Add central material calibration support

README.md

@@ -318,7 +318,7 @@ across the order's runs. The service neither reintegrates nor sums snapshots and
 does not bridge run boundaries.
 
 The result includes workplace/machine/calculation identifiers, both order identifiers,
-article context, nominal width, both original source timestamps, good area, aligned
+article context, nominal width, the UTC ERP feedback instant and selected material timestamp, good area, aligned
 consumption, `material_consumption_kg_per_m2 = consumption_kg / good_quantity_m2`,
 and `material_consumption_g_per_m2 = material_consumption_kg_per_m2 * 1000`.
 Nominal width comes from generic ERP description parsing and is context only;
@@ -352,9 +352,9 @@ result = service.evaluate_current()
 
 Aware ERP timestamps are compared as UTC instants. Naive ERP timestamps require
 explicit `erp_timezone`; there is no inferred system/database timezone. Ambiguous
-or nonexistent local times during DST transitions are rejected. The original ERP
-timestamp (including naivety) and selected material timestamp are preserved in the
-result; retain the source timezone configuration alongside it for interpretation.
+or nonexistent local times during DST transitions are rejected. The result carries the
+ERP feedback instant normalized to UTC and the selected aware material timestamp.
+The original ERP status object remains unchanged.
 
 This alignment avoids knowingly including future material consumption, but does
 not eliminate ERP roll-feedback timing uncertainty (feedback may be roughly one
@@ -366,11 +366,10 @@ stored timestamps satisfy the cutoff; a later cumulative total cannot reconstruc
 an earlier value. Reliable final evaluation requires retaining final ERP feedback;
 the current-workplace adapter alone does not provide historical completed orders.
 
-Call on changed ERP feedback; no new runner or polling loop is provided. Results
-are returned in memory without modifying earlier results or material snapshots.
-No schema, Grafana, or timeseries changes are needed. Daily per-machine 24h reporting
-and aggregation remain future work. Repository SQL selection tests use an in-memory
-SQLite fixture with driver transport adaptation; they require no live PostgreSQL.
+The service itself returns results in memory without modifying material snapshots.
+The standalone persistence runner is described below. Daily per-machine 24h reporting
+and aggregation remain future work. Repository SQL tests use an in-memory SQLite
+fixture with driver transport adaptation; they require no live PostgreSQL.
 
 ## Peak-cycle detection
 
@@ -412,3 +411,58 @@ The normal unit test suite mocks PostgreSQL and requires no live database.
 
 See [PROJECT_KNOWLEDGE.md](PROJECT_KNOWLEDGE.md) for durable project context
 and [docs/roadmap.md](docs/roadmap.md) for the implementation sequence.
+
+### Feedback-driven material-efficiency persistence
+
+Apply the updated `db/schema.sql` using the PostgreSQL setup command above, then run
+this independent foreground process:
+
+```bash
+production-analytics run material-efficiency --config config/k7-material-efficiency.yaml
+```
+
+`poll_interval_seconds` in YAML defaults to 60 seconds (fixed delay after each
+cycle). Workplace, machine, calculation, order format and `erp_timezone` are also
+configured in YAML; K7 uses `Europe/Berlin`. PostgreSQL settings use the existing
+exported `POSTGRES_*` variables and `--secrets-file` (default `secrets/enlyze.env`);
+ERP uses `--erp-secrets-file` (default `secrets/erp.env`). No additional secrets are
+needed, and `.env` is not loaded automatically.
+
+`PostgresMaterialEfficiencyWriter.write(snapshot) -> bool` validates aware
+timestamps and finite numbers, then inserts all KPI fields in a short transaction.
+`material_efficiency_snapshots` retains one immutable point per
+`(calculation_id, machine_id, enlyze_production_order, erp_feedback_timestamp)`.
+The writer uses `RETURNING 1` to return `True` for a new insert and `False` for a
+duplicate. Only new inserts produce a flushed stdout line with feedback time,
+workplace, order, good m², material kg and g/m². Unavailable evaluations and
+duplicates remain silent.
+Repeated evaluations attempt `ON CONFLICT DO NOTHING`; they never update history,
+including after a restart. Missing/invalid KPI inputs produce no row and can be
+retried on a later cycle. Nullable article context remains SQL NULL.
+
+Persistence frequency follows ERP feedback changes, not ENLYZE sample frequency.
+This runner is independent of the 10-second material polling process. Live values
+are plausibility indicators; final production-order (FA) values are more meaningful.
+Grafana can read PostgreSQL alone:
+
+```sql
+SELECT erp_feedback_timestamp AS "time", material_consumption_g_per_m2
+FROM material_efficiency_snapshots
+WHERE $__timeFilter(erp_feedback_timestamp)
+  AND calculation_id = 'k7-fiber-consumption'
+  AND machine_id = 'c220f95c-a65e-4cb7-99b7-0626d6c7508c'
+ORDER BY erp_feedback_timestamp;
+```
+
+ERP read errors and transient PostgreSQL connection/operational errors are reported
+using error classes only and retried after the configured delay. Each database
+operation opens a fresh connection. Configuration, schema/programming and invalid
+timestamp contract errors terminate with a nonzero CLI exit; ambiguous/nonexistent
+DST feedback remains rejected. Ctrl-C stops the foreground runner cleanly.
+
+The current-status ERP source cannot backfill feedback events missed between polls
+or during outages, nor guarantee observation of final FA feedback before the order
+changes. Daily 24h reports and final order summary tables remain future work.
+No dashboard, aggregation or lag correction is added here.
+
+Bento 1: [fresh bentonite consumption configuration and scope](docs/bento1-fresh-bentonite.md).

config/bento1-material-consumption.yaml

@@ -0,0 +1,21 @@
+# Fresh bentonite only: the recycled/recovered third spreader is excluded.
+calculations:
+  - id: bento1-fresh-bentonite-consumption
+    type: material_consumption
+    version: "1"
+    machine_ref: 5f42a4f6-9ca0-4f6f-9786-40d50a35b230
+    process_application_calculation_id: bento1-fresh-bentonite-application
+    source_mode: rotational_discharge
+    rotational_speed_signal_refs:
+      - 6e5d2d94-98f9-4cc1-8a88-7987c6282525
+      - cd7385c4-337b-4759-ab32-45d65beaf190
+    calibration_ref: bento1-spreader-1-2
+    # Transport Auszug Geschwindigkeit Istwert, m/min (production gate only).
+    gate_signal_ref: fef41976-1103-4090-b780-eaeecc02fdfa
+    gate_threshold: 0.3
+    max_sample_gap_seconds: 20.0
+    erp_workplace: Bento 1
+    production_order_format: "Bento 1-{production_order}"
+    output_metric: material_consumption
+    output_unit: kg
+    group_by: production_order

config/bento1-material-efficiency.yaml

@@ -0,0 +1,7 @@
+workplace: BENTO 1
+machine_id: 5f42a4f6-9ca0-4f6f-9786-40d50a35b230
+calculation_id: bento1-fresh-bentonite-consumption
+output_calculation_id: bento1-fresh-bentonite-efficiency
+production_order_format: "Bento 1-{production_order}"
+erp_timezone: Europe/Berlin
+poll_interval_seconds: 60

config/k7-material-efficiency.yaml

@@ -0,0 +1,6 @@
+workplace: K7
+machine_id: c220f95c-a65e-4cb7-99b7-0626d6c7508c
+calculation_id: k7-fiber-consumption
+production_order_format: "K 7-{production_order}"
+erp_timezone: Europe/Berlin
+poll_interval_seconds: 60

config/material-calibrations.yaml

@@ -0,0 +1,14 @@
+calibrations:
+  bento1-spreader-1-2:
+    type: rotational_discharge
+    value: 2.75
+    unit: kg_per_rev_m
+    calibrated_at: 2026-09-08
+    method: gravimetric_tray
+    description: Bento 1 fresh-bentonite spreaders 1 and 2
+    reference:
+      measured_application_g_m2: 4068
+      line_speed_m_min: 2.3
+      signal_values:
+        left: 1.65
+        right: 1.75

db/schema.sql

@@ -11,3 +11,38 @@ CREATE TABLE IF NOT EXISTS material_consumption_snapshots (
 -- Machine time series across orders; the primary key covers a specific order.
 CREATE INDEX IF NOT EXISTS material_consumption_snapshots_machine_time_idx
     ON material_consumption_snapshots (calculation_id, machine_id, timestamp);
+
+CREATE TABLE IF NOT EXISTS material_efficiency_snapshots (
+    erp_feedback_timestamp timestamptz NOT NULL,
+    material_snapshot_timestamp timestamptz NOT NULL,
+    calculation_id text NOT NULL,
+    machine_id text NOT NULL,
+    workplace text NOT NULL,
+    erp_production_order text NOT NULL,
+    enlyze_production_order text NOT NULL,
+    article_number text NULL,
+    article_description text NULL,
+    nominal_width_m double precision NULL,
+    good_quantity_m2 double precision NOT NULL,
+    material_consumption_kg double precision NOT NULL,
+    material_consumption_kg_per_m2 double precision NOT NULL,
+    material_consumption_g_per_m2 double precision NOT NULL,
+    PRIMARY KEY (calculation_id, machine_id, enlyze_production_order, erp_feedback_timestamp)
+);
+
+CREATE INDEX IF NOT EXISTS material_efficiency_snapshots_machine_time_idx
+    ON material_efficiency_snapshots (calculation_id, machine_id, erp_feedback_timestamp);
+
+-- Instantaneous process measurements; no ERP good-area denominator.
+CREATE TABLE IF NOT EXISTS material_application_snapshots (
+    timestamp timestamptz NOT NULL,
+    calculation_id text NOT NULL,
+    machine_id text NOT NULL,
+    production_order text NOT NULL,
+    run_id text NOT NULL,
+    application_g_m2 double precision NOT NULL,
+    PRIMARY KEY (calculation_id, machine_id, production_order, timestamp)
+);
+
+CREATE INDEX IF NOT EXISTS material_application_snapshots_machine_time_idx
+    ON material_application_snapshots (calculation_id, machine_id, timestamp);

