What’s A Compact Concrete Batching Plant?
A Compact Concrete Batching Plant is a multipurpose concrete mixing plant that combines the specific features of mobile and stationary concrete batching plants. This batching plant comprises smaller model units of prewired or pre-designed components.
This innovative model design style allows compact concrete batching plants to be readily installed and transported while providing great performance and efficiency in creating concrete products.
As you may be aware, a compact concrete plant excellently creates concrete by blending and mixing powdered materials. These materials include gravel, sand, crushed stone, cement, fine stone, and more.
In addition, liquid materials include water, additive, and more in specific proportions based on the client’s needs and the project.
Compact concrete batching plant typically features an aggregate feeding system, a cement silo, an aggregate weighing system, water, an additive feeding system, a cement feeding system, an automatic control system, a central mixing host, and other components.
Common Types Of Compact Concrete Batching Plant
1. Mobile & Stationary Compact Concrete Batching Plants
Concrete batching machines are classified into several categories based on various classification criteria. Stationary concrete batching plant and mobile concrete stations are the two most basic and prevalent forms.
A compact concrete mixing plant is a type of mobile concrete plant. In most large-scale engineering construction stations, the modular splicing designs are mainly used for large manufacturing capability and reliable anti-interference ability.
A towing unit can tow a compact mobile concrete batching plant, making it more versatile and efficient than fixed concrete plants.
2. Engineering and Commercial Concrete Plant
Concrete batching facilities are classified into engineering stations and commercial stations based on the application.
A commercial plant is a concrete batching plant that sells manufactured concrete products for retail or profit purposes. It generally necessitates a large-capacity, low-cost, and eco-friendly batching facility. On the other hand, the engineering station is often set up for a specific project or self-use.
This article describes a compact batching plant typically seen in engineering plants.
Users are advised to select the suitable station type based on the real application before purchasing.
3. Single & Twin Mixer Batching Plant
Concrete mixing plants are classified into two categories based on the number of primary mixers: single mixer concrete plants and twin shaft mixer concrete plants.
4. Batching Plants With a Single Mixer and a Batching Plant With Two Mixers
Concrete mixing plants are classified into two categories based on the number of primary mixers: single mixer concrete plants and double mixer concrete plants.
Obviously, the output of the double mixer plant is double that of the single mixer plant. It’s much more stable because manufacturing output may continue on the other if one host fails. However, this twin mixer configuration is clearly unsuitable for compact concrete stations.
5. Independent weighing and cumulative weighing type plant
Compact Concrete batching plant is classified into two categories based on their weighing method: single weighing type and cumulative weighing type.
Each raw material belongs to a distinct weighing hopper in the single weighing plant. All raw components are blended and stirred in the mixing host after being individually weighed. This high-efficient weighing system is better suited for concrete mixing plants that feature large and medium production capabilities.
Various aggregates are consecutively fed into the same weighing hopper, weighed in succession, and then transported to the main mixer in the cumulative weighing type.
This weighing method requires only one weighing device to measure all aggregates, which significantly reduces clients’ concrete footprint area and costs. Clearly, compact and cost-effectiveness attributes are desirable features in a compact batching plant.
6. Containerized Batch Plant
Interestingly, this form of mixing equipment is a container concrete batch machinery. It comprises the following components: a control system, a mixing system, a weighing system, a material storage system, and a conveying system.
Compared to a standard concrete mixing plant, it does not require the installation of legs and mounting brackets.
Furthermore, the containerized concrete batch plant has outstanding environmental performance, easy to transport, and is simple to install. It is also appropriate for manufacturing concretes for highway, hydropower, port, bridge, airport, other building projects, and commercial concrete plants construction.
Containerized concrete mixing plant is a type of compact concrete batching plant in some ways.
