The WEProS Mass Balance & KPI Platform converts production data, weighbridge data, quality analyses and operational records into a consistent decision layer for plant performance.
- Reconstructed input composition
- Recovery, purity, yield and residual losses
- Validated KPI output for operations, management and reporting
- Less manual spreadsheet consolidation and more structured process insight
Sorting plants generate large amounts of operational data, but data alone does not create process control. Output tonnage, quality analyses, weighbridge records and daily reports only become useful when they are connected through a consistent mass-balance logic.
The Mass Balance & KPI Platform provides that calculation layer. It is designed for operators, management teams, quality departments and reporting teams that need a technically defensible view of material performance.
The problem: output tonnage does not explain performance
A sorting plant can produce many tonnes and still lose valuable material in residual or side streams. A lower output can also be caused by a lower concentration of valuable material in the input, rather than by poor separation performance.
Without a structured mass balance, these effects are difficult to separate. The result is often a reporting layer that shows what was produced, but not why it was produced or where material performance was gained or lost.
- Output tonnage shows what left the plant.
- Input composition explains what was available for recovery.
- Recovery and purity show whether valuable material was actually recovered in the right stream.
- Residual composition shows where valuable material is still being lost.
What the platform does
The Mass Balance & KPI Platform is not a generic dashboard. It is an installation-specific process engine that maps plant data, applies validated calculation logic and produces KPI outputs that can be used for operational steering and management reporting.
The platform turns fragmented plant data into a structured performance view: from raw plant records to reconstructed input composition, recovery, purity, yield, residual losses and dashboard-ready KPI output.
Core capabilities
- Data mapping: Translation of plant data sources, Excel exports, quality forms or database fields into a stable data model.
- Mass Balance Engine: Installation-specific mass-flow logic that reconstructs input composition from outputs, quality analyses and residual streams.
- KPI calculation: Calculation of recovery, purity, yield, residual losses, throughput deviation and related plant-performance indicators.
- Data validation: Checks for missing samples, inconsistent records, unexpected deviations and calculation gaps before KPI use.
- Dashboard output: Visual output for operations, management review and structured performance follow-up.
- Reporting-ready export: KPI output suitable for publication workflows, Power BI, export files, APIs or customer reporting environments.
From plant data to a controlled KPI layer
The platform follows a practical calculation structure. Available data are harmonised, mapped to the agreed plant model and checked before they are used for mass-balance calculations. KPI values are therefore not just visualised; they are created from a controlled calculation basis.
This approach allows the plant to distinguish between input variation, data quality issues and real performance changes in the sorting process.
- Production and weighbridge data are connected to quality and residual information.
- Material flows are reconstructed into a consistent input-output view.
- KPI outputs remain traceable to the underlying data logic.
- Deviations and missing data are made visible instead of being hidden in manual spreadsheets.
Operational and management value
The platform helps a sorting plant move from fragmented reporting to repeatable performance steering. It provides one calculation basis for operational review, management discussions and structured reporting.
- Better process interpretation: understand whether lower output is caused by input variation, data issues or real recovery loss.
- More reliable KPI discussions: discuss recovery, purity and yield on the basis of one consistent calculation structure.
- Earlier detection of losses: identify valuable materials still present in residual or side streams.
- Less manual consolidation: reduce repetitive spreadsheet work and manual KPI preparation.
- Improved internal alignment: give operations, quality, management and reporting teams the same technical reference point.
KPI outputs
The final KPI set is configured per installation. Typical outputs include:
- Input composition: reconstructed material composition of the incoming stream.
- Recovery: share of a material fraction in the input that is recovered into the correct product stream.
- Purity: share of target material in a product stream, based on the applicable quality protocol.
- Yield: periodic product yield compared with reconstructed input.
- Residual composition: valuable or recyclable materials remaining in residual streams.
- Throughput deviation: difference between measured throughput and reconstructed input.
- Operational availability: runtime, preventive maintenance, corrective maintenance and related indicators.
- Transition view: material-flow view from input fractions to product, metal and residual streams.
Quality data as the foundation
A mass balance is only as reliable as the data foundation behind it. If sampling points, quality analyses, fraction definitions or registration methods are not yet stable, WEProS can support the setup of a practical measurement and quality-control framework.
This support is not positioned as a separate administrative layer. It is a preparation step to make plant data suitable for mass-balance calculations and reliable KPI use.
Designed for sorting and post-separation plants
The platform is relevant for installations that need a more technical view of material performance than output tonnage alone can provide.
- Municipal waste sorting and post-separation plants
- Plastic sorting and recycling-related operations
- Plants with multiple product, metal, residual or side streams
- Installations using Excel, forms, database exports or mixed reporting sources
- Plants preparing for more structured internal or external KPI reporting
- Management teams that need a reliable basis for investment, optimisation or performance discussions
Implementation approach
The implementation is structured around the actual plant layout, available data sources and reporting needs. The exact scope depends on the installation and the maturity of the existing data structure.
- Technical intake: clarify plant layout, data sources, existing reports and management needs.
- Process and data mapping: define relevant streams, fractions, outputs, residual streams and data fields.
- Engine configuration: configure the installation-specific calculation logic and KPI definitions.
- Historical data validation: test the logic on available historical data and identify data gaps.
- Dashboard and KPI output: prepare the operational and management output layer.
- Operational use and support: support first runs, interpretation and refinement of the KPI workflow.
Built for practical plant operation
The platform is designed to work with existing operational reality. It can start from Excel exports, quality forms, database exports or other structured data sources. The objective is not to create extra administration, but to convert existing plant information into a more reliable decision layer.
- Installation-specific, not one-size-fits-all
- Compatible with staged implementation
- Suitable for internal management reporting and operational follow-up
- Can be connected to existing dashboard or reporting environments where needed
- Focused on traceable, technically defensible process information
Technical background
For a broader technical explanation of why output tonnage alone is not sufficient to assess sorting plant performance, read the WEPROS Insights article: Why Tonnage Alone Is Not Enough to Assess a Sorting Plant.
Discuss your plant data and mass-balance potential
Would you like to understand how an operational mass balance could support process control, KPI reporting or performance optimisation for your sorting plant?
Frequently asked questions
Is this a standard dashboard?
No. The dashboard is only the presentation layer. The core is the installation-specific calculation logic behind the KPI output.
Do we need perfect data before starting?
No. The first step is often to map available data and identify gaps. The platform can be implemented in stages.
Can existing Excel files still be used?
Yes. Excel can remain an input or control format, but the mass-balance logic should not depend on manual spreadsheet consolidation.
Is quality control required?
Reliable quality data are important. Where the data foundation is not yet mature, WEProS can help define a practical measurement and registration structure.