docs/bento1-fresh-bentonite.md

@@ -0,0 +1,250 @@
+# Bento 1 fresh bentonite KPIs
+
+
+## Three distinct quantities
+
+All **fresh bentonite** values exclude the third recycled/recovered-material
+scatterer. Only the two actual rpm signals listed below are used; no SET signals
+are introduced. The specific discharge is central calibration
+data: **2.75 kg/(revolution × metre product width)**.
+
+A) **Instantaneous process application [g/m²]**
+
+`application_g_m2 = (rpm_left + rpm_right) × 2.75 × 1000 / line_speed_m_min`
+
+Emitted only for observed samples with line speed **strictly greater than
+0.3 m/min**. Zero, near-zero, negative and threshold-equal speeds emit no point.
+Width cancels between kg/min and m²/min; neither nominal width nor ERP good area
+enters this formula. For 3.739 + 3.956 rpm at 8 m/min the result is 2645.15625 g/m².
+This is fresh-roll process application, not FA material efficiency.
+
+B) **Cumulative fresh consumption [kg]**, unchanged
+
+`kg/min = (rpm_left + rpm_right) × nominal_width_m × 2.75`
+
+The existing previous-value integration sums `kg/min × elapsed_seconds / 60`
+for eligible intervals, using the preceding sample's production gate. Width
+continues to come from the ERP nominal-width parser. The integration algorithm,
+gap handling, order checkpoint format and disjoint-run accumulation are unchanged.
+
+C) **FA material efficiency [g/m²]**
+
+`efficiency_g_m2 = cumulative_fresh_bentonite_kg × 1000 / cumulative_good_area_m2`
+
+The generic material-efficiency service reads the latest exact-order cumulative
+snapshot **at or before the ERP feedback timestamp**, then divides by that
+feedback's cumulative good area. Missing/nonpositive good area emits no point.
+This ratio includes losses captured by the existing consumption model (startup
+material, rejects and other consumed material not represented in good area).
+It does not add consumption during intervals excluded by the validated gate or
+gap rules, including stopped-line periods. Disjoint runs of one FA share the
+existing order total; their cumulative snapshots must not be summed again.
+
+## Configuration, PostgreSQL and Grafana
+
+| Calculation ID | Table | Value column | Time column |
+| --- | --- | --- | --- |
+| `bento1-fresh-bentonite-application` | `material_application_snapshots` | `application_g_m2` | `timestamp` |
+| `bento1-fresh-bentonite-consumption` | `material_consumption_snapshots` | `consumption_kg` | `timestamp` |
+| `bento1-fresh-bentonite-efficiency` | `material_efficiency_snapshots` | `material_consumption_g_per_m2` | `erp_feedback_timestamp` |
+
+Scope Grafana queries by calculation ID and
+`machine_id = '5f42a4f6-9ca0-4f6f-9786-40d50a35b230'`; optionally filter by
+`production_order` (application/consumption) or `enlyze_production_order`
+(efficiency). The efficiency table also stores `good_quantity_m2`,
+`material_consumption_kg`, `material_consumption_kg_per_m2` and
+`material_snapshot_timestamp` for auditability.
+
+`config/bento1-material-consumption.yaml` opts into process snapshots through
+`process_application_calculation_id`. This generic option requires rotational
+sources and a positive speed gate. Both outputs reuse the same configured ACT
+signals, discharge factor and samples. Process points use source timestamps,
+including bootstrap samples from disjoint runs; no interpolation or hold-forward
+points are stored for inactive periods. Configure Grafana to leave missing
+periods as gaps rather than carrying the last active value forward.
+
+The shared consumption poller still requires valid ERP width/order context to
+complete a cycle, although the application formula itself has no width input.
+Application rows are committed before the existing checkpoint advances; a failed
+application write retries the window. Duplicate source timestamps are ignored by
+the primary key. Existing checkpoints are retained, so earlier application
+history is not automatically backfilled. K7 does not enable this output.
+
+`config/bento1-material-efficiency.yaml` uses the existing generic runner.
+`calculation_id` selects the cumulative input; optional `output_calculation_id`
+sets the distinct persisted KPI ID. Omitting it preserves existing behavior,
+including K7. ERP workplace `strip().casefold()` normalization is unchanged.
+
+Before deploying, apply the additive, idempotent `db/schema.sql` to the existing
+PostgreSQL database to create `material_application_snapshots` and its index.
+The existing consumption and efficiency tables need no column migration. For
+example, on the deployment host:
+
+```sh
+docker compose exec -T timescaledb psql -U production_analytics -d production_analytics \
+  -v ON_ERROR_STOP=1 < db/schema.sql
+```
+
+Restart the configured Bento consumption runner to enable process persistence,
+and supervise a separate generic efficiency runner:
+
+```sh
+production-analytics run material-efficiency \
+  --config config/bento1-material-efficiency.yaml \
+  --secrets-file secrets/enlyze.env --erp-secrets-file secrets/erp.env
+```
+
+No cleanup/reset of validated rpm consumption state or snapshots is required for
+these additions. No database migration, live service restart or historical data
+cleanup was performed as part of this implementation.
+
+## Validated cumulative model details
+
+`config/bento1-material-consumption.yaml` defines
+`bento1-fresh-bentonite-consumption`, an estimate of **fresh bentonite consumption**
+from actual spreader roll speeds. Both needle rolls apply sequentially across the
+full web width. The recycled/recovered third spreader is excluded.
+
+The generic `rotational_discharge` source converts one or more rpm signals to the
+existing integrator's kg/h: `sum(rpm) × nominal_width_m × specific_discharge_kg_per_rev_m × 60`.
+Bento config sets the factor to **2.75 kg/(rev·m)** and uses:
+
+- Right ACT: `6e5d2d94-98f9-4cc1-8a88-7987c6282525`
+- Left ACT: `cd7385c4-337b-4759-ab32-45d65beaf190`
+
+ENLYZE now returns physical rpm directly (scaling factor 1.0); no division by
+1000 is applied. For 3.739 + 3.956 rpm and 5 m width, the rate is 105.80625 kg/min
+(6348.375 kg/h), giving 17.634375 kg in ten seconds.
+
+For cumulative consumption, transport speed
+`fef41976-1103-4090-b780-eaeecc02fdfa` remains exclusively the production gate:
+speed must be strictly greater than 0.3 m/min. It does not multiply the mass rate.
+For instantaneous application, this same speed is also the denominator. The generic rotational mode also supports omitting
+`gate_signal_ref` and `gate_threshold`, in which case all valid intervals are
+active. Bento retains its gate.
+
+The two old SET sources `19ea65d2-bd35-4d02-89de-4495583d9026` and
+`d9f47615-69cf-4f97-88df-199585764491` are no longer requested by Bento.
+`direct_mass_rate` remains the default for K7; `area_application` remains
+available for other configurations. There is no Bento branch in the integrator.
+
+The previous-value integration, JSON state format and order bootstrap/resume
+remain unchanged. Totals accumulate across disjoint runs, with a new baseline
+at each run boundary, even if the inter-run gap is under 20 seconds. Intervals
+up to 20 seconds use the preceding rate and gate; longer sample gaps and
+unobserved run tails are not integrated. Missing/nonfinite source values reject
+the cycle. Finite negative speeds retain the existing generic signed-rate
+semantics; no clamping is introduced.
+
+Width comes from the existing ERP nominal-width parser, with workplace
+`Bento 1` and order format `Bento 1-{production_order}`. Workplace comparisons
+use `strip().casefold()`; order matching remains strict. Missing/mismatched ERP
+context or an unparseable width rejects the cycle without saving state. The
+current ERP context supplies width for all runs of the same order, assuming
+constant article width. Historical orders no longer in the ERP workplace view
+need a historical width source for replay.
+
+The current factor is **2.75 kg/(rev*m)**, independently derived on
+**2026-09-08** by the **gravimetric tray method**: measured application
+**4068 g/m²**, line speed **2.3 m/min**, actual rotational signals **left 1.65**
+and **right 1.75**. The derivation is `4.068 × 2.3 / (1.65 + 1.75) ≈ 2.75188`,
+rounded to the configured 2.75. This supersedes the earlier 3.12 estimate.
+See [central calibration configuration](material-calibrations.md) for updates
+and persistence semantics.
+
+Tests use realistic rpm values and synthetic samples, including disjoint-run
+bootstrap and persisted resume. They are not a new replay of recorded ENLYZE data.
+
+## Historical migration from SET to rpm: review before execution
+
+The following records the earlier source-model migration, **not a prerequisite
+cleanup for adding these KPIs**. Its deployment observations are historical.
+If the validated rpm model is already deployed, retain its state and snapshots;
+do not execute this historical cleanup for the KPI extension. Recheck deployment
+provenance separately if that earlier migration is still outstanding.
+
+No production state or database rows were changed during this implementation,
+and no service start was requested. The operator reports Bento stopped;
+sandbox systemd access could not independently confirm that state.
+The deployed `/etc/systemd/system/production-analytics-bento1.service` specifies
+`/opt/git-projects/production-analytics/data/state/material` as its state directory.
+
+The existing state file for machine `5f42a4f6-9ca0-4f6f-9786-40d50a35b230`
+and order `Bento 1-12026000857` is exactly:
+
+```text
+/opt/git-projects/production-analytics/data/state/material/4d6cc209e35bc58887e5b4a3816835006425429e810e0d957f651971723e8c2f.json
+```
+
+This identity was verified using the store's SHA-256 of the JSON machine/order
+pair. The file exists but its contents are not readable by the sandbox user.
+The other state file, `6d11088159b8e4fd21543560a54a31a0f86faf22bbf8f16873b228d1903c23f9.json`,
+has not been attributed here and must be left untouched.
+
+Old PostgreSQL snapshots are in `material_consumption_snapshots`, scoped by both
+`calculation_id = 'bento1-fresh-bentonite-consumption'` and
+`machine_id = '5f42a4f6-9ca0-4f6f-9786-40d50a35b230'`.
+The table has no calculation-source/version provenance column. Given the stopped
+service and no rpm deployment yet, existing rows in this scope belong to the old
+calculation. PostgreSQL was unreachable from the sandbox, so exact row counts,
+order/run membership and timestamp bounds remain unverified. Do not mistake
+this predicate for a completed row inventory. Review the following output first.
+
+Run these **read-only inventory commands** on the deployment host:
+
+```sh
+cd /opt/git-projects/production-analytics
+sudo systemctl is-active production-analytics-bento1.service
+sudo cat data/state/material/4d6cc209e35bc58887e5b4a3816835006425429e810e0d957f651971723e8c2f.json
+sudo docker compose exec -T timescaledb psql -U production_analytics -d production_analytics -v ON_ERROR_STOP=1 <<'SQL'
+BEGIN READ ONLY;
+SELECT production_order, run_id, count(*) AS rows,
+       min(timestamp) AS first_snapshot, max(timestamp) AS last_snapshot,
+       min(consumption_kg), max(consumption_kg)
+FROM material_consumption_snapshots
+WHERE calculation_id = 'bento1-fresh-bentonite-consumption'
+  AND machine_id = '5f42a4f6-9ca0-4f6f-9786-40d50a35b230'
+GROUP BY production_order, run_id ORDER BY first_snapshot;
+SELECT * FROM material_consumption_snapshots
+WHERE calculation_id = 'bento1-fresh-bentonite-consumption'
+  AND machine_id = '5f42a4f6-9ca0-4f6f-9786-40d50a35b230'
+ORDER BY production_order, timestamp;
+COMMIT;
+SQL
+```
+
+After reviewing the inventory, and **only with cleanup authorization**, keep the
+service stopped and execute this backup-and-delete transaction. The backup table
+intentionally has no `IF NOT EXISTS`: a repeated invocation fails rather than
+reusing an older backup. Only rows with the backed-up primary keys are deleted.
+K7 rows are outside the predicate.
+
+```sh
+cd /opt/git-projects/production-analytics
+sudo docker compose exec -T timescaledb psql -U production_analytics -d production_analytics -v ON_ERROR_STOP=1 <<'SQL'
+BEGIN;
+CREATE TABLE bento1_material_snapshots_before_rpm_20260907 AS
+SELECT * FROM material_consumption_snapshots
+WHERE calculation_id = 'bento1-fresh-bentonite-consumption'
+  AND machine_id = '5f42a4f6-9ca0-4f6f-9786-40d50a35b230';
+DELETE FROM material_consumption_snapshots AS s
+USING bento1_material_snapshots_before_rpm_20260907 AS old
+WHERE s.calculation_id = old.calculation_id AND s.machine_id = old.machine_id
+  AND s.production_order = old.production_order AND s.timestamp = old.timestamp;
+COMMIT;
+SQL
+sudo mv -n -- \
+  data/state/material/4d6cc209e35bc58887e5b4a3816835006425429e810e0d957f651971723e8c2f.json \
+  data/state/material/4d6cc209e35bc58887e5b4a3816835006425429e810e0d957f651971723e8c2f.json.before-rpm-20260907
+```
+
+Verify the original JSON path is absent before restarting; `mv -n` preserves an
+existing backup and will not overwrite it. If inventory reveals other Bento
+orders, derive their paths with `JsonMaterialStateStore._path(machine, order)`
+and review any existing files before moving them too. Do not clear the shared
+directory. Complete both state and snapshot cleanup before starting the new
+code: the state schema deliberately does not detect a changed source model.
+
+A later start bootstraps only the currently open order using its current ERP
+width. It does not automatically rebuild snapshots for closed historical
+orders. Reconstructing those requires a separately reviewed historical replay.

docs/material-calibrations.md

@@ -0,0 +1,73 @@
+# Material calibrations
+
+Process calibration values live in the version-controlled
+`config/material-calibrations.yaml`. Calculations refer to opaque IDs; IDs have
+no special meaning to the parser. The current entry is:
+
+```yaml
+calibrations:
+  bento1-spreader-1-2:
+    type: rotational_discharge
+    value: 2.75
+    unit: kg_per_rev_m
+    calibrated_at: 2026-09-08
+    method: gravimetric_tray
+    description: Bento 1 fresh-bentonite spreaders 1 and 2
+    reference:
+      measured_application_g_m2: 4068
+      line_speed_m_min: 2.3
+      signal_values:
+        left: 1.65
+        right: 1.75
+```
+
+All entry fields are required. Type, unit, method and description are non-empty
+strings; value must be a finite number (booleans are rejected); calibrated_at is
+a calendar date in YYYY-MM-DD format, quoted or unquoted. Reference is a non-empty
+mapping whose contents preserve source-specific measurement provenance. Unknown
+entry fields and duplicate YAML keys are rejected. The generic registry permits
+other types and units; each consuming calculation checks its own compatibility.
+
+`config/bento1-material-consumption.yaml` contains
+`calibration_ref: bento1-spreader-1-2`. During configuration loading, references
+resolve from `material-calibrations.yaml` in the calculation file's directory,
+independently of the working directory. The entire registry is validated when a
+reference is used. Rotational discharge requires type `rotational_discharge`,
+unit `kg_per_rev_m` and a positive value. Resolution supplies the existing
+`specific_discharge_kg_per_rev_m` runtime field for both application and
+consumption; the calculation algorithms are unchanged. There is no unit conversion.
+
+Missing/unreadable files, missing IDs, invalid metadata and incompatible type or
+unit raise `CalculationConfigError` before a runner starts. Existing direct numeric
+configurations remain supported; specifying both a reference and a direct factor
+is rejected. References are currently supported by rotational discharge consumers.
+K7 uses direct mass rate and does not load or require a calibration file.
+
+## Updating a calibration
+
+After a physical measurement, edit only the central entry's value, date, method
+and reference details, and keep its ID stable. Review and version-control the
+change. Additional machines can add new IDs using the same structure. A new
+calculation type needs an explicit consumer compatibility contract.
+
+Ship the central YAML alongside the calculation YAML and restart the consuming
+process to load changes. No new CLI flag, environment variable, database migration
+or UI is required. There is no hot reload or historical date-based selection.
+Changes affect future calculations and explicitly rebuilt calculations. Historical
+persisted snapshots are **not automatically recalculated**. Existing checkpoints
+retain accumulated totals, so subsequent increments use the newly loaded factor;
+a complete historical rebuild requires a separately planned replay. Persisted
+snapshots do not gain calibration-version provenance through this change.
+
+## Current Bento provenance
+
+On 2026-09-08, an independent gravimetric tray measurement found 4068 g/m² at
+2.3 m/min with actual rotational signals left 1.65 and right 1.75.
+`(4068 / 1000) × 2.3 / (1.65 + 1.75) ≈ 2.75188 kg/(rev*m)` gives the configured
+rounded factor **2.75 kg/(rev*m)**. The original measurement remains recorded,
+without fitting or adjusting the runtime value to reproduce it exactly.
+
+Only fresh-bentonite spreaders 1 and 2 are included. Before adding spreader 3,
+confirm its material scope, actual signal units, independent calibration and
+whether its output belongs in the fresh-material KPIs. No spreader 3 support is
+included here.

src/production_analytics/calculations/calibrations.py

@@ -0,0 +1,89 @@
+"""Generic, version-controlled calibration values and measurement provenance."""
+
+from dataclasses import dataclass
+from datetime import date
+from pathlib import Path
+from typing import Any
+
+import yaml
+
+from production_analytics.calculations.config import (
+    CalculationConfigError,
+    _UniqueLoader,
+    finite_number,
+)
+
+
+@dataclass(frozen=True, slots=True)
+class Calibration:
+    type: str
+    value: float
+    unit: str
+    calibrated_at: date
+    method: str
+    description: str
+    reference: dict[str, Any]
+
+
+def load_calibrations(path: str | Path) -> dict[str, Calibration]:
+    """Validate every entry, retaining opaque IDs and free-form reference metadata."""
+    try:
+        with Path(path).open(encoding="utf-8") as stream:
+            document = yaml.load(stream, Loader=_UniqueLoader)
+    except (OSError, UnicodeError) as exc:
+        raise CalculationConfigError(f"Cannot read calibration configuration: {path}") from exc
+    except yaml.YAMLError as exc:
+        raise CalculationConfigError(f"Invalid YAML in calibration configuration: {path}") from exc
+    if not isinstance(document, dict) or set(document) != {"calibrations"}:
+        raise CalculationConfigError("Calibration configuration must contain only 'calibrations'")
+    entries = document["calibrations"]
+    if not isinstance(entries, dict) or not entries:
+        raise CalculationConfigError("calibrations must be a non-empty mapping")
+    result = {}
+    required = {"type", "value", "unit", "calibrated_at", "method", "description", "reference"}
+    for identifier, entry in entries.items():
+        prefix = f"calibrations[{identifier!r}]"
+        if not identifier.strip():
+            raise CalculationConfigError("Calibration IDs must be non-empty strings")
+        if not isinstance(entry, dict) or set(entry) != required:
+            raise CalculationConfigError(
+                f"{prefix}: required fields are {', '.join(sorted(required))}"
+            )
+        for name in ("type", "unit", "method", "description"):
+            if not isinstance(entry[name], str) or not entry[name].strip():
+                raise CalculationConfigError(f"{prefix}.{name} must be a non-empty string")
+        calibrated_at = entry["calibrated_at"]
+        if isinstance(calibrated_at, str):
+            try:
+                parsed = date.fromisoformat(calibrated_at)
+                if parsed.isoformat() != calibrated_at:
+                    raise ValueError
+                calibrated_at = parsed
+            except ValueError as exc:
+                raise CalculationConfigError(f"{prefix}.calibrated_at must be YYYY-MM-DD") from exc
+        if type(calibrated_at) is not date:
+            raise CalculationConfigError(f"{prefix}.calibrated_at must be YYYY-MM-DD")
+        if not isinstance(entry["reference"], dict) or not entry["reference"]:
+            raise CalculationConfigError(f"{prefix}.reference must be a non-empty mapping")
+        result[identifier] = Calibration(
+            **{**entry, "calibrated_at": calibrated_at,
+               "value": finite_number(entry["value"], f"{prefix}.value")},
+        )
+    return result
+
+
+def resolve_calibration(
+    calibrations: dict[str, Calibration], reference: str, *, expected_type: str, expected_unit: str,
+) -> Calibration:
+    """Require explicit compatibility; no implicit conversion or ID interpretation."""
+    if not isinstance(reference, str) or not reference.strip():
+        raise CalculationConfigError("calibration_ref must be a non-empty string")
+    if reference not in calibrations:
+        raise CalculationConfigError(f"Missing calibration ID: {reference!r}")
+    calibration = calibrations[reference]
+    for field, expected in (("type", expected_type), ("unit", expected_unit)):
+        if getattr(calibration, field) != expected:
+            raise CalculationConfigError(
+                f"Calibration {reference!r}: incompatible {field}; expected {expected!r}"
+            )
+    return calibration

src/production_analytics/calculations/config.py

@@ -1,6 +1,6 @@
 """Strict configuration for executable material-consumption instances."""
 
