSL aikuari.com/i | sh -s K7Q2M9XP
Release signature verified
Service started on boot
Paired with Hulu Langat Gateway
Signed configuration in sync
All Sensors
Read over RS-485 by the site gateway, every value with its unit, time and quality.
Automation Rule
When U Tank Temperature Is Above 165 °C for 5 min
Condition FalseCondition True for 5 min
Tested first with a Dry Run against the last 7 days of real data.
Actions Run in Order
- Raise Alert Done
- Send Email to the Plant Manager Queued
- Show Popup in the Control Room Shown
- Controller8 Relays On, Off After 30 min Confirmed
Offline Buffer and Local Rules
Local Rule Heater Relay Off at 166 °C Ran Offline
Gaps are recorded, never hidden. Local Rules are signed and checked against limits on the gateway.
AI Assistant
Which bitumen tank ran hot last night?
The U Shape tank ran above 165 °C for 12 minutes from 02:10. The Rule switched its relays once and the alert cleared at 02:22.
Turn the U tank heater off for one hour.
Done. Heater relay is Off, confirmed by the controller. It switches back On at 10:42.
Voice input, six AI model choices, and only the rights of the person asking.
Health and Work Orders
Rules That Act, an AI That Answers.
Set a Rule once and the platform alerts, emails and switches relays for you. Ask the AI chat anything about your site, by typing or by voice.
Automation Rules
Triggers, conditions and ten action types, with delays, versions and a 7 day Dry Run replay.
See AutomationControl and Relays
Controller8 relays switched by hand, by Rule or by AI, each command confirmed and read back.
See ControlAI Chat
Named for your company, it sees every Node, answers from history and runs on the AI you choose.
See AI ChatBuilt for Every Shift.
Alarms that find the person on duty, maintenance planned before a breakdown, and sign-in as strong as your plant needs.
Alerts Everywhere
SMS, WhatsApp, Telegram, push and a voice call for Critical alarms, with an on-call rota and shift handover.
See AlertsPredictive Maintenance
AI anomaly detection, remaining-useful-life estimates and Work Orders raised with the spare parts.
See MaintenanceSecurity and Sign-In
Two-factor sign-in, single sign-on with Microsoft or Google, IP allowlists and a tamper-evident audit log.
See SecuritySee the Heat, Stage by Stage.
Explore the Digital TwinLoading the 3D plant…
Show Readings as a Table
| Machine | Reading | Value | Limit | Status |
|---|
Interactive demo. The plant and its readings are simulated; the limits are the ones AI Quarry uses.
New
Bitumen Tanks in Live 3D.
The 3D Tank View links each tank to its radar level and temperature probe. Realistic or Thermal, a Cutaway at the live level, and a red glow the moment the over temperature Rule fires.
See the Platform.
Real screens from a demo quarry, Granite Ridge Quarry, with its Bukit Batu Quarry and Stockyard and Dispatch sites.
Screenshots of the live platform, taken on a demo company with demo data.
Hardware for Every Stage.
Thirty devices in seven families, built to work together and with AI Quarry.
AI That Shows Its Working.
Every prediction, detection and answer comes with the numbers behind it, and a person confirms before anything is logged.
Failure Prediction
Days left before a bearing or motor reaches its alarm limit, from its own trend.
Camera AI
Missing PPE, danger zones, belt damage and dust plumes, queued for a person to confirm.
Limit Checks
Dust, noise, blast vibration and water discharge checked against the Malaysian limits.
Ask AI
Fuel, energy, stock, dust or alarms, answered from your own data with the working shown.
Ask AI, from Any Page.
Plain questions about production, machines, stock, fuel, dust, blasts and alarms, answered from your own plant data.
- No outside AI service. Your plant data stays in the system.
- Shows its working. Every answer says how it was worked out and opens the page behind it.
- Respects access. Answers cover only the sites each person can see.
Which machines are predicted to fail?
One machine: the secondary cone crusher at North Quarry is heading for its 85 °C bearing alarm in about 4 days.
| Machine | Reading | Days to Limit |
|---|---|---|
| Cone crusher, North Quarry | Bearing temperature | 4.1 |
How this was worked out: A straight-line trend over the last 72 hours of running data, shown only when the fit is strong (r² 0.5 or more, 12 points or more).