Related: Mobile Concrete Plant
Compact Concrete Batching Plant Specifications
|Mixing system type||Twin-shaft concrete mixer|
|Aggregate feeder||Bucket (Skip hopper)||Belt conveyor|
|Discharging height||1500 – 3800mm||3800mm||3900mm|
|After-sale service||Erection & commissioning, operator training|
|Warranty||12 months after erection|
|Max. mixing size||80/60mm||80/60mm||80/60mm||80/60mm|
|Aggregate batching machine||PLD800||PLD1200||PLD1600||PLD1600|
|Storage bins quantity||2 or 3 or 4 sorts||3 or 4 sorts||3 or 4 sorts||2 or 3 or 4 sorts|
|Aggregate scale hopper||800L||1200L||1600L||2400L|
|Feeding height of batching machine||1850mm – 2900mm|
Features & Pros Of Compact Concrete Plants
Compact concrete batch machines are readily moved to project sites and erected in a short time. As a result, they produce outstanding quality concrete products, thanks to the high efficiency of stationary concrete batching plants and the great mobility feature of mobile concrete batching plants.
LUTON Compact Concrete Plants feature a production capacity of less than 60m3/h, and it’s also known as containerized concrete plants. Small concrete batching plants provide consumers with economic benefits due to their compact model design and the need for minimal infrastructure investment.
A skip hoist technology is used rather than a belt conveyor in LUTON Compact Batching Plants to reduce overall size. This is the most important aspect influencing the overall plant footprint size on the building site.
1. Affordability and Flexibility
This compact concrete batching plant is more versatile and easier to move about whenever and wherever needed. A compact concrete mixing plant allows you to fulfill several clients at once. It may be used on the building site and quickly moved from one location to another with minimal effort and cost.
As a result, a compact plant is cost-effective, saving you a significant amount of money in the long run.
The compact concrete plant modular design ensures the flexibility of quick installation, removal, and dismantling a compact plant. Based on this module design, a compact concrete plant also requires less space for installation, making it very easy to install on project sites.
2. Quick and Efficient
In comparison to a large concrete batching plant, a compact batching machine can swiftly and efficiently manufacture the amount of concrete required without creating a concrete backlog, which may result in product waste.
A compact plant can be quickly dismantled and readily loaded by trucks, resulting in lower transportation costs. Furthermore, the expense of removing plants is lower.
4. Durable and Steady
It features a steel structure that is strong and stable, with square and rectangular support legs for extended durability and anti-corrosion.
5. Requires No Foundation
Compact concrete plants, as opposed to stationary concrete plants, require less foundation, which means they may be utilized to create concrete immediately after being shipped to a new location. As a result, it can save clients money and time.
6. Low Operating Costs & Easy Maintenance
Due to its module structure and simple components, compact concrete batching plants are easy to maintain with minimal operating costs.
- Maximum productivity on a given capability.
- It manufactures concretes of high quality and precision. Also, electric weighing and computer control are used in the PLD aggregate batching system, making it more precise and efficient in its mode of action.
Our small concrete batching plants are eco-friendly due to their anti-noise design and dust collecting technology.
- The use of a JS twin shaft concrete mixer provides excellent efficiency and an optimal mixing effect.
Related: Mini Concrete Batching Plant
Features of HZS35 Compact Concrete Batching Plant
Aggregate Batching Machine
PLD1200 aggregate batching machine features an electronic weighing system and PLY control system. It can automatically batch 3 to 4 types of aggregates, such as sand, cement, or stone, at the same time. It is possible to achieve precise weighing, automated adjustment, and speedy operation. This is possible using a weighing pressure sensor and a computer.
There is a hopper cumulative weighing system for the LUTON HZS35 compact concrete batching plant.
Most LUTON’s compact concrete mixing plants hoist aggregate materials with skip hoppers. This technology is smaller and requires less space than belt conveyors.
JS750 Mixing Machine
JS750 concrete mixers components are twin horizontal shaft compulsory mixers with a mixing duration of 60 seconds and a maximum aggregate size of 80/60mm. These features are the reasons for the HZS35 efficiency and strength.