-from dataclasses import dataclass, fields
+from dataclasses import MISSING, dataclass, fields
 from math import isfinite
 from pathlib import Path
 
@@ -48,12 +48,20 @@ class MaterialCalculationConfig:
     version: str
     machine_ref: str
     rate_signal_ref: str
-    gate_signal_ref: str
+    gate_signal_ref: str | None
     gate_threshold: float
     max_sample_gap_seconds: float
     output_metric: str
     output_unit: str
     group_by: str
+    source_mode: str = "direct_mass_rate"
+    application_signal_refs: tuple[str, ...] = ()
+    rotational_speed_signal_refs: tuple[str, ...] = ()
+    specific_discharge_kg_per_rev_m: float | None = None
+    calibration_ref: str | None = None
+    erp_workplace: str = ""
+    production_order_format: str = ""
+    process_application_calculation_id: str | None = None
 
 
 def load_material_calculation(
@@ -71,20 +79,32 @@ def load_material_calculation(
     entries = document["calculations"]
     if not isinstance(entries, list) or not entries:
         raise CalculationConfigError("calculations must be a non-empty list")
-    required = {field.name for field in fields(MaterialCalculationConfig)}
+    allowed = {field.name for field in fields(MaterialCalculationConfig)}
+    required = {field.name for field in fields(MaterialCalculationConfig)
+                if field.default is MISSING}
     instances = {}
+    calibrations = None
     for index, entry in enumerate(entries):
         prefix = f"calculations[{index}]"
         if not isinstance(entry, dict):
             raise CalculationConfigError(f"{prefix} must be a mapping")
         if "type" in entry and entry["type"] != "material_consumption":
             raise CalculationConfigError(f"{prefix}.type: only 'material_consumption' is supported")
+        area = entry.get("source_mode", "direct_mass_rate") == "area_application"
+        rotational = entry.get("source_mode") == "rotational_discharge"
+        if rotational:
+            entry.setdefault("gate_signal_ref", None)
+            entry.setdefault("gate_threshold", 0.0)
+        if area or rotational:
+            entry.setdefault("rate_signal_ref", "unused")
         missing = required - entry.keys()
         if missing:
             raise CalculationConfigError(f"{prefix}: missing fields: {', '.join(sorted(missing))}")
-        if entry.keys() - required:
+        if entry.keys() - allowed:
             raise CalculationConfigError(f"{prefix}: unknown fields (check spelling)")
         for name in sorted(required - {"gate_threshold", "max_sample_gap_seconds"}):
+            if name == "gate_signal_ref" and rotational and entry[name] is None:
+                continue
             if not isinstance(entry[name], str) or not entry[name].strip():
                 raise CalculationConfigError(f"{prefix}.{name} must be a non-empty string")
         for name, expected in (
@@ -98,9 +118,82 @@ def load_material_calculation(
         entry["max_sample_gap_seconds"] = finite_number(
             entry["max_sample_gap_seconds"], f"{prefix}.max_sample_gap_seconds", positive=True,
         )
+        mode = entry.get("source_mode", "direct_mass_rate")
+        if not isinstance(mode, str) or mode not in {
+            "direct_mass_rate", "area_application", "rotational_discharge",
+        }:
+            raise CalculationConfigError("Unsupported material source_mode")
+        if area or rotational:
+            refs_name = "rotational_speed_signal_refs" if rotational else "application_signal_refs"
+            other = "application_signal_refs" if rotational else "rotational_speed_signal_refs"
+            if other in entry:
+                raise CalculationConfigError(f"{mode} cannot specify {other}")
+            refs = entry.get(refs_name)
+            if (not isinstance(refs, list) or not refs
+                    or any(not isinstance(ref, str) or not ref.strip() for ref in refs)
+                    or len(set(refs)) != len(refs)):
+                raise CalculationConfigError(
+                    f"{refs_name} must be unique signal strings"
+                )
+            if entry["rate_signal_ref"] != "unused":
+                raise CalculationConfigError(f"{mode} cannot specify rate_signal_ref")
+            for name in ("erp_workplace", "production_order_format"):
+                if not isinstance(entry.get(name), str) or not entry[name].strip():
+                    raise CalculationConfigError(f"{mode} requires {name}")
+            from production_analytics.context import build_enlyze_production_order
+            try:
+                build_enlyze_production_order("0", entry["production_order_format"])
+            except ValueError as exc:
+                raise CalculationConfigError("Invalid production_order_format") from exc
+            entry[refs_name] = tuple(refs)
+        elif any(name in entry for name in (
+            "application_signal_refs", "rotational_speed_signal_refs",
+            "erp_workplace", "production_order_format",
+        )):
+            raise CalculationConfigError("Width context fields require a width-based source mode")
+        if "calibration_ref" in entry:
+            if not rotational:
+                raise CalculationConfigError("calibration_ref requires rotational_discharge")
+            if "specific_discharge_kg_per_rev_m" in entry:
+                raise CalculationConfigError(
+                    "Specify calibration_ref or direct specific discharge, not both"
+                )
+            from production_analytics.calculations.calibrations import (
+                load_calibrations,
+                resolve_calibration,
+            )
+            if calibrations is None:
+                calibrations = load_calibrations(Path(path).parent / "material-calibrations.yaml")
+            calibration = resolve_calibration(
+                calibrations, entry["calibration_ref"],
+                expected_type="rotational_discharge", expected_unit="kg_per_rev_m",
+            )
+            entry["specific_discharge_kg_per_rev_m"] = calibration.value
+        if rotational:
+            entry["specific_discharge_kg_per_rev_m"] = finite_number(
+                entry.get("specific_discharge_kg_per_rev_m"),
+                "specific_discharge_kg_per_rev_m", positive=True,
+            )
+        elif "specific_discharge_kg_per_rev_m" in entry:
+            raise CalculationConfigError("Specific discharge requires rotational_discharge")
+        if "process_application_calculation_id" in entry:
+            process_id = entry["process_application_calculation_id"]
+            if (not isinstance(process_id, str) or not process_id.strip()
+                    or "\x00" in process_id or process_id == entry["id"]):
+                raise CalculationConfigError(
+                    "process application ID must be a distinct non-empty string"
+                )
+            if not rotational or not entry["gate_signal_ref"] or entry["gate_threshold"] <= 0:
+                raise CalculationConfigError(
+                    "Process application requires rotational_discharge and a positive speed gate"
+                )
         if entry["id"] in instances:
             raise CalculationConfigError("Calculation ids must be unique")
         instances[entry["id"]] = MaterialCalculationConfig(**entry)
+    process_ids = [c.process_application_calculation_id for c in instances.values()
+                   if c.process_application_calculation_id is not None]
+    if len(set(process_ids)) != len(process_ids) or set(process_ids) & instances.keys():
+        raise CalculationConfigError("Calculation ids must be unique across all outputs")
     if calculation_id is not None:
         if calculation_id not in instances:
             raise CalculationConfigError("Requested calculation id was not found")

src/production_analytics/calculations/material_application.py

@@ -0,0 +1,25 @@
+"""Width-independent process application from actual rotational speeds."""
+
+from collections.abc import Iterable
+from math import isfinite
+
+
+def rotational_application_g_m2(
+    rotational_speeds_rpm: Iterable[float], specific_discharge_kg_per_rev_m: float,
+    line_speed_m_min: float, gate_threshold: float,
+) -> float | None:
+    speeds = tuple(rotational_speeds_rpm)
+    if not speeds or not all(isfinite(value) for value in speeds):
+        raise ValueError("rotational speeds must be non-empty and finite")
+    if not isfinite(specific_discharge_kg_per_rev_m) or specific_discharge_kg_per_rev_m <= 0:
+        raise ValueError("specific discharge must be finite and positive")
+    if not isfinite(gate_threshold) or gate_threshold <= 0:
+        raise ValueError("speed gate threshold must be finite and positive")
+    if not isfinite(line_speed_m_min):
+        raise ValueError("line speed must be finite")
+    if line_speed_m_min <= gate_threshold:
+        return None
+    value = sum(speeds) * specific_discharge_kg_per_rev_m * 1000 / line_speed_m_min
+    if not isfinite(value):
+        raise ValueError("derived application must be finite")
+    return value

src/production_analytics/calculations/material_consumption.py

@@ -13,6 +13,7 @@ class MaterialSample:
     timestamp: datetime
     material_rate_kg_per_hour: float
     gate_value: float
+    application_g_m2: float | None = None
 
 
 @dataclass(frozen=True, slots=True)
@@ -102,3 +103,38 @@ class MaterialConsumptionIntegrator:
         for sample in samples:
             self.process(sample)
         return self.state
+
+
+def area_application_rate_kg_per_hour(
+    applications_g_m2: Iterable[float], nominal_width_m: float, line_speed_m_min: float,
+) -> float:
+    """Normalize summed area application to the integrator's canonical kg/h."""
+    applications = tuple(applications_g_m2)
+    if not applications or not all(isfinite(value) for value in applications):
+        raise ValueError("application values must be non-empty and finite")
+    if not isfinite(nominal_width_m) or nominal_width_m <= 0:
+        raise ValueError("nominal width must be finite and positive")
+    if not isfinite(line_speed_m_min):
+        raise ValueError("line speed must be finite")
+    rate = sum(applications) * nominal_width_m * line_speed_m_min * 60 / 1000
+    if not isfinite(rate):
+        raise ValueError("derived material rate must be finite")
+    return rate
+
+
+def rotational_discharge_rate_kg_per_hour(
+    rotational_speeds_rpm: Iterable[float], nominal_width_m: float,
+    specific_discharge_kg_per_rev_m: float,
+) -> float:
+    """Convert full-width roll speeds and specific discharge to canonical kg/h."""
+    speeds = tuple(rotational_speeds_rpm)
+    if not speeds or not all(isfinite(value) for value in speeds):
+        raise ValueError("rotational speeds must be non-empty and finite")
+    if not isfinite(nominal_width_m) or nominal_width_m <= 0:
+        raise ValueError("nominal width must be finite and positive")
+    if not isfinite(specific_discharge_kg_per_rev_m) or specific_discharge_kg_per_rev_m <= 0:
+        raise ValueError("specific discharge must be finite and positive")
+    rate = sum(speeds) * nominal_width_m * specific_discharge_kg_per_rev_m * 60
+    if not isfinite(rate):
+        raise ValueError("derived material rate must be finite")
+    return rate

src/production_analytics/cli/__main__.py

@@ -37,10 +37,18 @@ def _parser() -> argparse.ArgumentParser:
     raw.add_argument("--query", action="append", type=_query_item, default=[], metavar="KEY=VALUE")
     raw.add_argument("--pretty", action="store_true", help="Pretty-print sanitized JSON")
     raw.add_argument("--verbose", action="store_true", help="Show safe request progress on stderr")
-    raw.add_argument("--save-fixture", metavar="NAME", help="Save sanitized JSON under fixtures/enlyze/")
-    raw.add_argument("--save-raw", metavar="NAME", help="Save unmodified response under ignored data/raw/enlyze/")
-    raw.add_argument("--fixture-dir", type=Path, default=Path("fixtures/enlyze"), help=argparse.SUPPRESS)
-    raw.add_argument("--raw-dir", type=Path, default=Path("data/raw/enlyze"), help=argparse.SUPPRESS)
+    raw.add_argument(
+        "--save-fixture", metavar="NAME", help="Save sanitized JSON under fixtures/enlyze/"
+    )
+    raw.add_argument(
+        "--save-raw", metavar="NAME", help="Save unmodified response under ignored data/raw/enlyze/"
+    )
+    raw.add_argument(
+        "--fixture-dir", type=Path, default=Path("fixtures/enlyze"), help=argparse.SUPPRESS
+    )
+    raw.add_argument(
+        "--raw-dir", type=Path, default=Path("data/raw/enlyze"), help=argparse.SUPPRESS
+    )
     raw.add_argument(
         "--secrets-file",
         type=Path,
@@ -52,18 +60,44 @@ def _parser() -> argparse.ArgumentParser:
     timeseries.add_argument("--start", required=True, help="ISO 8601 datetime with timezone")
     timeseries.add_argument("--end", required=True, help="ISO 8601 datetime with timezone")
     timeseries.add_argument("--variable", required=True, help="Variable UUID")
-    timeseries.add_argument("--resampling-interval", type=int, help="Seconds; schema range is 10..604800")
+    timeseries.add_argument(
+        "--resampling-interval", type=int, help="Seconds; schema range is 10..604800"
+    )
     timeseries.add_argument(
         "--resampling-method",
-        choices=["first", "last", "max", "min", "count", "sum", "avg", "median", "std", "q5", "q25", "q75", "q95"],
+        choices=[
+            "first",
+            "last",
+            "max",
+            "min",
+            "count",
+            "sum",
+            "avg",
+            "median",
+            "std",
+            "q5",
+            "q25",
+            "q75",
+            "q95",
+        ],
         help="Optional schema-defined method for this variable",
     )
     timeseries.add_argument("--pretty", action="store_true", help="Pretty-print sanitized JSON")
-    timeseries.add_argument("--verbose", action="store_true", help="Show safe request progress on stderr")
-    timeseries.add_argument("--save-fixture", metavar="NAME", help="Save sanitized JSON under fixtures/enlyze/")
-    timeseries.add_argument("--save-raw", metavar="NAME", help="Save unmodified response under ignored data/raw/enlyze/")
-    timeseries.add_argument("--fixture-dir", type=Path, default=Path("fixtures/enlyze"), help=argparse.SUPPRESS)
-    timeseries.add_argument("--raw-dir", type=Path, default=Path("data/raw/enlyze"), help=argparse.SUPPRESS)
+    timeseries.add_argument(
+        "--verbose", action="store_true", help="Show safe request progress on stderr"
+    )
+    timeseries.add_argument(
+        "--save-fixture", metavar="NAME", help="Save sanitized JSON under fixtures/enlyze/"
+    )
+    timeseries.add_argument(
+        "--save-raw", metavar="NAME", help="Save unmodified response under ignored data/raw/enlyze/"
+    )
+    timeseries.add_argument(
+        "--fixture-dir", type=Path, default=Path("fixtures/enlyze"), help=argparse.SUPPRESS
+    )
+    timeseries.add_argument(
+        "--raw-dir", type=Path, default=Path("data/raw/enlyze"), help=argparse.SUPPRESS
+    )
     timeseries.add_argument(
         "--secrets-file",
         type=Path,
@@ -78,6 +112,11 @@ def _parser() -> argparse.ArgumentParser:
     material.add_argument("--poll-interval-seconds", type=float, default=10.0)
     material.add_argument("--state-directory", type=Path, default=Path("data/state/material"))
     material.add_argument("--secrets-file", type=Path, default=Path("secrets/enlyze.env"))
+    material.add_argument("--erp-secrets-file", type=Path, default=Path("secrets/erp.env"))
+    efficiency = runners.add_parser("material-efficiency", help="Persist ERP feedback KPI points")
+    efficiency.add_argument("--config", type=Path, required=True)
+    efficiency.add_argument("--secrets-file", type=Path, default=Path("secrets/enlyze.env"))
+    efficiency.add_argument("--erp-secrets-file", type=Path, default=Path("secrets/erp.env"))
     return parser
 
 
@@ -102,8 +141,11 @@ def _run_material(args: argparse.Namespace) -> int:
     try:
         calculation = load_material_calculation(args.config, args.calculation_id)
         runner = build_material_runner(
-            calculation, poll_interval_seconds=args.poll_interval_seconds,
-            state_directory=args.state_directory, secrets_file=args.secrets_file,
+            calculation,
+            poll_interval_seconds=args.poll_interval_seconds,
+            state_directory=args.state_directory,
+            erp_secrets_file=args.erp_secrets_file,
+            secrets_file=args.secrets_file,
         )
         runner.run()
     except (CalculationConfigError, ConfigurationError) as exc:
@@ -117,9 +159,35 @@ def _run_material(args: argparse.Namespace) -> int:
     return 0
 
 
+def _run_material_efficiency(args: argparse.Namespace) -> int:
+    from production_analytics.calculations.config import CalculationConfigError
+    from production_analytics.enlyze.exploration import ConfigurationError
+    from production_analytics.service.material_efficiency_runtime import (
+        build_material_efficiency_runner,
+    )
+
+    try:
+        build_material_efficiency_runner(
+            args.config,
+            secrets_file=args.secrets_file,
+            erp_secrets_file=args.erp_secrets_file,
+        ).run()
+    except (CalculationConfigError, ConfigurationError) as exc:
+        print(f"Config/startup error: {exc}", file=sys.stderr)
+        return 2
+    except Exception as exc:
+        print(f"Startup/runtime error: {type(exc).__name__}", file=sys.stderr)
+        return 1
+    except KeyboardInterrupt:
+        return 0
+    return 0
+
+
 def main(argv: Sequence[str] | None = None) -> int:
     args = _parser().parse_args(argv)
     if args.namespace == "run":
+        if args.command == "material-efficiency":
+            return _run_material_efficiency(args)
         return _run_material(args)
     if args.namespace != "enlyze" or args.command not in {"raw", "timeseries"}:
         return 2
@@ -133,7 +201,8 @@ def main(argv: Sequence[str] | None = None) -> int:
             operation = "GET" if args.command == "raw" else "POST"
             target = args.path if args.command == "raw" else "/v2/timeseries"
             print(
-                f"Requesting {operation} {target} (timeout={settings.timeout_seconds:g}s; authentication {authentication}).",
+                f"Requesting {operation} {target} (timeout={settings.timeout_seconds:g}s; "
+                f"authentication {authentication}).",
                 file=sys.stderr,
             )
         client = ExplorationClient(settings)
@@ -141,8 +210,13 @@ def main(argv: Sequence[str] | None = None) -> int:
             response = client.get(args.path, dict(args.query))
             request = {"method": "GET", "path": response.path}
         else:
-            if args.resampling_interval is not None and not 10 <= args.resampling_interval <= 604800:
-                raise ExplorationError("--resampling-interval must be between 10 and 604800 seconds.")
+            if (
+                args.resampling_interval is not None
+                and not 10 <= args.resampling_interval <= 604800
+            ):
+                raise ExplorationError(
+                    "--resampling-interval must be between 10 and 604800 seconds."
+                )
             variable: dict[str, str] = {"uuid": args.variable}
             if args.resampling_method:
                 variable["resampling_method"] = args.resampling_method
@@ -170,9 +244,15 @@ def main(argv: Sequence[str] | None = None) -> int:
         indent = 2 if args.pretty or args.save_fixture else None
         print(json.dumps(payload, indent=indent, sort_keys=True))
         if args.save_fixture:
-            print(f"Sanitized fixture written to {_write_fixture(args.fixture_dir, args.save_fixture, payload)}")
+            print(
+                "Sanitized fixture written to "
+                f"{_write_fixture(args.fixture_dir, args.save_fixture, payload)}"
+            )
         if args.save_raw:
-            print(f"Raw response written to {_write_fixture(args.raw_dir, args.save_raw, raw_payload)}")
+            print(
+                "Raw response written to "
+                f"{_write_fixture(args.raw_dir, args.save_raw, raw_payload)}"
+            )
     except ExplorationError as error:
         print(f"ENLYZE exploration error: {error}")
         return 1

src/production_analytics/enlyze/gateway.py

@@ -4,7 +4,11 @@ from dataclasses import dataclass
 from datetime import UTC, datetime
 from math import isfinite
 
