AI Powered Quarry IoT
The quarry operations management system, from the blast to the delivered load.
Try the System.
One simulated quarry day in the real app shell: twelve steps, every module, live alarms, and the product's own rules. Press Play, or click any module.
- 00:00 · Before the Shift Group View
Midnight. Four sites, six plants and 28 days of history behind every number.
- 06:00 · Rain Overnight Stockpiles
18 mm of rain fell on North Quarry between 01:00 and 05:00. The open 14 mm pile went from 3.0 % to 4.6 % moisture.
- 06:05 · Wet Stone Costs Fuel Asphalt Plant
Plant A1 starts the day with 4.6 % moisture at the cold feed. The screen recommends the covered pile and a lower setpoint.
- 09:30 · Blast at Bench 3 Blasting
Blast B-2026-014 fired at 09:30: 4.8 mm/s at 320 m against a 5.0 mm/s limit.
- 11:00 · A Bearing on Its Way to Failure Machine Condition
The secondary cone crusher bearing on line N1 is heating up: 71 °C and rising 3.4 °C a day, its 85 °C alarm in about 4 days.
- 12:00 · Thermal Camera: a Hot Idler Conveyors
One return idler on CV2 is 34 °C hotter than the idlers beside it.
- 13:00 · Belt Damage Camera Review
The belt camera saw a tear on CV2 at 91 % confidence. It goes to a person, not to a machine.
- 14:30 · Dust Blowing Toward the Village Environment
PM10 at the village-side monitor: 178 µg/m³ over the 150 trigger, wind from 62°. The dust rule switched the sprinklers on.
- 15:00 · No Helmet Near the Conveyor Safety
The walkway camera saw a person without a helmet beside CV2 at 88 % confidence.
- 15:45 · A Load That Will Arrive Too Cold Loading and Delivery
Ticket DEMO-0415: loaded at 149 °C with a 128 °C cold corner. An 80-minute haul lands below the 140 °C minimum.
- 16:30 · Idle Machines and Missing Diesel Fleet and Fuel
Haul truck HT-2 used 27 % more fuel per engine hour than its own 14-day median; 45 L were issued with no engine hours behind them.
- 18:00 · The Day in Numbers Group View
Aggregate 6,420 t and asphalt 1,452 t produced. Crushing 2.41 kWh/t, asphalt 7.1 L/t, CO₂ 41.8 t.
Interactive demo of VYROX Quarry. Demo Quarry Sdn Bhd is a fictional company; every figure is simulated with the product's own rules and limits.
Built for Quarries and Asphalt Plants.
Runs on the VYROX AI IoT Platform: its own sign-in, its own database, a full audit log.
A Live Picture
Every machine, sensor and camera on site in one view.
Limits and Predictions
Readings checked against limits; failures predicted days ahead.
Alarms to a Person
Acknowledged, turned into work orders, and recorded.
Many Sites, One Group
Group, region, site and plant views, scoped per person.
Reports
Daily, environmental and ESG reports from the same data.
Private by Design
Its own sign-in, its own database and a full audit log.
Built for the People Who Run the Site.
Quarry Owner and Group Manager
Group View across every site, ESG and environmental reports, CO2 by source and the cross-site watch list.
Plant Manager
Tonnes per hour, stops by reason, kWh and fuel per tonne, stock days of cover and the daily report.
Maintenance Engineer
Health scores, days to the alarm limit, thermal hot spots and work orders raised from a prediction.
HSE Officer
Dust, noise and blast limits, camera detections confirmed by a person, near-miss records and SOS alarms.
From the Sensor to the Board Report.
Sense
Vibration, temperature, dust, noise, blast, level, belt scales, thermal and AI cameras on every stage of the site.
Connect
LoRaWAN and 4G gateways carry readings to the cloud over HTTPS. Where a legacy plant has no signal wired out, a gateway agent reads its HMI screen with AI vision, reading only.
Monitor
One live picture per group, site, plant and machine, and a control-room screen that rotates through the sites.
Analyse
Tonnes per hour, kWh and fuel per tonne, CO2 by source, days of cover and stops by reason, from the same readings.
Alert
Warning and alarm limits with an ISA-18.2 style deadband, banners in the app, acknowledgements and a full history.
Predict
A straight-line trend over 72 hours of running data projects the days to a bearing or motor alarm and raises the work order early.
Guide
Recommendation cards on the plant screens, and Ask AI answers from your own data with the working shown.
Control
Rule-driven commands queued for the site gateway, such as sprinklers on a dust rule. Nothing stops a machine by itself; a person confirms every camera detection.
Report
Daily operations, environmental and ESG reports against Bursa Malaysia indicators, CSV export and an audit log.
Seventeen Modules, One System.
Group View
KPIs, production and a watch list across sites.
Machine Condition
A 0 to 100 health score, every lost point explained.
Control-Room Screen
A wall display that rotates through the sites.
Blasting
PPV and air overpressure checked on every blast.
Crushing
Throughput, kWh per tonne and stops by reason.
Conveyors
Belt load and hot idlers from thermal cameras.
Stockpiles
Tonnes, days of cover and survey drift.
Asphalt Plant
Fuel per tonne, mix temperature and baghouse health.
Digital Twin
The batch plant in 3D, with process and heat views and a replay of the day.
Loading and Delivery
Predicted arrival temperature for every load.
Fleet and Fuel
Idle time and unusual fuel use flagged.
Environment
Dust, noise and water; sprinklers switched by rule.
Safety
Camera alerts become near-miss records in one step.
Alarms
Deadbands, acknowledgements and a clear history.
Work Orders
Raised from an alarm, a prediction or by hand.
Camera Review
Nine AI detections, each confirmed by a person.
Ask AI
An assistant on every page answers plain questions from your data, with the working.
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 | 4.2 |
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 6.5 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 6.1 mm/s, inside the site limit.
| Blast | PPV mm/s | Air Overpressure dBL |
|---|---|---|
| 2 Sep | 4.8 | 118 |
| 5 Sep | 6.1 | 121 |
| 9 Sep | 5.2 | 119 |
How this was worked out: Every blast record checked against the legal limits 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 × 0.585 kg CO₂/kWh, the factors 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.
| 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.