They are popularly used in industrial and civil construction, precast concrete factories, bridge construction, waterworks, airports, highways, and harbors. This popularity is attributed to the ability to effectively mix plastic concrete, dry hard concrete, light aggregate concrete, flow concrete, and other mortars.
This component of HZ35 may be customized based on different factors, including footprint size, production capacity, and environmental protection requirements.
It is designed to feature an air pressure monitoring system, a cement volume monitoring system, a safety warning system, a dust collecting system, and other features that can make a cement silo with a long lifespan, a small footprint, and cost-effectiveness.
Screw conveyors are typically available in two diameters, ∅219mm and ∅273mm. Their length may be customized to the specific installation requirements.
The HZS35 concrete mixing system features cement weighing, water weighing, additive weighing, and other weighing systems that can be customized to meet the client’s needs.
Electric Controls System
The HZS35 control system is a fully automated electric control system that features a manual control panel, making it easy to achieve precise control.
Luton Group provides effective dust collection systems to minimize dust emissions and eco-friendly manufacturing. Two different types of dust collection systems can be selected by our specialists based on the needs of the customer. The first is a bag-type dust collection system, while the second is a water dust collection system.
Bag-type collection systems employ a two-stage dust extraction system. The first stage consists of gravity dust removal and the second stage consists of bag dust removal.
Mostly, a three-step dust removal system is advised, with the first stage consisting of gravity dust removal, the second stage consisting of whirlwind dust removal, and the third stage consisting of water dust removal.
This system comprises the following components: a gas tank, an air compressor, a pneumatic triplet, an air cylinder, a solenoid valve, and a pneumatic valve. Also, the plant’s air compressor produces compressed air, which is then purified and regulated by the pneumatic triplex’s filter and pressure regulator.
The control signal is then sent to each pneumatic actuator, which subsequently regulates the action of every pneumatic valve following the instruction of the control signal. This results in the opening and closing control of each door component.
Related: Portable Concrete Batch Plant
What Is The Cost Of A Compact Concrete Batching Plant?
The cost of constructing a compact concrete plant typically ranges between $25,000 and $100,000, based on the production capacity, the use of the concrete, the effect of various customized configurations, and many more.
The first is the expense of acquiring the whole concrete mixing plant’s equipment. This is followed by the cost of shipping.
Then, suppose you haven’t done anything like this before, in that case, you’ll need to hire professionals to assist you in setting up the plant, which is also an unavoidable cost.
Cost of labor, power supply, water supply, environmental protection expenses, and many other factors are considered.
You should be aware that no fixed or universal budget plan can be applied to all concrete mixing plants. This is due to factors such as the volume of concrete used, the product quality standards, and the plant operating environment of each plant varies.
Consider site size, output size, transportation, and location before constructing the plant. This will supply you with the vital information required to create and construct a concrete mixing plant precisely.
Related: Mini Concrete Batch Plant for Sale
Top 10 Compact Concrete Batch Plant Manufacturers
Since the first concrete batch plant was built in 1934, the construction plant manufacturing industry has grown for 87 years, from the first elementary concrete mixing plant to multiple automatic concrete mixing plants.
At this time, more and more consistent innovative manufacturers have emerged. As a result, they have contributed their quota in developing productive manufacturing technology, advanced machinery designing, scientific management methods, refined and powerful servicing, and many more.
SANY is a Chinese construction machinery and equipment manufacturer founded in 1989. Its primary products include digging machinery, concrete equipment, hoisting machinery, coal machinery, road construction machinery, and more.
ZOOMLION, created in 1992, designs and manufactures infrastructure equipment and machinery for energy engineering, project construction, transportation engineering, environmental engineering, and other fields.
THE LUTON GROUP
LUTON provides a diverse selection of Concrete Mixing Plants and high-quality Concrete Mixers. With LUTON Group, you can Compact, Stationary, and Mobile concrete plants designs as bespoke solutions for various types of concrete based on your needs.
Also, LUTON offers Planetary Single Shaft and Twin Shaft Concrete Mixers that can meet a variety of applications while increasing production flexibility.