-from production_analytics.calculations.material_consumption import MaterialSample
+from production_analytics.calculations.material_consumption import (
+    MaterialSample,
+    area_application_rate_kg_per_hour,
+    rotational_discharge_rate_kg_per_hour,
+)
 from production_analytics.enlyze.exploration import ExplorationClient
 
 
@@ -86,23 +90,34 @@ class EnlyzeApiGateway:
         *,
         machine_id: str,
         rate_variable_id: str,
-        gate_variable_id: str,
+        gate_variable_id: str | None,
         start: datetime,
         end: datetime,
+        application_variable_ids: tuple[str, ...] = (),
+        nominal_width_m: float | None = None,
+        rotational_speed_variable_ids: tuple[str, ...] = (),
+        specific_discharge_kg_per_rev_m: float | None = None,
+        process_application_gate_threshold: float | None = None,
     ) -> list[MaterialSample]:
         for name, value in (("start", start), ("end", end)):
             if value.tzinfo is None or value.utcoffset() is None:
                 raise ValueError(f"{name} must be timezone-aware")
         if end < start:
             raise ValueError("end must not precede start")
+        if application_variable_ids and rotational_speed_variable_ids:
+            raise ValueError("Material source modes are mutually exclusive")
+        if gate_variable_id is None and not rotational_speed_variable_ids:
+            raise ValueError("This source requires a gate signal")
+        source_ids = (
+            rotational_speed_variable_ids or application_variable_ids or (rate_variable_id,)
+        )
+        gate_ids = (gate_variable_id,) if gate_variable_id else ()
+        variable_ids = list(dict.fromkeys((*source_ids, *gate_ids)))
         request_body = {
             "machine": machine_id,
             "start": start.astimezone(UTC).isoformat(),
             "end": end.astimezone(UTC).isoformat(),
-            "variables": [
-                {"uuid": rate_variable_id},
-                {"uuid": gate_variable_id},
-            ],
+            "variables": [{"uuid": variable_id} for variable_id in variable_ids],
         }
         samples = []
         followed_cursors: set[str] = set()
@@ -114,27 +129,52 @@ class EnlyzeApiGateway:
                 columns = data["columns"]
                 if not isinstance(columns, list):
                     raise ValueError("columns must be a list")
-                for required in ("time", rate_variable_id, gate_variable_id):
+                for required in ("time", *variable_ids):
                     if columns.count(required) != 1:
                         raise ValueError(f"required column {required!r} must occur exactly once")
                 time_index = columns.index("time")
-                rate_index = columns.index(rate_variable_id)
-                gate_index = columns.index(gate_variable_id)
+                source_indices = [columns.index(ref) for ref in source_ids]
+                gate_index = columns.index(gate_variable_id) if gate_variable_id else None
                 if not isinstance(data["records"], list):
                     raise ValueError("records must be a list")
                 for index, record in enumerate(data["records"]):
                     try:
                         if not isinstance(record, list) or len(record) != len(columns):
                             raise ValueError("record must match columns")
-                        rate, gate = record[rate_index], record[gate_index]
-                        for value in (rate, gate):
+                        sources = [record[i] for i in source_indices]
+                        gate = record[gate_index] if gate_index is not None else 1.0
+                        for value in (*sources, gate):
                             if isinstance(value, bool) or not isinstance(value, (int, float)):
                                 raise ValueError("rate and gate must be numeric")
                             if not isfinite(value):
                                 raise ValueError("rate and gate must be finite")
+                        if rotational_speed_variable_ids:
+                            if nominal_width_m is None or specific_discharge_kg_per_rev_m is None:
+                                raise ValueError("rotational discharge requires width and factor")
+                            rate = rotational_discharge_rate_kg_per_hour(
+                                sources, nominal_width_m, specific_discharge_kg_per_rev_m,
+                            )
+                        elif application_variable_ids:
+                            if nominal_width_m is None:
+                                raise ValueError("area application requires nominal width")
+                            rate = area_application_rate_kg_per_hour(sources, nominal_width_m, gate)
+                        else:
+                            rate = sources[0]
+                        application = None
+                        if process_application_gate_threshold is not None:
+                            if not rotational_speed_variable_ids or gate_variable_id is None:
+                                raise ValueError("Process application requires rpm and speed gate")
+                            from production_analytics.calculations.material_application import (
+                                rotational_application_g_m2,
+                            )
+                            application = rotational_application_g_m2(
+                                sources, specific_discharge_kg_per_rev_m, gate,
+                                process_application_gate_threshold,
+                            )
                         samples.append(MaterialSample(
                             timestamp=_parse_timestamp(record[time_index]),
                             material_rate_kg_per_hour=float(rate), gate_value=float(gate),
+                            application_g_m2=application,
                         ))
                     except (TypeError, ValueError) as exc:
                         raise ValueError(f"malformed record {index}: {exc}") from exc

src/production_analytics/service/material_context.py

@@ -0,0 +1,25 @@
+"""ERP nominal-width resolution for an explicitly matched production order."""
+
+from production_analytics.context import build_enlyze_production_order, extract_nominal_width_m
+from production_analytics.erp import ErpWorkplaceStatusGateway
+
+
+class ErpNominalWidthProvider:
+    def __init__(
+        self, gateway: ErpWorkplaceStatusGateway, *, workplace: str, format_template: str,
+    ) -> None:
+        self.gateway = gateway
+        self.workplace = workplace
+        self.format_template = format_template
+
+    def __call__(self, production_order: str) -> float:
+        status = self.gateway.get_current_workplace_status(self.workplace)
+        if (status is None
+                or status.workplace.strip().casefold() != self.workplace.strip().casefold()
+                or build_enlyze_production_order(status.production_order, self.format_template)
+                != production_order):
+            raise ValueError("ERP context does not match the production order")
+        width = extract_nominal_width_m(status.article_description)
+        if width is None:
+            raise ValueError("ERP article description has no unambiguous nominal width")
+        return width

src/production_analytics/service/material_efficiency.py

@@ -38,12 +38,14 @@ class MaterialEfficiencyService:
         self, erp: WorkplaceStatusReader, materials: MaterialSnapshotRepository, *,
         workplace: str, machine_id: str, calculation_id: str, format_template: str,
         erp_timezone: ZoneInfo | None = None,
+        output_calculation_id: str | None = None,
     ) -> None:
         self.erp = erp
         self.materials = materials
         self.workplace = workplace
         self.machine_id = machine_id
         self.calculation_id = calculation_id
+        self.output_calculation_id = output_calculation_id or calculation_id
         self.format_template = format_template
         self.erp_timezone = erp_timezone
 
@@ -58,7 +60,7 @@ class MaterialEfficiencyService:
         Configuration, timestamp and adapter contract errors raise ValueError.
         Database failures propagate, rather than being treated as missing data.
         """
-        if status.workplace != self.workplace:
+        if status.workplace.strip().casefold() != self.workplace.strip().casefold():
             raise ValueError("ERP workplace does not match configured workplace")
         order = build_enlyze_production_order(status.production_order, self.format_template)
         quantity = status.good_quantity_m2
@@ -88,11 +90,12 @@ class MaterialEfficiencyService:
             return None
         return MaterialEfficiencySnapshot(
             workplace=status.workplace, machine_id=self.machine_id,
-            calculation_id=self.calculation_id, erp_production_order=status.production_order,
+            calculation_id=self.output_calculation_id,
+            erp_production_order=status.production_order,
             enlyze_production_order=order, article_number=status.article_number,
             article_description=status.article_description,
             nominal_width_m=extract_nominal_width_m(status.article_description),
-            erp_feedback_timestamp=status.feedback_timestamp,
+            erp_feedback_timestamp=cutoff,
             material_snapshot_timestamp=material.timestamp,
             good_quantity_m2=quantity, material_consumption_kg=consumption,
             material_consumption_kg_per_m2=kg_per_m2,

src/production_analytics/service/material_efficiency_runner.py

@@ -0,0 +1,60 @@
+"""Independent foreground ERP feedback polling; PostgreSQL owns deduplication."""
+
+import sys
+import time
+from collections.abc import Callable
+from typing import TextIO
+
+import psycopg
+
+from production_analytics.calculations.config import finite_number
+from production_analytics.erp import ErpReadError
+from production_analytics.service.material_efficiency import MaterialEfficiencyService
+from production_analytics.service.postgres_material_efficiency import MaterialEfficiencyWriter
+
+
+class MaterialEfficiencyRunner:
+    def __init__(
+        self,
+        service: MaterialEfficiencyService,
+        writer: MaterialEfficiencyWriter,
+        *,
+        poll_interval_seconds: float = 60,
+        sleep: Callable[[float], None] = time.sleep,
+        stderr: TextIO | None = None,
+        stdout: TextIO | None = None,
+    ) -> None:
+        self.service = service
+        self.writer = writer
+        self.interval = finite_number(poll_interval_seconds, "poll interval", positive=True)
+        self.sleep = sleep
+        self.stderr = stderr if stderr is not None else sys.stderr
+        self.stdout = stdout if stdout is not None else sys.stdout
+
+    def run(self) -> None:
+        try:
+            while True:
+                try:
+                    snapshot = self.service.evaluate_current()
+                    if snapshot is not None and self.writer.write(snapshot):
+                        print(
+                            f"{snapshot.erp_feedback_timestamp.isoformat()} "
+                            f"workplace={snapshot.workplace!r} "
+                            f"production_order={snapshot.enlyze_production_order!r} "
+                            f"good_m2={snapshot.good_quantity_m2:.3f} "
+                            f"material_kg={snapshot.material_consumption_kg:.3f} "
+                            f"g_per_m2={snapshot.material_consumption_g_per_m2:.3f}",
+                            file=self.stdout,
+                            flush=True,
+                        )
+                except (ErpReadError, psycopg.OperationalError, psycopg.InterfaceError) as exc:
+                    # Never include driver messages, SQL, credentials or response bodies.
+                    print(
+                        f"Material efficiency cycle failed: {type(exc).__name__}",
+                        file=self.stderr,
+                        flush=True,
+                    )
+                # Fixed delay even after unavailable evaluations or transient failures.
+                self.sleep(self.interval)
+        except KeyboardInterrupt:
+            return

src/production_analytics/service/material_efficiency_runtime.py

@@ -0,0 +1,83 @@
+"""Small strict YAML configuration and composition for KPI persistence."""
+
+import os
+from pathlib import Path
+from zoneinfo import ZoneInfo, ZoneInfoNotFoundError
+
+import yaml
+
+from production_analytics.calculations.config import (
+    CalculationConfigError,
+    _UniqueLoader,
+    finite_number,
+)
+from production_analytics.context import build_enlyze_production_order
+from production_analytics.enlyze.exploration import ConfigurationError, load_secret_file
+from production_analytics.erp import ErpSettings, ErpWorkplaceStatusGateway
+from production_analytics.service.material_efficiency import MaterialEfficiencyService
+from production_analytics.service.material_efficiency_runner import MaterialEfficiencyRunner
+from production_analytics.service.postgres_material import (
+    PostgresMaterialSnapshotRepository,
+    PostgresSettings,
+)
+from production_analytics.service.postgres_material_efficiency import (
+    PostgresMaterialEfficiencyWriter,
+)
+
+
+def build_material_efficiency_runner(
+    config: Path,
+    *,
+    secrets_file: Path = Path("secrets/enlyze.env"),
+    erp_secrets_file: Path = Path("secrets/erp.env"),
+) -> MaterialEfficiencyRunner:
+    try:
+        document = yaml.load(config.read_text(encoding="utf-8"), Loader=_UniqueLoader)
+    except (OSError, UnicodeError, yaml.YAMLError):
+        raise CalculationConfigError("Cannot read material efficiency YAML configuration") from None
+    required = {
+        "workplace",
+        "machine_id",
+        "calculation_id",
+        "production_order_format",
+        "erp_timezone",
+    }
+    if (
+        not isinstance(document, dict)
+        or not required <= document.keys()
+        or document.keys() - required - {"poll_interval_seconds", "output_calculation_id"}
+    ):
+        raise CalculationConfigError("Invalid material efficiency configuration fields")
+    for name in required | ({"output_calculation_id"} & document.keys()):
+        value = document[name]
+        if not isinstance(value, str) or not value.strip() or "\x00" in value:
+            raise CalculationConfigError(f"{name} must be a non-empty string without NUL bytes")
+    try:
+        timezone = ZoneInfo(document["erp_timezone"])
+        build_enlyze_production_order("0", document["production_order_format"])
+    except (ValueError, ZoneInfoNotFoundError):
+        raise CalculationConfigError("Invalid ERP timezone or production order format") from None
+    interval = finite_number(
+        document.get("poll_interval_seconds", 60), "poll interval", positive=True
+    )
+    environment = dict(os.environ)
+    try:
+        environment.update(load_secret_file(secrets_file))
+    except Exception:
+        raise ConfigurationError("PostgreSQL settings file could not be loaded") from None
+    postgres = PostgresSettings.from_environment(environment)
+    erp = ErpSettings.from_secret_file(erp_secrets_file)
+    return MaterialEfficiencyRunner(
+        MaterialEfficiencyService(
+            ErpWorkplaceStatusGateway(erp),
+            PostgresMaterialSnapshotRepository(postgres),
+            workplace=document["workplace"],
+            machine_id=document["machine_id"],
+            calculation_id=document["calculation_id"],
+            format_template=document["production_order_format"],
+            erp_timezone=timezone,
+            output_calculation_id=document.get("output_calculation_id"),
+        ),
+        PostgresMaterialEfficiencyWriter(postgres),
+        poll_interval_seconds=interval,
+    )

src/production_analytics/service/material_polling.py

@@ -1,5 +1,6 @@
 """Single-cycle live material polling orchestration."""
 