Open the Machine Condition PageWhich plant used the most fuel per tonne today?
Plant A2 used the most: 7.9 litres per tonne, against 6.8 at Plant A1.
| Plant | Fuel L/t | Tonnes |
|---|---|---|
| Plant A2 | 7.9 | 612 |
| Plant A1 | 6.8 | 840 |
How this was worked out: Burner fuel used today divided by tonnes of mix produced, plant by plant.
Open the Asphalt Plant PageWhy did fuel per tonne rise at Plant A1 today?
Mostly moisture: cold-feed moisture averaged 4.6 % against 3.0 % yesterday, about 11 kWh per tonne of extra drying.
| Driver | Today | Yesterday |
|---|---|---|
| Cold-feed moisture | 4.6 % | 3.0 % |
| Mix temperature | 161 °C | 159 °C |
How this was worked out: Drying energy of 6.86 kWh/t for each 1 % of moisture (Factors page), applied to the change in moisture.
Open the Asphalt Plant PageWhich crushing line uses the most energy per tonne this week?
North Quarry uses 2.41 kWh per tonne, 18 % more than South Quarry.
| Line | kWh/t | Tonnes |
|---|---|---|
| North Quarry | 2.41 | 18,420 |
| South Quarry | 2.04 | 15,960 |
How this was worked out: Metered power on every crusher, screen and conveyor, divided by belt-scale tonnes.
Open the Crushing PageHow much 14 mm stock is left?
4,860 tonnes of 14 mm in two piles, about 6.4 days at this week's rate of draw.
| Pile | Tonnes | Days of Cover |
|---|---|---|
| North Quarry, 14 mm | 3,120 | 5.8 |
| South Quarry, 14 mm | 1,740 | 7.9 |
How this was worked out: Book stock from belt scales and deliveries, checked against the latest survey. Days of cover divide tonnes by this week's average daily draw.
Open the Stockpiles PageWere any blasts over the vibration limit this month?
No. Three blasts this month; the highest ground vibration was 4.8 mm/s, inside the 5.0 mm/s site limit.
| Blast | PPV mm/s | Air Overpressure dBL |
|---|---|---|
| 2 Sep | 4.8 | 118 |
| 5 Sep | 4.1 | 115 |
| 9 Sep | 3.6 | 113 |
How this was worked out: Every blast record checked against the site limit set on the Legal Limits page.
Open the Blasting PageWhat is our CO2 this month?
412 tonnes of CO₂ so far this month: 293 from fuel (Scope 1) and 119 from grid electricity (Scope 2).
| Source | t CO₂ |
|---|---|
| Diesel and burner fuel | 293 |
| Grid electricity | 119 |
How this was worked out: Litres of fuel × 2.68 kg CO₂/L, and kWh × the grid emission factor set on the Factors page.
Open the Reports PageHow is the dust at North Quarry?
Within the limit: the 24-hour PM10 is 62 µg/m³ at the village boundary, against 100 µg/m³ in MAAQS 2020.
| Monitor | PM10 24 h | PM2.5 24 h |
|---|---|---|
| Village boundary | 62 | 21 |
| Plant gate | 74 | 26 |
How this was worked out: 24-hour averages against the Malaysian Ambient Air Quality Standard 2020.
Open the Environment PageWhere did we lose production time this week?
3.4 hours at North Quarry, mostly feed shortage after blasts (1.9 hours).
| Reason | Hours |
|---|---|
| Feed shortage after blast | 1.9 |
| Belt tracking | 0.8 |
| Planned maintenance | 0.7 |
How this was worked out: Stops on the crushing lines, grouped by the reason operators gave them.
Open the Crushing PageHow many alarms are open?
Five open alarms: one serious and four warnings. The oldest has been open for 3 hours. The three most recent are listed.
| Alarm | Site | Since |
|---|---|---|
| Hot idler, feed conveyor | North Quarry | 10:40 |
| Drum shell hot spot | Plant A1 | 13:00 |
| Cone crusher bearing | North Quarry | 13:25 |
How this was worked out: Open alarms, plus those that cleared by themselves but are not yet acknowledged, across the sites you can see.
Open the Alarms PageSample answers from the guided-demo company; the numbers are simulated. In the product: no outside AI service is used.