LUTON GROUP offers over 20 years of experience in concrete plant manufacturing as one of the world’s leading concrete batching plants manufacturers. LUTON is located in China and helps customers promote efficiency and performance at low operating and maintenance costs.
Founded in 1997, Fujian South Highway Machinery Co., Ltd is a company that specializes in equipment manufacturing. NFLG specializes in manufacturing building material batching machinery, mining machinery, construction material batching machinery, and more. Manufacturing concrete batching plants is just one minor part of NFLG’s capability.
Founded in 1943, Xuzhou Concrete Machinery Group Co., Ltd is a research and production company specializing in manufacturing hoisting machinery, excavators, mining machinery, loaders, piling machinery, road machinery, tunnel gear, concrete, other construction machinery.
Putzmeister, a German construction machinery producer since 1958. They specialize in the continuous development of machinery for distributing, pumping, placing, transporting, and storing construction materials, including high-density soil, concrete, and mortar.
Another top manufacturer of concrete mixing plants is the Schwing Group. They are a supplier of concrete construction equipment and related services. SCHWING offers products including truck mixer, truck-mounted concrete pump, truck mixer pump, concrete recycling plant, concrete mix plant, cleaning system for mixers, environment, and industry pump system, and more.
For over 30 years, MEKA has been a provider and manufacturer of various types of concrete plants, ready concrete batch plants, road concrete solutions, precast applications, fiber dosing equipment, and recycling systems.
JEL – founded in 2013, is another proficient concrete plant manufacturing company domiciled in the US. They specialize in manufacturing varieties of concrete mixing plants.
What Is The Operation Of A Compact Batching Plant?
The operation of a compact batching plant should follow the following stages:
1. Supply of raw materials
The following steps are included in the raw material preparation stage: cement, aggregate, and other admixtures are loaded into the cement silo for storage.
2. Measuring /Weighing raw materials
Activate the mixing machine and estimate the level of concrete raw material compositions needed to run the mini batching plant. Weigh the items one at a time using the weighing system.
3. Transportation of raw materials
The aggregate hopper door is shut after weighing. The discharge gate opens, and aggregates are discharged to the running conveyor. The aggregate is then transported via the conveyor to the inclined belt conveyor, transporting aggregates to the aggregate hopper.
4. Unloading of raw materials
After weighing the water and admixture, the admixture metering bucket is discharged by a pneumatic butterfly valve, and the admixture enters the water metering bucket. The aggregate, cement, water, and additives are eventually released into the concrete mixer according to the operating sequence.
Related: Mobile Concrete Batching Plant
For more than 20 years, LUTON GROUP has specialized in creating and manufacturing concrete batching equipment, with the capacity to design and manufacture full-range concrete batching plants to suit varied client demands. Our factory guarantees high-end and quality after-sales services. Contact us today for more inquiries, purchases, as well as visits to our workshop!
LUTON’s products include ready mixing concrete batching plants, stationary concrete mixing plants, precast concrete batching plants, portable or mobile concrete batching plants, hopper concrete batching plants, belt concrete batching plants, wet concrete mix plants, and dry concrete mix plants, among others.
Frequently Asked Questions (F.A.Qs)
1. Are compact concrete batching plants mobile or transportable?
YES, A compact concrete batching plant can be unquestionably mobile. It is simple to install, disassembled, and moved by truck since it is a portable concrete plant with a compact design.
Compact concrete mixing plants are becoming increasingly popular in the construction industry. Thanks to the flexibility of mobile concrete batching plants and the reliability offered by stationary concrete plants.
2. How large can a compact concrete batching facility be?
However, these sizes and capacities are only theoretical values. This is because it is difficult to ensure the actual theoretical capacities due to some factors. Mixing loss, missing schedule, and delay in batching management, the production time cycle may be more than the theoretical value. As a result, the actual production capacity maybe just 60 to 75 percent of theoretical capacity.