+from collections.abc import Callable
 from dataclasses import dataclass
 from datetime import datetime
 from typing import Protocol
@@ -13,6 +14,7 @@ from production_analytics.enlyze.gateway import (
     EnlyzeApiGateway,
     EnlyzeProductionRun,
 )
+from production_analytics.service.postgres_material_application import MaterialApplicationWriter
 
 
 @dataclass(frozen=True, slots=True)
@@ -50,17 +52,41 @@ class MaterialPollingService:
         state_store: MaterialStateStore,
         machine_id: str,
         rate_variable_id: str,
-        gate_variable_id: str,
+        gate_variable_id: str | None,
         gate_threshold: float,
         max_sample_gap_seconds: float,
+        application_variable_ids: tuple[str, ...] = (),
+        rotational_speed_variable_ids: tuple[str, ...] = (),
+        specific_discharge_kg_per_rev_m: float | None = None,
+        nominal_width_provider: Callable[[str], float] | None = None,
+        process_application_calculation_id: str | None = None,
+        application_writer: MaterialApplicationWriter | None = None,
     ) -> None:
+        if application_variable_ids and rotational_speed_variable_ids:
+            raise ValueError("Material source modes are mutually exclusive")
+        if process_application_calculation_id is not None and (
+            not rotational_speed_variable_ids or not gate_variable_id
+            or gate_threshold <= 0 or application_writer is None
+        ):
+            raise ValueError(
+                "Process application requires rotational source, positive gate and writer"
+            )
+        self._process_application_calculation_id = process_application_calculation_id
+        self._application_writer = application_writer
+        self._rotational_speed_variable_ids = rotational_speed_variable_ids
+        self._specific_discharge = specific_discharge_kg_per_rev_m
+        self._application_variable_ids = application_variable_ids
+        self._nominal_width_provider = nominal_width_provider
+        if ((application_variable_ids or rotational_speed_variable_ids)
+                and nominal_width_provider is None):
+            raise ValueError("width-based source requires a nominal width provider")
         self._gateway = gateway
         self._state_store = state_store
         self._machine_id = machine_id
         self._rate_variable_id = rate_variable_id
         self._gate_variable_id = gate_variable_id
         self._config = MaterialIntegratorConfig(
-            gate_threshold=gate_threshold,
+            gate_threshold=gate_threshold if gate_variable_id is not None else 0.0,
             max_sample_gap_seconds=max_sample_gap_seconds,
         )
 
@@ -71,6 +97,8 @@ class MaterialPollingService:
         if run is None or now < run.start:
             return None
 
+        width = (self._nominal_width_provider(run.production_order)
+                 if self._application_variable_ids or self._rotational_speed_variable_ids else None)
         saved_polling_state = self._state_store.load(
             self._machine_id,
             run.production_order,
@@ -92,6 +120,7 @@ class MaterialPollingService:
                     raise ValueError("Historical production run overlaps the current open run")
                 integrated = self._integrate(
                     initial_state, start=previous.start, end=previous.end,
+                    width=width, run=previous,
                 )
                 initial_state = MaterialIntegrationState(
                     cumulative_consumption_kg=integrated.cumulative_consumption_kg,
@@ -116,7 +145,7 @@ class MaterialPollingService:
         if now < start:
             return None
 
-        state = self._integrate(initial_state, start=start, end=now)
+        state = self._integrate(initial_state, start=start, end=now, width=width, run=run)
 
         self._state_store.save(
             self._machine_id,
@@ -134,13 +163,36 @@ class MaterialPollingService:
 
     def _integrate(
         self, initial_state: MaterialIntegrationState, *, start: datetime, end: datetime,
+        width: float | None = None, run: EnlyzeProductionRun | None = None,
     ) -> MaterialIntegrationState:
         integrator = MaterialConsumptionIntegrator(self._config, initial_state=initial_state)
+        source_options = {}
+        if self._application_variable_ids:
+            source_options = dict(
+                application_variable_ids=self._application_variable_ids, nominal_width_m=width,
+            )
+        if self._rotational_speed_variable_ids:
+            source_options = dict(
+                rotational_speed_variable_ids=self._rotational_speed_variable_ids,
+                specific_discharge_kg_per_rev_m=self._specific_discharge, nominal_width_m=width,
+            )
+        if self._process_application_calculation_id is not None:
+            source_options["process_application_gate_threshold"] = self._config.gate_threshold
         samples = self._gateway.get_material_samples(
             machine_id=self._machine_id,
             rate_variable_id=self._rate_variable_id,
             gate_variable_id=self._gate_variable_id,
             start=start,
             end=end,
+            **source_options,
         )
-        return integrator.process_many(samples)
+        state = integrator.process_many(samples)
+        if self._process_application_calculation_id is not None:
+            assert self._application_writer is not None and run is not None
+            # Persist before advancing the checkpoint, so failed writes can be retried.
+            self._application_writer.write(
+                calculation_id=self._process_application_calculation_id,
+                machine_id=self._machine_id, production_order=run.production_order,
+                run_id=run.uuid, samples=samples,
+            )
+        return state

src/production_analytics/service/material_runtime.py

@@ -14,6 +14,8 @@ from production_analytics.enlyze.exploration import (
     load_secret_file,
 )
 from production_analytics.enlyze.gateway import EnlyzeApiGateway
+from production_analytics.erp import ErpSettings, ErpWorkplaceStatusGateway
+from production_analytics.service.material_context import ErpNominalWidthProvider
 from production_analytics.service.material_polling import (
     MaterialPollingService,
     MaterialPollingState,
@@ -24,6 +26,9 @@ from production_analytics.service.postgres_material import (
     PostgresMaterialSnapshotWriter,
     PostgresSettings,
 )
+from production_analytics.service.postgres_material_application import (
+    PostgresMaterialApplicationWriter,
+)
 
 
 class _ReportingStateStore:
@@ -48,6 +53,7 @@ class _ReportingStateStore:
 def build_material_runner(
     calculation: MaterialCalculationConfig, *, poll_interval_seconds: float,
     state_directory: Path, secrets_file: Path,
+    erp_secrets_file: Path = Path("secrets/erp.env"),
 ) -> MaterialPollingRunner:
     finite_number(poll_interval_seconds, "poll interval", positive=True)
     environment = dict(os.environ)
@@ -69,6 +75,27 @@ def build_material_runner(
             f"State directory startup check failed: {type(exc).__name__}"
         ) from exc
     postgres_settings = PostgresSettings.from_environment(environment)
+    source_options = {}
+    if calculation.source_mode in {"area_application", "rotational_discharge"}:
+        source_options = dict(
+            application_variable_ids=calculation.application_signal_refs,
+            nominal_width_provider=ErpNominalWidthProvider(
+                ErpWorkplaceStatusGateway(ErpSettings.from_secret_file(erp_secrets_file)),
+                workplace=calculation.erp_workplace,
+                format_template=calculation.production_order_format,
+            ),
+        )
+    if calculation.source_mode == "rotational_discharge":
+        source_options.pop("application_variable_ids")
+        source_options.update(
+            rotational_speed_variable_ids=calculation.rotational_speed_signal_refs,
+            specific_discharge_kg_per_rev_m=calculation.specific_discharge_kg_per_rev_m,
+        )
+    if calculation.process_application_calculation_id is not None:
+        source_options.update(
+            process_application_calculation_id=calculation.process_application_calculation_id,
+            application_writer=PostgresMaterialApplicationWriter(postgres_settings),
+        )
     service = MaterialPollingService(
         gateway=EnlyzeApiGateway(ExplorationClient(settings)),
         state_store=_ReportingStateStore(JsonMaterialStateStore(state_directory)),
@@ -77,6 +104,7 @@ def build_material_runner(
         gate_variable_id=calculation.gate_signal_ref,
         gate_threshold=calculation.gate_threshold,
         max_sample_gap_seconds=calculation.max_sample_gap_seconds,
+        **source_options,
     )
     return MaterialPollingRunner(
         service, calculation_id=calculation.id,

src/production_analytics/service/postgres_material_application.py

@@ -0,0 +1,53 @@
+"""Generic process application snapshots, timestamped at the source sample."""
+
+from collections.abc import Sequence
+from typing import Protocol
+
+import psycopg
+
+from production_analytics.calculations.config import finite_number
+from production_analytics.calculations.material_consumption import MaterialSample
+from production_analytics.service.postgres_material import PostgresSettings
+
+
+class MaterialApplicationWriter(Protocol):
+    def write(
+        self, *, calculation_id: str, machine_id: str, production_order: str,
+        run_id: str, samples: Sequence[MaterialSample],
+    ) -> None: ...
+
+
+class PostgresMaterialApplicationWriter:
+    def __init__(self, settings: PostgresSettings) -> None:
+        self.settings = settings
+
+    def write(
+        self, *, calculation_id: str, machine_id: str, production_order: str,
+        run_id: str, samples: Sequence[MaterialSample],
+    ) -> None:
+        rows = []
+        for sample in samples:
+            if sample.application_g_m2 is None:
+                continue
+            if sample.timestamp.utcoffset() is None:
+                raise ValueError("Application timestamp must be timezone-aware")
+            finite_number(sample.application_g_m2, "application_g_m2")
+            rows.append((sample.timestamp, calculation_id, machine_id, production_order,
+                         run_id, sample.application_g_m2))
+        if not rows:
+            return
+        with psycopg.connect(
+            host=self.settings.host, port=self.settings.port, dbname=self.settings.dbname,
+            user=self.settings.user, password=self.settings.password, connect_timeout=10,
+            options="-c statement_timeout=10000",
+        ) as connection:
+            with connection.cursor() as cursor:
+                cursor.executemany(
+                    """INSERT INTO material_application_snapshots
+                       (timestamp, calculation_id, machine_id, production_order,
+                        run_id, application_g_m2)
+                       VALUES (%s, %s, %s, %s, %s, %s)
+                       ON CONFLICT (calculation_id, machine_id, production_order, timestamp)
+                       DO NOTHING""",
+                    rows,
+                )

src/production_analytics/service/postgres_material_efficiency.py

@@ -0,0 +1,71 @@
+"""Immutable PostgreSQL history of feedback-aligned KPI points."""
+
+from typing import Protocol
+
+import psycopg
+
+from production_analytics.calculations.config import finite_number
+from production_analytics.service.material_efficiency import MaterialEfficiencySnapshot
+from production_analytics.service.postgres_material import PostgresSettings
+
+
+class MaterialEfficiencyWriter(Protocol):
+    def write(self, snapshot: MaterialEfficiencySnapshot) -> bool: ...
+
+
+class PostgresMaterialEfficiencyWriter:
+    def __init__(self, settings: PostgresSettings) -> None:
+        self.settings = settings
+
+    def write(self, snapshot: MaterialEfficiencySnapshot) -> bool:
+        for name in ("erp_feedback_timestamp", "material_snapshot_timestamp"):
+            if getattr(snapshot, name).utcoffset() is None:
+                raise ValueError(f"{name} must be timezone-aware")
+        for name in (
+            "good_quantity_m2",
+            "material_consumption_kg",
+            "material_consumption_kg_per_m2",
+            "material_consumption_g_per_m2",
+        ):
+            finite_number(getattr(snapshot, name), name)
+        if snapshot.nominal_width_m is not None:
+            finite_number(snapshot.nominal_width_m, "nominal_width_m")
+        # Context exit commits/rolls back and closes; later cycles reconnect after outages.
+        with psycopg.connect(
+            host=self.settings.host,
+            port=self.settings.port,
+            dbname=self.settings.dbname,
+            user=self.settings.user,
+            password=self.settings.password,
+            connect_timeout=10,
+            options="-c statement_timeout=10000",
+        ) as connection:
+            row = connection.execute(
+                """INSERT INTO material_efficiency_snapshots (
+                    erp_feedback_timestamp, material_snapshot_timestamp, calculation_id,
+                    machine_id, workplace, erp_production_order, enlyze_production_order,
+                    article_number, article_description, nominal_width_m, good_quantity_m2,
+                    material_consumption_kg, material_consumption_kg_per_m2,
+                    material_consumption_g_per_m2
+                ) VALUES (%s, %s, %s, %s, %s, %s, %s, %s, %s, %s, %s, %s, %s, %s)
+                ON CONFLICT (calculation_id, machine_id, enlyze_production_order,
+                             erp_feedback_timestamp) DO NOTHING
+                RETURNING 1""",
+                (
+                    snapshot.erp_feedback_timestamp,
+                    snapshot.material_snapshot_timestamp,
+                    snapshot.calculation_id,
+                    snapshot.machine_id,
+                    snapshot.workplace,
+                    snapshot.erp_production_order,
+                    snapshot.enlyze_production_order,
+                    snapshot.article_number,
+                    snapshot.article_description,
+                    snapshot.nominal_width_m,
+                    snapshot.good_quantity_m2,
+                    snapshot.material_consumption_kg,
+                    snapshot.material_consumption_kg_per_m2,
+                    snapshot.material_consumption_g_per_m2,
+                ),
+            ).fetchone()
+        return row is not None