AI That Reads What Others Cannot.
A weighbridge terminal or an old plant panel with no data output can still be read: from its screen, value by value, with a person checking anything the AI is unsure of.
Screen Scraper
A Windows PC captures the machine's screen; AI reads the mapped numbers.
Every Value Checked
Each value is checked for its range and for sudden jumps before it is stored.
Held for Review
Low-confidence values wait for a person instead of landing in your charts.
Reading Only
The scraper only reads the screen. It never presses a key on the machine.
Questions, Answered.
What is AI Quarry?
AI Quarry is an AI-powered IoT platform and quarry operations management system, purpose-built for quarries and asphalt plants. It joins crushers, conveyors, stockpiles, asphalt plants, trucks and environmental monitors into one live picture, then raises alarms, work orders and reports.
What does the AI do?
It projects how many days a bearing or motor has left before its alarm limit, sorts camera detections such as missing PPE, people in danger zones and belt damage for a person to confirm, checks dust, noise and water against Malaysian standards, and reads the screens of machines that have no data output.
What is Ask AI?
Ask AI is the assistant on every page of AI Quarry. It answers ten kinds of plain questions, such as which machines are predicted to fail, how much stock is left or how the dust is, from your own plant data. Every answer shows how it was worked out, and no outside AI service is used.
What is the Screen Scraper?
The Standalone System Screen Scraper reads a machine that has no data output, such as a weighbridge terminal or an older plant HMI. A Windows PC captures the screen, AI reads each mapped value, every value is checked for its range and for sudden jumps, and low-confidence values are held for a person to review. It only reads; it never controls the machine.
Which hardware does it use?
VYROX sensors, AI and thermal cameras and LoRaWAN gateways: dust and noise stations, blast vibration monitors, vibration and temperature sensors, belt scales, moisture probes and level sensors. A Linux site gateway also reads Modbus RTU over RS-485 or RS-232, Modbus TCP and ASCII serial equipment, and supported sensors come from the Sensor Catalog with their register maps ready.
How are gateways kept up to date?
Automatically. A gateway installs with one command and pairs itself. Each update is signed and checked by the gateway before it installs, updates roll out in stages, and a gateway goes back to its previous version by itself if the new one fails.
Does it work for asphalt plants?
Yes. It tracks burner fuel per tonne, mix temperature against the specification window and baghouse health, and includes a 3D digital twin of batch asphalt plants with process and heat views.
Can it switch equipment?
Yes, with care. Control writes, such as sprinklers on a dust rule, are off by default, limited to a minimum and maximum per Node, signed by the cloud, checked again by the gateway and recorded in the audit log.
What reports does it produce?
Daily operations, environmental (dust, noise and water) and ESG reports against Bursa Malaysia indicators, all from the same data the engineers use, as A4 PDFs sent by email on a schedule. Data can be exported to CSV.
Can alarms reach us by WhatsApp or SMS?
Yes. AI Quarry sends alarms by SMS, WhatsApp, Telegram, email, push notification in the iOS and Android app, and Microsoft Teams or Slack. An unacknowledged Critical alarm escalates to a voice call to the on-call person, following a rota with quiet hours per person.
Does AI Quarry support two-factor sign-in?
Yes. Every user can sign in with an authenticator app or an SMS code, and an Owner can require it for the whole company. Single sign-on with Microsoft Entra ID or Google Workspace (SAML or OIDC), IP allowlists and session timeouts are also available.
Will the site keep running if the internet drops?
Yes. The site gateway runs offline edge Rules that keep switching relays and raising local alarms, buffers every reading, and syncs when the link returns. A 4G or 5G failover link, managed from the cloud, takes over when the fixed line fails.
How do I start?
Create an account and start a 14-day free trial, or contact sales for a site survey.
Who supplies and supports it?
VYROX International Sdn Bhd in Kuala Lumpur, Malaysia, building AI and IoT systems since 2015 and certified to ISO 9001:2015 and ISO/IEC 27001:2022, with MSC Malaysia status (awarded by MDEC) and CIDB Grade G7 contractor registration. VYROX designs, installs and supports the whole system.
Tell Us About Your Quarry.
We survey the site, spec the devices, install the network and set up AI Quarry. Or start a 14-day free trial today.