tests/test_area_material_consumption.py

@@ -0,0 +1,257 @@
+from dataclasses import replace
+from datetime import datetime, timedelta
+from types import SimpleNamespace
+from unittest.mock import Mock
+
+import pytest
+import yaml
+
+from production_analytics.calculations.config import (
+    CalculationConfigError,
+    load_material_calculation,
+)
+from production_analytics.calculations.material_consumption import (
+    MaterialConsumptionIntegrator,
+    MaterialIntegratorConfig,
+    area_application_rate_kg_per_hour,
+)
+from production_analytics.enlyze.gateway import EnlyzeApiGateway, EnlyzeProductionRun
+from production_analytics.service.material_context import ErpNominalWidthProvider
+from production_analytics.service.material_polling import MaterialPollingService
+from production_analytics.service.material_state_store import JsonMaterialStateStore
+
+
+def timestamp(value):
+    return datetime.fromisoformat(value.replace('Z', '+00:00'))
+
+
+def test_area_units_and_strict_gate():
+    client = Mock()
+    start = timestamp('2026-08-25T05:27:18Z')
+    client.post_json.return_value.body = {'data': {
+        'columns': ['speed', 's2', 'time', 's1'],
+        'records': [[speed, 2000, (start + timedelta(minutes=i)).isoformat(), 3000]
+                    for i, speed in enumerate([2, 0.3, 0, 2, 2])],
+    }}
+    samples = EnlyzeApiGateway(client).get_material_samples(
+        machine_id='machine', rate_variable_id='unused', gate_variable_id='speed',
+        application_variable_ids=('s1', 's2'), nominal_width_m=5,
+        start=start, end=start + timedelta(minutes=4),
+    )
+    state = MaterialConsumptionIntegrator(MaterialIntegratorConfig(0.3, 60)).process_many(samples)
+    assert state.cumulative_consumption_kg == 100
+    assert state.integrated_running_seconds == 120
+    assert client.post_json.call_args.args[1]['variables'] == [
+        {'uuid': 's1'}, {'uuid': 's2'}, {'uuid': 'speed'},
+    ]
+
+
+@pytest.mark.parametrize('sources,width,speed', [
+    ([], 5, 2), ([float('nan')], 5, 2), ([1], 0, 2), ([1], 5, float('inf')),
+])
+def test_invalid_area_inputs(sources, width, speed):
+    with pytest.raises(ValueError):
+        area_application_rate_kg_per_hour(sources, width, speed)
+
+
+@pytest.mark.parametrize('bad', [None, True, float('nan')])
+def test_missing_or_invalid_spreader_fails(bad):
+    client = Mock()
+    now = timestamp('2026-08-25T05:27:18Z')
+    client.post_json.return_value.body = {'data': {
+        'columns': ['time', 's1', 's2', 'speed'],
+        'records': [[now.isoformat(), 3000, bad, 2]],
+    }}
+    with pytest.raises(ValueError):
+        EnlyzeApiGateway(client).get_material_samples(
+            machine_id='machine', rate_variable_id='unused', gate_variable_id='speed',
+            application_variable_ids=('s1', 's2'), nominal_width_m=5, start=now, end=now,
+        )
+
+
+def width_provider():
+    erp = Mock()
+    erp.get_current_workplace_status.return_value = SimpleNamespace(
+        workplace='Bento 1', production_order='12026000814', article_number='180305',
+        article_description='Bfix NSP 5300,     5,00 x 40 m',
+    )
+    return ErpNominalWidthProvider(
+        erp, workplace='Bento 1', format_template='Bento 1-{production_order}',
+    )
+
+
+@pytest.mark.parametrize('configured,returned', [
+    ('Bento 1', 'BENTO 1'),
+    ('Bento 1', ' \tBENTO 1\n'),
+    (' \tBento 1\n', 'BENTO 1'),
+    ('K7', ' k7 '),
+])
+def test_width_context_normalizes_workplace(configured, returned):
+    provider = width_provider()
+    provider.workplace = configured
+    provider.gateway.get_current_workplace_status.return_value.workplace = returned
+    assert provider('Bento 1-12026000814') == 5.0
+
+
+@pytest.mark.parametrize('production_order', [
+    'Bento 1-12026000815',
+    'BENTO 1-12026000814',
+    ' Bento 1-12026000814 ',
+])
+def test_width_context_keeps_production_order_strict(production_order):
+    provider = width_provider()
+    provider.gateway.get_current_workplace_status.return_value.workplace = 'BENTO 1'
+    with pytest.raises(ValueError, match='ERP context does not match the production order'):
+        provider(production_order)
+
+
+@pytest.mark.parametrize('field,value', [
+    ('production_order', '12026000815'), ('workplace', 'K7'),
+    ('article_description', None), ('article_description', '180305'),
+])
+def test_width_context_fails_closed(field, value):
+    provider = width_provider()
+    setattr(provider.gateway.get_current_workplace_status.return_value, field, value)
+    with pytest.raises(ValueError):
+        provider('Bento 1-12026000814')
+
+
+@pytest.mark.parametrize('inter_run_gap_seconds', [5, 3761])
+def test_bento_rpm_bootstrap_and_persistent_resume(tmp_path, inter_run_gap_seconds):
+    """Synthetic aggregate fixture, not recorded ENLYZE samples.
+
+    Uses realistic rpm values and synthetic active time within actual run boundaries.
+    """
+    config = load_material_calculation('config/bento1-material-consumption.yaml')
+    order = 'Bento 1-12026000814'
+    runs = [EnlyzeProductionRun(
+        uuid, config.machine_ref, 'external-product', order, timestamp(start), timestamp(end),
+    ) for uuid, start, end in [
+        ('b675818c-4636-4976-be6c-3e0e24da9e8a',
+         '2026-08-25T05:27:18Z', '2026-08-26T04:40:58Z'),
+        ('25d67424-8346-42d4-b844-75b4097382bd',
+         '2026-08-26T05:43:39Z', '2026-08-26T05:54:05Z'),
+    ]]
+    runs[1] = replace(
+        runs[1], start=runs[0].end + timedelta(seconds=inter_run_gap_seconds),
+        end=runs[0].end + timedelta(seconds=inter_run_gap_seconds + 626),
+    )
+    speed = 2.0
+    client = Mock()
+
+    def response(path, body):
+        start, end = timestamp(body['start']), timestamp(body['end'])
+        run = next(run for run in runs if run.start <= start <= run.end)
+        active_seconds = 1256 * 60 - 626 if run == runs[0] else 626
+        stop = run.start + timedelta(seconds=active_seconds)
+        times = {start, end}
+        t = start
+        while t < end:
+            times.add(t)
+            t += timedelta(seconds=10)
+        if start <= stop <= end:
+            times.add(stop)
+        return SimpleNamespace(body={'data': {
+            'columns': ['time', *config.rotational_speed_signal_refs, config.gate_signal_ref],
+            'records': [[t.isoformat(), 3.739, 3.956, speed if t < stop else 0]
+                        for t in sorted(times)],
+        }})
+
+    client.post_json.side_effect = response
+    gateway = EnlyzeApiGateway(client)
+    gateway.get_open_production_run = Mock(return_value=replace(runs[1], end=None))
+    gateway.get_production_runs = Mock(return_value=runs)
+    store = JsonMaterialStateStore(tmp_path)
+
+    def service():
+        return MaterialPollingService(
+            gateway=gateway, state_store=store, machine_id=config.machine_ref,
+            rate_variable_id=config.rate_signal_ref, gate_variable_id=config.gate_signal_ref,
+            gate_threshold=config.gate_threshold,
+            max_sample_gap_seconds=config.max_sample_gap_seconds,
+            rotational_speed_variable_ids=config.rotational_speed_signal_refs,
+            specific_discharge_kg_per_rev_m=config.specific_discharge_kg_per_rev_m,
+            nominal_width_provider=width_provider(),
+        )
+
+    partial = service().poll_once(now=runs[1].start + timedelta(seconds=300))
+    result = service().poll_once(now=runs[1].end)
+    assert result.state.cumulative_consumption_kg - partial.state.cumulative_consumption_kg == (
+        pytest.approx((3.739 + 3.956) * 5 * 2.75 * 326 / 60)
+    )
+    assert result.state.integrated_running_seconds / 60 == pytest.approx(1256)
+    assert result.state.cumulative_consumption_kg == pytest.approx(
+        (3.739 + 3.956) * 5 * 2.75 * 1256,
+    )
+    assert service().poll_once(now=runs[1].end).state == result.state
+    assert gateway.get_production_runs.call_count == 1
+    assert [(timestamp(call.args[1]['start']), timestamp(call.args[1]['end']))
+            for call in client.post_json.call_args_list[:2]] == [
+                (runs[0].start, runs[0].end),
+                (runs[1].start, runs[1].start + timedelta(seconds=300)),
+            ]
+
+
+def test_k7_config_defaults_remain_direct():
+    config = load_material_calculation('config/k7-material-consumption.yaml')
+    assert config.source_mode == 'direct_mass_rate'
+    assert config.rotational_speed_signal_refs == ()
+    assert config.application_signal_refs == ()
+    assert config.gate_threshold == 0.5
+    assert config.rate_signal_ref == 'c9d06af5-f6d6-4ede-b6c4-5a98bac77129'
+
+
+@pytest.mark.parametrize('field,value', [
+    ('source_mode', 'unknown'), ('rotational_speed_signal_refs', []),
+    ('rotational_speed_signal_refs', ['same', 'same']), ('erp_workplace', ''),
+    ('production_order_format', '{wrong}'), ('rate_signal_ref', 'direct'),
+])
+def test_invalid_rotational_configuration(tmp_path, field, value):
+    with open('config/bento1-material-consumption.yaml') as stream:
+        document = yaml.safe_load(stream)
+    document['calculations'][0][field] = value
+    path = tmp_path / 'config.yaml'
+    path.write_text(yaml.safe_dump(document))
+    with pytest.raises(CalculationConfigError):
+        load_material_calculation(path)
+
+
+def test_rotational_context_failure_does_not_touch_persistent_state(tmp_path):
+    config = load_material_calculation('config/bento1-material-consumption.yaml')
+    gateway = Mock()
+    now = timestamp('2026-08-25T05:27:18Z')
+    gateway.get_open_production_run.return_value = EnlyzeProductionRun(
+        'run', config.machine_ref, None, 'Bento 1-12026000814', now, None,
+    )
+    provider = width_provider()
+    provider.gateway.get_current_workplace_status.return_value = None
+    store = Mock()
+    service = MaterialPollingService(
+        gateway=gateway, state_store=store, machine_id=config.machine_ref,
+        rate_variable_id=config.rate_signal_ref, gate_variable_id=config.gate_signal_ref,
+        gate_threshold=config.gate_threshold, max_sample_gap_seconds=20,
+        rotational_speed_variable_ids=config.rotational_speed_signal_refs,
+        specific_discharge_kg_per_rev_m=config.specific_discharge_kg_per_rev_m,
+        nominal_width_provider=provider,
+    )
+    with pytest.raises(ValueError, match='context'):
+        service.poll_once(now=now)
+    gateway.get_material_samples.assert_not_called()
+    store.save.assert_not_called()
+
+
+def test_area_gateway_pagination():
+    client = Mock()
+    now = timestamp('2026-08-25T05:27:18Z')
+    client.post_json.side_effect = [SimpleNamespace(body={
+        'metadata': {'next_cursor': cursor},
+        'data': {'columns': ['time', 's1', 's2', 'speed'],
+                 'records': [[(now + timedelta(seconds=i * 10)).isoformat(), 3000, 2000, 2]]},
+    }) for i, cursor in enumerate(['next', None])]
+    samples = EnlyzeApiGateway(client).get_material_samples(
+        machine_id='machine', rate_variable_id='unused', gate_variable_id='speed',
+        application_variable_ids=('s1', 's2'), nominal_width_m=5,
+        start=now, end=now + timedelta(seconds=10),
+    )
+    assert [sample.material_rate_kg_per_hour for sample in samples] == [3000, 3000]
+    assert client.post_json.call_args.args[1]['cursor'] == 'next'

tests/test_calibrations.py

@@ -0,0 +1,143 @@
+from dataclasses import replace
+from datetime import UTC, date, datetime, timedelta
+from pathlib import Path
+from unittest.mock import Mock
+
+import pytest
+import yaml
+
+from production_analytics.calculations.calibrations import load_calibrations, resolve_calibration
+from production_analytics.calculations.config import (
+    CalculationConfigError,
+    load_material_calculation,
+)
+from production_analytics.calculations.material_application import rotational_application_g_m2
+from production_analytics.calculations.material_consumption import (
+    MaterialConsumptionIntegrator,
+    MaterialIntegratorConfig,
+)
+from production_analytics.enlyze.gateway import EnlyzeApiGateway
+
+CALIBRATIONS = Path('config/material-calibrations.yaml')
+BENTO = Path('config/bento1-material-consumption.yaml')
+ID = 'bento1-spreader-1-2'
+
+
+def resolve(entries, identifier=ID):
+    return resolve_calibration(entries, identifier, expected_type='rotational_discharge',
+                               expected_unit='kg_per_rev_m')
+
+
+def test_load_and_resolve():
+    calibration = resolve(load_calibrations(CALIBRATIONS))
+    assert calibration.value == 2.75
+    assert calibration.calibrated_at == date(2026, 9, 8)
+    assert calibration.method == 'gravimetric_tray'
+    assert calibration.reference == {
+        'measured_application_g_m2': 4068, 'line_speed_m_min': 2.3,
+        'signal_values': {'left': 1.65, 'right': 1.75},
+    }
+    assert load_material_calculation(BENTO).specific_discharge_kg_per_rev_m == 2.75
+
+
+@pytest.mark.parametrize('field', ['type', 'value', 'unit', 'calibrated_at', 'method',
+                                   'description', 'reference'])
+def test_missing_metadata(tmp_path, field):
+    document = yaml.safe_load(CALIBRATIONS.read_text())
+    del document['calibrations'][ID][field]
+    path = tmp_path / 'material-calibrations.yaml'
+    path.write_text(yaml.safe_dump(document))
+    with pytest.raises(CalculationConfigError, match='required fields'):
+        load_calibrations(path)
+
+
+@pytest.mark.parametrize('field,value', [
+    ('type', ''), ('unit', None), ('method', 12), ('description', ' '),
+    ('calibrated_at', '2026-02-30'), ('calibrated_at', 123),
+    ('reference', []), ('reference', {}), ('value', True), ('value', float('nan')),
+])
+def test_invalid_metadata(tmp_path, field, value):
+    document = yaml.safe_load(CALIBRATIONS.read_text())
+    document['calibrations'][ID][field] = value
+    path = tmp_path / 'material-calibrations.yaml'
+    path.write_text(yaml.safe_dump(document))
+    with pytest.raises(CalculationConfigError, match=field):
+        load_calibrations(path)
+
+
+@pytest.mark.parametrize('field,value,error', [
+    ('type', 'other', 'incompatible type'), ('unit', 'kg_per_rev', 'incompatible unit'),
+    ('value', 0, 'greater than zero'),
+])
+def test_incompatible_at_config_load(tmp_path, field, value, error):
+    document = yaml.safe_load(CALIBRATIONS.read_text())
+    document['calibrations'][ID][field] = value
+    (tmp_path / CALIBRATIONS.name).write_text(yaml.safe_dump(document))
+    path = tmp_path / BENTO.name
+    path.write_text(BENTO.read_text())
+    with pytest.raises(CalculationConfigError, match=error):
+        load_material_calculation(path)
+
+
+def test_missing_id_and_file(tmp_path):
+    with pytest.raises(CalculationConfigError, match='Missing calibration ID'):
+        resolve(load_calibrations(CALIBRATIONS), 'unknown')
+    path = tmp_path / BENTO.name
+    path.write_text(BENTO.read_text())
+    with pytest.raises(CalculationConfigError, match='Cannot read calibration'):
+        load_material_calculation(path)
+    (tmp_path / CALIBRATIONS.name).write_text(CALIBRATIONS.read_text())
+    path.write_text(BENTO.read_text().replace(ID, 'unknown'))
+    with pytest.raises(CalculationConfigError, match='Missing calibration ID'):
+        load_material_calculation(path)
+
+
+def test_exact_direct_value_equivalence(tmp_path):
+    referenced = load_material_calculation(BENTO)
+    document = yaml.safe_load(BENTO.read_text())
+    entry = document['calculations'][0]
+    del entry['calibration_ref']
+    entry['specific_discharge_kg_per_rev_m'] = 2.75
+    path = tmp_path / 'direct.yaml'
+    path.write_text(yaml.safe_dump(document))
+    direct = load_material_calculation(path)
+    assert replace(referenced, calibration_ref=None) == direct
+    start = datetime(2026, 9, 8, tzinfo=UTC)
+    outputs = []
+    for config in (referenced, direct):
+        factor = config.specific_discharge_kg_per_rev_m
+        application = rotational_application_g_m2([1.65, 1.75], factor, 2.3, 0.3)
+        client = Mock()
+        client.post_json.return_value.body = {'data': {
+            'columns': ['time', 'left', 'right', 'speed'],
+            'records': [[(start + timedelta(seconds=t)).isoformat(), 1.65, 1.75, speed]
+                        for t, speed in [(0, 2.3), (10, 0), (20, 2.3), (50, 2.3), (60, 2.3)]],
+        }}
+        samples = EnlyzeApiGateway(client).get_material_samples(
+            machine_id='m', rate_variable_id='unused', gate_variable_id='speed',
+            rotational_speed_variable_ids=('left', 'right'), nominal_width_m=5,
+            specific_discharge_kg_per_rev_m=factor, start=start,
+            end=start + timedelta(seconds=60),
+        )
+        integrator = MaterialConsumptionIntegrator(MaterialIntegratorConfig(0.3, 20))
+        state = integrator.process_many(samples)
+        assert samples[0].material_rate_kg_per_hour == 2805.0
+        assert state.integrated_running_seconds == 20
+        outputs.append((application, samples, state))
+    assert outputs[0] == outputs[1]
+    assert outputs[0][0] == pytest.approx(4065.217391304348)
+
+
+def test_update_only_central_file(tmp_path):
+    path = tmp_path / BENTO.name
+    path.write_text(BENTO.read_text())
+    (tmp_path / CALIBRATIONS.name).write_text(CALIBRATIONS.read_text().replace('2.75', '2.8'))
+    assert load_material_calculation(path).specific_discharge_kg_per_rev_m == 2.8
+
+
+def test_k7_without_calibration_file(tmp_path):
+    original = Path('config/k7-material-consumption.yaml')
+    path = tmp_path / original.name
+    path.write_text(original.read_text())
+    assert load_material_calculation(path) == load_material_calculation(original)
+    assert load_material_calculation(path).calibration_ref is None

tests/test_material_application.py

@@ -0,0 +1,158 @@
+from datetime import UTC, datetime, timedelta
+from pathlib import Path
+from unittest.mock import MagicMock, Mock
+
+import psycopg
+import pytest
+import yaml
+
+from production_analytics.calculations.config import (
+    CalculationConfigError,
+    load_material_calculation,
+)
+from production_analytics.calculations.material_application import rotational_application_g_m2
+from production_analytics.calculations.material_consumption import MaterialSample
+from production_analytics.enlyze.gateway import EnlyzeApiGateway, EnlyzeProductionRun
+from production_analytics.service.material_polling import MaterialPollingService
+from production_analytics.service.postgres_material import PostgresSettings
+from production_analytics.service.postgres_material_application import (
+    PostgresMaterialApplicationWriter,
+)
+
+NOW = datetime(2026, 9, 7, tzinfo=UTC)
+
+
+def test_realistic_application_and_generic_factor():
+    assert rotational_application_g_m2([3.739, 3.956], 3.12, 8, 0.3) == pytest.approx(3001.05)
+    assert rotational_application_g_m2([2, 3], 1.5, 10, 0.5) == 750
+
+
+@pytest.mark.parametrize('speed', [-10, 0, 1e-300, 0.299999999, 0.3])
+def test_inactive_and_near_zero(speed):
+    assert rotational_application_g_m2([3.739, 3.956], 3.12, speed, 0.3) is None
+
+
+@pytest.mark.parametrize('speeds,factor,speed,threshold', [
+    ([], 3.12, 8, 0.3), ([float('nan')], 3.12, 8, 0.3),
+    ([1], 0, 8, 0.3), ([1], float('inf'), 8, 0.3),
+    ([1], 3.12, float('nan'), 0.3), ([1], 3.12, 8, 0),
+    ([1], 3.12, 8, float('inf')), ([1e308], 3.12, 8, 0.3),
+])
+def test_invalid_inputs(speeds, factor, speed, threshold):
+    with pytest.raises(ValueError):
+        rotational_application_g_m2(speeds, factor, speed, threshold)
+
+
+@pytest.mark.parametrize('width', [1, 4.85, 5, 100])
+def test_gateway_width_cancels_and_only_act_signals_requested(width):
+    config = load_material_calculation('config/bento1-material-consumption.yaml')
+    refs = [*config.rotational_speed_signal_refs, config.gate_signal_ref]
+    client = Mock()
+    client.post_json.return_value.body = {'data': {
+        'columns': ['time', *refs],
+        'records': [[NOW.isoformat(), 3.739, 3.956, 8],
+                    [(NOW + timedelta(seconds=10)).isoformat(), 3.739, 3.956, 0]],
+    }}
+    samples = EnlyzeApiGateway(client).get_material_samples(
+        machine_id=config.machine_ref, rate_variable_id='unused',
+        gate_variable_id=config.gate_signal_ref, start=NOW, end=NOW + timedelta(seconds=10),
+        rotational_speed_variable_ids=config.rotational_speed_signal_refs,
+        nominal_width_m=width, specific_discharge_kg_per_rev_m=3.12,
+        process_application_gate_threshold=0.3,
+    )
+    assert samples[0].application_g_m2 == pytest.approx(3001.05)
+    assert samples[1].application_g_m2 is None
+    assert samples[0].material_rate_kg_per_hour == pytest.approx(7.695 * width * 3.12 * 60)
+    assert client.post_json.call_args.args[1]['variables'] == [{'uuid': ref} for ref in refs]
+
+
+@pytest.mark.parametrize('changes', [
+    {'process_application_calculation_id': ''}, {'process_application_calculation_id': None},
+    {'process_application_calculation_id': 3}, {'process_application_calculation_id': 'x\x00'},
+    {'process_application_calculation_id': 'bento1-fresh-bentonite-consumption'},
+    {'gate_signal_ref': None}, {'gate_threshold': 0}, {'gate_threshold': -0.3},
+])
+def test_process_config_validation(tmp_path, changes):
+    document = yaml.safe_load(Path('config/bento1-material-consumption.yaml').read_text())
+    document['calculations'][0].update(changes)
+    path = tmp_path / 'config.yaml'
+    path.write_text(yaml.safe_dump(document))
+    with pytest.raises(CalculationConfigError):
+        load_material_calculation(path)
+
+
+def test_persistence_before_checkpoint_retries_and_disjoint_runs():
+    old = EnlyzeProductionRun('old', 'machine', None, 'order', NOW, NOW + timedelta(seconds=10))
+    current = EnlyzeProductionRun(
+        'new', 'machine', None, 'order', NOW + timedelta(seconds=15), None,
+    )
+    gateway = Mock()
+    gateway.get_open_production_run.return_value = current
+    gateway.get_production_runs.return_value = [old, current]
+
+    def samples(**kwargs):
+        start = kwargs['start']
+        assert kwargs['process_application_gate_threshold'] == 0.3
+        return [MaterialSample(start, 7202.52, 8, 3001.05),
+                MaterialSample(start + timedelta(seconds=10), 7202.52, 8, 3001.05)]
+
+    gateway.get_material_samples.side_effect = samples
+    store = Mock(load=Mock(return_value=None))
+    writer = Mock()
+    writer.write.side_effect = [None, psycopg.OperationalError(), None, None]
+    service = MaterialPollingService(
+        gateway=gateway, state_store=store, machine_id='machine', rate_variable_id='unused',
+        gate_variable_id='speed', gate_threshold=0.3, max_sample_gap_seconds=20,
+        rotational_speed_variable_ids=('right', 'left'), specific_discharge_kg_per_rev_m=3.12,
+        nominal_width_provider=lambda order: 5, process_application_calculation_id='application',
+        application_writer=writer,
+    )
+    with pytest.raises(psycopg.OperationalError):
+        service.poll_once(now=NOW + timedelta(seconds=25))
+    store.save.assert_not_called()
+    result = service.poll_once(now=NOW + timedelta(seconds=25))
+    assert result.state.cumulative_consumption_kg == pytest.approx(40.014)
+    assert result.state.integrated_running_seconds == 20
+    assert [c.kwargs['run_id'] for c in writer.write.call_args_list] == ['old', 'new', 'old', 'new']
+    store.save.assert_called_once()
+
+
+def test_sql_persistence_idempotent_and_inactive_omitted(monkeypatch):
+    import sqlite3
+
+    database = sqlite3.connect(':memory:')
+    database.executescript(Path('db/schema.sql').read_text())
+    connection = MagicMock()
+    cursor = connection.__enter__.return_value.cursor.return_value.__enter__.return_value
+    cursor.executemany.side_effect = lambda sql, rows: database.executemany(
+        sql.replace('%s', '?'),
+        [(row[0].isoformat(), *row[1:]) for row in rows],
+    )
+    connect = Mock(return_value=connection)
+    monkeypatch.setattr(psycopg, 'connect', connect)
+    writer = PostgresMaterialApplicationWriter(PostgresSettings('host', 5432, 'db', 'u', 'p'))
+    kwargs = dict(calculation_id='application', machine_id='machine', production_order='order',
+                  run_id='run', samples=[MaterialSample(NOW, 7202.52, 8, 3001.05),
+                                        MaterialSample(NOW + timedelta(seconds=10), 7202.52, 0)])
+    writer.write(**kwargs)
+    writer.write(**kwargs)
+    assert database.execute('SELECT * FROM material_application_snapshots').fetchall() == [
+        (NOW.isoformat(), 'application', 'machine', 'order', 'run', 3001.05),
+    ]
+    writer.write(**(kwargs | {'samples': [MaterialSample(NOW, 1, 0)]}))
+    assert connect.call_count == 2
+    database.close()
+
+
+@pytest.mark.parametrize('collision', ['output', 'consumption'])
+def test_output_ids_unique_across_config_entries(tmp_path, collision):
+    document = yaml.safe_load(Path('config/bento1-material-consumption.yaml').read_text())
+    first = document['calculations'][0]
+    second = dict(first, id='second-consumption')
+    if collision == 'consumption':
+        second['process_application_calculation_id'] = first['id']
+    document['calculations'].append(second)
+    path = tmp_path / 'config.yaml'
+    path.write_text(yaml.safe_dump(document))
+    with pytest.raises(CalculationConfigError, match='unique'):
+        load_material_calculation(path, first['id'])

tests/test_material_efficiency.py

@@ -152,14 +152,15 @@ def test_temporal_regression_and_successive_feedback():
     assert first.good_quantity_m2 == 800
 
 
-def test_naive_feedback_requires_explicit_timezone_and_preserves_source():
+def test_naive_feedback_requires_explicit_timezone_and_returns_instant():
     naive = datetime(2026, 9, 4, 12, 5)
     status = replace(STATUS, feedback_timestamp=naive)
     with pytest.raises(ValueError, match='explicit erp_timezone'):
         service().evaluate(status)
     subject = service(erp_timezone=ZoneInfo('Europe/Berlin'))
     result = subject.evaluate(status)
-    assert result.erp_feedback_timestamp == naive
+    assert result.erp_feedback_timestamp == FEEDBACK
+    assert status.feedback_timestamp == naive
     assert subject.materials.latest_at_or_before.call_args.kwargs['timestamp'] == FEEDBACK
 
 
@@ -171,10 +172,11 @@ def test_dst_gap_and_overlap_rejected(timestamp):
         )
 
 
-def test_aware_feedback_preserves_offset():
+def test_aware_feedback_returns_utc():
     timestamp = FEEDBACK.astimezone(ZoneInfo('Europe/Berlin'))
     result = service().evaluate(replace(STATUS, feedback_timestamp=timestamp))
-    assert result.erp_feedback_timestamp is timestamp
+    assert result.erp_feedback_timestamp == timestamp
+    assert result.erp_feedback_timestamp.tzinfo is UTC
 
 
 def test_database_failure_propagates():

tests/test_material_efficiency_persistence.py

@@ -0,0 +1,488 @@
+import io
+import sqlite3
+from dataclasses import replace
+from datetime import UTC, datetime
+from pathlib import Path
+from unittest.mock import MagicMock, Mock
+
+import psycopg
+import pytest
+import yaml
+
+from production_analytics.calculations.config import CalculationConfigError
+from production_analytics.cli.__main__ import main
+from production_analytics.erp import CurrentWorkplaceStatus, ErpReadError
+from production_analytics.service.material_efficiency import (
+    MaterialEfficiencySnapshot,
+)
+from production_analytics.service.material_efficiency_runner import MaterialEfficiencyRunner
+from production_analytics.service.material_efficiency_runtime import (
+    build_material_efficiency_runner,
+)
+from production_analytics.service.postgres_material import (
+    MaterialConsumptionSnapshot,
+    PostgresSettings,
+)
+from production_analytics.service.postgres_material_efficiency import (
+    PostgresMaterialEfficiencyWriter,
+)
+
+NOW = datetime(2026, 9, 4, 10, tzinfo=UTC)
+SNAPSHOT = MaterialEfficiencySnapshot(
+    "example",
+    "machine",
+    "calc",
+    "00123",
+    " ORDER/00123'; -- ",
+    "article",
+    "fabric 5 x 50 m",
+    5,
+    NOW,
+    NOW,
+    800,
+    1000,
+    1.25,
+    1250,
+)
+SETTINGS = PostgresSettings("localhost", 5432, "analytics", "writer", "secret")
+
+
+@pytest.fixture
+def storage(monkeypatch):
+    # Real schema and INSERT semantics, with only driver transport adapted for SQLite.
+    database = sqlite3.connect(":memory:")
+    database.executescript(Path("db/schema.sql").read_text())
+    connection = MagicMock()
+
+    def execute(sql, params):
+        assert sql.lstrip().startswith("INSERT INTO")
+        assert "SELECT" not in sql.upper()
+        assert "RETURNING 1" in sql
+        assert sql.count("%s") == 14
+        assert SNAPSHOT.enlyze_production_order not in sql
+        return database.execute(
+            sql.replace("%s", "?"),
+            tuple(value.isoformat() if isinstance(value, datetime) else value for value in params),
+        )
+
+    connection.__enter__.return_value.execute.side_effect = execute
+    connect = Mock(return_value=connection)
+    monkeypatch.setattr(psycopg, "connect", connect)
+    yield database, connect, connection
+    database.close()
+
+
+@pytest.mark.parametrize("nullable", [False, True])
+def test_all_fields_and_immutable_event(storage, nullable):
+    database, connect, connection = storage
+    snapshot = (
+        replace(SNAPSHOT, article_number=None, article_description=None, nominal_width_m=None)
+        if nullable
+        else SNAPSHOT
+    )
+    writer = PostgresMaterialEfficiencyWriter(SETTINGS)
+    assert writer.write(snapshot) is True
+    inserted = writer.write(
+        replace(
+            snapshot,
+            material_consumption_kg=9999,
+            material_snapshot_timestamp=NOW.replace(minute=1),
+        )
+    )
+    assert inserted is False
+    assert connection.__enter__.return_value.execute.call_count == 2
+    assert database.execute("SELECT * FROM material_efficiency_snapshots").fetchall() == [
+        (
+            NOW.isoformat(),
+            NOW.isoformat(),
+            "calc",
+            "machine",
+            "example",
+            "00123",
+            SNAPSHOT.enlyze_production_order,
+            snapshot.article_number,
+            snapshot.article_description,
+            snapshot.nominal_width_m,
+            800,
+            1000,
+            1.25,
+            1250,
+        )
+    ]
+    assert connect.call_count == 2
+    assert connect.call_args.kwargs["connect_timeout"] == 10
+    connection.__exit__.assert_called_with(None, None, None)
+
+
+@pytest.mark.parametrize(
+    "field,value",
+    [
+        ("calculation_id", "other"),
+        ("machine_id", "other"),
+        ("enlyze_production_order", SNAPSHOT.enlyze_production_order.strip()),
+        ("enlyze_production_order", SNAPSHOT.enlyze_production_order + "-combined"),
+        ("erp_feedback_timestamp", NOW.replace(minute=1)),
+    ],
+)
+def test_exact_identity(storage, field, value):
+    writer = PostgresMaterialEfficiencyWriter(SETTINGS)
+    writer.write(SNAPSHOT)
+    writer.write(replace(SNAPSHOT, **{field: value}))
+    assert storage[0].execute("SELECT count(*) FROM material_efficiency_snapshots").fetchone() == (
+        2,
+    )
+
+
+@pytest.mark.parametrize("field", ["erp_feedback_timestamp", "material_snapshot_timestamp"])
+def test_naive_rejected(storage, field):
+    with pytest.raises(ValueError, match="timezone-aware"):
+        PostgresMaterialEfficiencyWriter(SETTINGS).write(
+            replace(SNAPSHOT, **{field: NOW.replace(tzinfo=None)}),
+        )
+    storage[1].assert_not_called()
+
+
+@pytest.mark.parametrize(
+    "field",
+    [
+        "nominal_width_m",
+        "good_quantity_m2",
+        "material_consumption_kg",
+        "material_consumption_kg_per_m2",
+        "material_consumption_g_per_m2",
+    ],
+)
+@pytest.mark.parametrize("value", [float("nan"), float("inf"), -float("inf")])
+def test_nonfinite_rejected(storage, field, value):
+    with pytest.raises(ValueError, match="finite"):
+        PostgresMaterialEfficiencyWriter(SETTINGS).write(replace(SNAPSHOT, **{field: value}))
+    storage[1].assert_not_called()
+
+
+def run_cycles(service, writer, cycles, interval=60, stdout=None):
+    sleep = Mock(side_effect=[None] * (cycles - 1) + [KeyboardInterrupt])
+    errors = io.StringIO()
+    MaterialEfficiencyRunner(
+        service, writer, poll_interval_seconds=interval, sleep=sleep, stderr=errors, stdout=stdout
+    ).run()
+    assert sleep.call_args_list == [((interval,),)] * cycles
+    return errors.getvalue()
+
+
+def test_runner_history_and_none(storage):
+    service = Mock(
+        evaluate_current=Mock(
+            side_effect=[
+                None,
+                SNAPSHOT,
+                SNAPSHOT,
+                replace(SNAPSHOT, erp_feedback_timestamp=NOW.replace(minute=15)),
+            ]
+        )
+    )
+    output = io.StringIO()
+    run_cycles(service, PostgresMaterialEfficiencyWriter(SETTINGS), 4, 73, stdout=output)
+    lines = output.getvalue().splitlines()
+    assert len(lines) == 2
+    assert lines[0].startswith(NOW.isoformat())
+    assert lines[1].startswith(NOW.replace(minute=15).isoformat())
+    assert storage[1].call_count == 3
+    assert storage[0].execute("SELECT count(*) FROM material_efficiency_snapshots").fetchone() == (
+        2,
+    )
+
+
+@pytest.mark.parametrize("error", [ErpReadError, psycopg.OperationalError, psycopg.InterfaceError])
+def test_read_recovers(error):
+    service = Mock(evaluate_current=Mock(side_effect=[error("secret"), SNAPSHOT]))
+    writer = Mock()
+    errors = run_cycles(service, writer, 2)
+    writer.write.assert_called_once_with(SNAPSHOT)
+    assert error.__name__ in errors and "secret" not in errors
+
+
+def test_write_recovers_with_fresh_transaction(storage):
+    database, connect, connection = storage
+    connect.side_effect = [psycopg.OperationalError("secret"), connection]
+    errors = run_cycles(
+        Mock(evaluate_current=Mock(return_value=SNAPSHOT)),
+        PostgresMaterialEfficiencyWriter(SETTINGS),
+        2,
+    )
+    assert "OperationalError" in errors and "secret" not in errors
+    assert connect.call_count == 2
+    assert database.execute("SELECT count(*) FROM material_efficiency_snapshots").fetchone() == (1,)
+
+
+@pytest.mark.parametrize("error", [ValueError, TypeError, psycopg.ProgrammingError])
+def test_programming_errors_propagate(error):
+    with pytest.raises(error):
+        run_cycles(Mock(evaluate_current=Mock(side_effect=error("bad contract"))), Mock(), 1)
+
+
+@pytest.mark.parametrize("interval", [0, -1, float("nan"), float("inf"), True])
+def test_invalid_interval(interval):
+    with pytest.raises(CalculationConfigError):
+        MaterialEfficiencyRunner(Mock(), Mock(), poll_interval_seconds=interval)
+
+
+@pytest.fixture
+def runtime_files(tmp_path):
+    config = tmp_path / "config.yaml"
+    config.write_text(
+        yaml.safe_dump(
+            dict(
+                workplace="example",
+                machine_id="machine",
+                calculation_id="calc",
+                production_order_format="ORDER/{production_order}",
+                erp_timezone="Europe/Berlin",
+            )
+        )
+    )
+    postgres = tmp_path / "postgres.env"
+    postgres.write_text(
+        "POSTGRES_HOST=localhost\nPOSTGRES_PORT=5432\nPOSTGRES_DB=analytics\n"
+        "POSTGRES_USER=writer\nPOSTGRES_PASSWORD=secret\n"
+    )
+    erp = tmp_path / "erp.env"
+    erp.write_text(
+        "ERP_DB_HOST=localhost\nERP_DB_PORT=1433\nERP_DB_NAME=erp\n"
+        "ERP_DB_USER=reader\nERP_DB_PASSWORD=secret\n"
+    )
+    return config, postgres, erp
+
+
+def test_configured_runtime_naive_feedback_to_persistence(runtime_files, storage):
+    config, postgres, erp = runtime_files
+    runner = build_material_efficiency_runner(config, secrets_file=postgres, erp_secrets_file=erp)
+    assert runner.interval == 60
+    runner.service.erp = Mock(
+        get_current_workplace_status=Mock(
+            return_value=CurrentWorkplaceStatus(
+                "example",
+                "00123",
+                None,
+                None,
+                datetime(2026, 9, 4, 12),
+                None,
+                800,
+                None,
+                None,
+                None,
+            )
+        )
+    )
+    runner.service.materials = Mock(
+        latest_at_or_before=Mock(
+            return_value=MaterialConsumptionSnapshot(
+                NOW,
+                "calc",
+                "machine",
+                "ORDER/00123",
+                "run",
+                1000,
+            )
+        )
+    )
+    runner.sleep = Mock(side_effect=KeyboardInterrupt)
+    runner.run()
+    row = storage[0].execute("SELECT * FROM material_efficiency_snapshots").fetchone()
+    assert row[:7] == (
+        NOW.isoformat(),
+        NOW.isoformat(),
+        "calc",
+        "machine",
+        "example",
+        "00123",
+        "ORDER/00123",
+    )
+
+
+@pytest.mark.parametrize(
+    "changes",
+    [
+        {"erp_timezone": "invalid"},
+        {"production_order_format": "missing"},
+        {"workplace": ""},
+        {"machine_id": None},
+        {"poll_interval_seconds": 0},
+        {"unknown": 1},
+    ],
+)
+def test_startup_config_errors(runtime_files, changes, capsys):
+    config, postgres, erp = runtime_files
+    config.write_text(yaml.safe_dump(yaml.safe_load(config.read_text()) | changes))
+    assert (
+        main(
+            [
+                "run",
+                "material-efficiency",
+                "--config",
+                str(config),
+                "--secrets-file",
+                str(postgres),
+                "--erp-secrets-file",
+                str(erp),
+            ]
+        )
+        == 2
+    )
+    assert "Config/startup error" in capsys.readouterr().err
+
+
+def test_k7_config_and_cli(runtime_files, monkeypatch):
+    _, postgres, erp = runtime_files
+    runner = build_material_efficiency_runner(
+        Path("config/k7-material-efficiency.yaml"), secrets_file=postgres, erp_secrets_file=erp
+    )
+    assert runner.service.workplace == "K7"
+    assert runner.service.machine_id == "c220f95c-a65e-4cb7-99b7-0626d6c7508c"
+    assert runner.service.calculation_id == "k7-fiber-consumption"
+    assert runner.service.format_template == "K 7-{production_order}"
+    assert runner.service.erp_timezone.key == "Europe/Berlin"
+    run = Mock()
+    monkeypatch.setattr(MaterialEfficiencyRunner, "run", run)
+    assert (
+        main(
+            [
+                "run",
+                "material-efficiency",
+                "--config",
+                "config/k7-material-efficiency.yaml",
+                "--secrets-file",
+                str(postgres),
+                "--erp-secrets-file",
+                str(erp),
+            ]
+        )
+        == 0
+    )
+    run.assert_called_once()
+
+
+def test_failed_insert_rolls_back_and_later_cycle_reconnects(storage):
+    database, connect, connection = storage
+    execute = connection.__enter__.return_value.execute
+    original = execute.side_effect
+    attempts = 0
+
+    def fail_once(sql, params):
+        nonlocal attempts
+        attempts += 1
+        if attempts == 1:
+            raise psycopg.OperationalError("secret SQL")
+        return original(sql, params)
+
+    execute.side_effect = fail_once
+    errors = run_cycles(
+        Mock(evaluate_current=Mock(return_value=SNAPSHOT)),
+        PostgresMaterialEfficiencyWriter(SETTINGS),
+        2,
+    )
+    assert "secret" not in errors
+    assert connect.call_count == 2
+    assert connection.__exit__.call_args_list[0].args[0] is psycopg.OperationalError
+    assert database.execute("SELECT count(*) FROM material_efficiency_snapshots").fetchone() == (1,)
+
+
+def test_configured_interval_and_missing_settings(runtime_files, monkeypatch):
+    config, postgres, erp = runtime_files
+    config.write_text(
+        yaml.safe_dump(yaml.safe_load(config.read_text()) | {"poll_interval_seconds": 91})
+    )
+    runner = build_material_efficiency_runner(config, secrets_file=postgres, erp_secrets_file=erp)
+    assert runner.interval == 91
+    postgres.write_text("")
+    for key in ("HOST", "PORT", "DB", "USER", "PASSWORD"):
+        monkeypatch.delenv(f"POSTGRES_{key}", raising=False)
+    from production_analytics.enlyze.exploration import ConfigurationError
+
+    with pytest.raises(ConfigurationError, match="POSTGRES_HOST"):
+        build_material_efficiency_runner(config, secrets_file=postgres, erp_secrets_file=erp)
+
+
+@pytest.mark.parametrize("result", [None, False, True])
+def test_runner_success_output(result):
+    snapshot = replace(SNAPSHOT, enlyze_production_order="ORDER/00123")
+    service = Mock(evaluate_current=Mock(return_value=None if result is None else snapshot))
+    writer = Mock(write=Mock(return_value=result))
+    output = Mock(wraps=io.StringIO())
+    errors = run_cycles(service, writer, 1, stdout=output)
+    assert errors == ""
+    if result is None:
+        writer.write.assert_not_called()
+    else:
+        writer.write.assert_called_once_with(snapshot)
+    if result is True:
+        assert output.getvalue() == (
+            "2026-09-04T10:00:00+00:00 workplace='example' production_order='ORDER/00123' "
+            "good_m2=800.000 material_kg=1000.000 g_per_m2=1250.000\n"
+        )
+        output.flush.assert_called_once_with()
+    else:
+        assert output.getvalue() == ""
+        output.flush.assert_not_called()
+
+
+def test_repeated_duplicates_are_silent(storage):
+    writer = PostgresMaterialEfficiencyWriter(SETTINGS)
+    assert writer.write(SNAPSHOT) is True
+    output = io.StringIO()
+    run_cycles(Mock(evaluate_current=Mock(return_value=SNAPSHOT)), writer, 3, stdout=output)
+    assert output.getvalue() == ""
+
+
+def test_commit_failure_does_not_log_success(storage):
+    _, _, connection = storage
+    connection.__exit__.side_effect = [psycopg.OperationalError("secret driver SQL"), None]
+    output = io.StringIO()
+    errors = run_cycles(
+        Mock(evaluate_current=Mock(return_value=SNAPSHOT)),
+        PostgresMaterialEfficiencyWriter(SETTINGS),
+        1,
+        stdout=output,
+    )
+    assert output.getvalue() == ""
+    assert errors == "Material efficiency cycle failed: OperationalError\n"
+
+
+def test_bento_uses_generic_efficiency_and_distinct_output_id(runtime_files, storage):
+    _, postgres, erp = runtime_files
+    runner = build_material_efficiency_runner(
+        Path('config/bento1-material-efficiency.yaml'),
+        secrets_file=postgres, erp_secrets_file=erp,
+    )
+    from production_analytics.service.material_efficiency import MaterialEfficiencyService
+
+    assert type(runner.service) is MaterialEfficiencyService
+    service = runner.service
+    status = CurrentWorkplaceStatus(
+        'Bento 1', '00123', None, None, NOW, None, 800, None, None, None,
+    )
+    service.erp = Mock(get_current_workplace_status=Mock(return_value=status))
+    service.materials = Mock(latest_at_or_before=Mock(return_value=MaterialConsumptionSnapshot(
+        NOW, 'bento1-fresh-bentonite-consumption', service.machine_id, 'Bento 1-00123', 'run', 2400,
+    )))
+    snapshot = service.evaluate_current()
+    assert snapshot.calculation_id == 'bento1-fresh-bentonite-efficiency'
+    assert snapshot.material_consumption_g_per_m2 == 3000
+    assert snapshot.nominal_width_m is None
+    service.materials.latest_at_or_before.assert_called_once_with(
+        calculation_id='bento1-fresh-bentonite-consumption', machine_id=service.machine_id,
+        production_order='Bento 1-00123', timestamp=NOW,
+    )
+    runner.writer.write(snapshot)
+    row = storage[0].execute(
+        'SELECT calculation_id, material_consumption_g_per_m2 FROM material_efficiency_snapshots'
+    ).fetchone()
+    assert row == ('bento1-fresh-bentonite-efficiency', 3000)
+
+
+@pytest.mark.parametrize('value', ['', None, 12, 'bad\x00id'])
+def test_invalid_output_calculation_id(runtime_files, value):
+    config, postgres, erp = runtime_files
+    document = yaml.safe_load(config.read_text()) | {'output_calculation_id': value}
+    config.write_text(yaml.safe_dump(document))
+    with pytest.raises(CalculationConfigError, match='output_calculation_id'):
+        build_material_efficiency_runner(config, secrets_file=postgres, erp_secrets_file=erp)

tests/test_rotational_material_consumption.py

@@ -0,0 +1,122 @@
+from datetime import UTC, datetime, timedelta
+from pathlib import Path
+from unittest.mock import Mock, patch
+
+import pytest
+import yaml
+
+from production_analytics.calculations.config import (
+    CalculationConfigError,
+    load_material_calculation,
+)
+from production_analytics.calculations.material_consumption import (
+    MaterialConsumptionIntegrator,
+    MaterialIntegratorConfig,
+    rotational_discharge_rate_kg_per_hour,
+)
+from production_analytics.enlyze.gateway import EnlyzeApiGateway
+from production_analytics.service.material_runtime import build_material_runner
+
+
+@pytest.mark.parametrize('speeds,width,factor,expected', [
+    ([3.739, 3.956], 5, 3.12, 7202.52),
+    ([3.739, 3.956], 4.85, 3.12, 6986.4444),
+    ([2], 4, 1.5, 720),
+    ([2, 3, 4], 4, 1.5, 3240),
+])
+def test_conversion(speeds, width, factor, expected):
+    assert rotational_discharge_rate_kg_per_hour(speeds, width, factor) == pytest.approx(expected)
+
+
+@pytest.mark.parametrize('speeds,width,factor', [
+    ([], 5, 3.12), ([float('nan')], 5, 3.12), ([1], 0, 3.12),
+    ([1], float('inf'), 3.12), ([1], 5, 0), ([1], 5, float('nan')),
+    ([1e308], 5, 3.12),
+])
+def test_invalid_conversion(speeds, width, factor):
+    with pytest.raises(ValueError):
+        rotational_discharge_rate_kg_per_hour(speeds, width, factor)
+
+
+@pytest.mark.parametrize('gate_id', ['speed', None])
+def test_gate_and_gap(gate_id):
+    start = datetime(2026, 8, 25, tzinfo=UTC)
+    times = [0, 10, 20, 40, 61, 71, 81]
+    gates = [2, 0.3, 0, 8, 1, 1, 1]
+    client = Mock()
+    client.post_json.return_value.body = {'data': {
+        'columns': ['time', 'right', 'left'] + ([gate_id] if gate_id else []),
+        'records': [[(start + timedelta(seconds=t)).isoformat(), 3.739, 3.956]
+                    + ([gate] if gate_id else []) for t, gate in zip(times, gates, strict=True)],
+    }}
+    samples = EnlyzeApiGateway(client).get_material_samples(
+        machine_id='m', rate_variable_id='unused', gate_variable_id=gate_id,
+        rotational_speed_variable_ids=('right', 'left'), nominal_width_m=5,
+        specific_discharge_kg_per_rev_m=3.12, start=start, end=start + timedelta(seconds=81),
+    )
+    assert all(s.material_rate_kg_per_hour == pytest.approx(7202.52) for s in samples)
+    state = MaterialConsumptionIntegrator(MaterialIntegratorConfig(0.3, 20)).process_many(samples)
+    seconds = 30 if gate_id else 60
+    assert state.integrated_running_seconds == seconds
+    assert state.cumulative_consumption_kg == pytest.approx(120.042 * seconds / 60)
+    assert client.post_json.call_args.args[1]['variables'] == [
+        {'uuid': ref} for ref in ['right', 'left'] + ([gate_id] if gate_id else [])]
+
+
+@pytest.mark.parametrize('field,value', [
+    ('specific_discharge_kg_per_rev_m', None), ('specific_discharge_kg_per_rev_m', 0),
+    ('specific_discharge_kg_per_rev_m', True), ('specific_discharge_kg_per_rev_m', float('inf')),
+    ('application_signal_refs', ['set']), ('rotational_speed_signal_refs', ['']),
+])
+def test_invalid_config(tmp_path, field, value):
+    document = yaml.safe_load(open('config/bento1-material-consumption.yaml'))
+    document['calculations'][0][field] = value
+    path = tmp_path / 'config.yaml'
+    path.write_text(yaml.safe_dump(document))
+    with pytest.raises(CalculationConfigError):
+        load_material_calculation(path)
+
+
+def test_optional_gate_config(tmp_path):
+    document = yaml.safe_load(open('config/bento1-material-consumption.yaml'))
+    del document['calculations'][0]['process_application_calculation_id']
+    del document['calculations'][0]['gate_signal_ref']
+    del document['calculations'][0]['gate_threshold']
+    path = tmp_path / 'config.yaml'
+    path.write_text(yaml.safe_dump(document))
+    (tmp_path / 'material-calibrations.yaml').write_text(
+        Path('config/material-calibrations.yaml').read_text())
+    config = load_material_calculation(path)
+    assert config.gate_signal_ref is None
+    assert config.gate_threshold == 0
+
+
+def test_bento_runtime_wiring(tmp_path, monkeypatch):
+    monkeypatch.setenv('ENLYZE_BASE_URL', 'https://example.invalid/api/')
+    for key, value in dict(HOST='localhost', PORT='5432', DB='analytics',
+                           USER='user', PASSWORD='test').items():
+        monkeypatch.setenv(f'POSTGRES_{key}', value)
+    secrets = tmp_path / 'secret.env'
+    secrets.write_text('ENLYZE_API_KEY=test\n')
+    config = load_material_calculation('config/bento1-material-consumption.yaml')
+    with patch('production_analytics.service.material_runtime.ErpSettings') as erp_settings:
+        runner = build_material_runner(
+            config, poll_interval_seconds=10, state_directory=tmp_path / 'state',
+            secrets_file=secrets, erp_secrets_file=tmp_path / 'erp.env',
+        )
+    service = runner.service
+    assert config.source_mode == 'rotational_discharge'
+    assert service._process_application_calculation_id == 'bento1-fresh-bentonite-application'
+    from production_analytics.service.postgres_material_application import (
+        PostgresMaterialApplicationWriter,
+    )
+    assert isinstance(service._application_writer, PostgresMaterialApplicationWriter)
+    assert service._rotational_speed_variable_ids == (
+        '6e5d2d94-98f9-4cc1-8a88-7987c6282525', 'cd7385c4-337b-4759-ab32-45d65beaf190',
+    )
+    assert service._application_variable_ids == ()
+    assert service._specific_discharge == 2.75
+    assert service._gate_variable_id == 'fef41976-1103-4090-b780-eaeecc02fdfa'
+    assert service._config == MaterialIntegratorConfig(0.3, 20)
+    assert service._nominal_width_provider.workplace == 'Bento 1'
+    erp_settings.from_secret_file.assert_called_once_with(tmp_path / 'erp.env')