Concrete Mixer Batching Plant

What is a concrete mixer batching plant?

The concrete mixer batching plant is an automatic production system that combines various raw materials such as sand and gravel, cement, water, and additives to produce a concrete mixture. The equipment is composed of batching machine, conveying equipment, weighing equipment, mixing host, cement bin, etc. The main mixing machine is the heart of the concrete batching plant. Customers have the choice to configure mixing hosts with different capacities and mixing modes according to their requirements to meet their objectives.

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What is the role of raw materials in concrete batch mix plants?

The main ingredients required for producing concrete are cement, water, and sand. The sand acts as a skeleton and becomes the aggregate. Cement and water combined together form cement paste, which wraps the surface of aggregate and fills its gaps. Before the mixture hardens, the grout lubricates and gives the concrete mixture good workability. Once the cement paste hardens, the aggregate gets cemented to form a full solid. The concrete mixer batching plant is also called a cement mixing plant.

How Much Does a Concrete Mixer Batching Plant Cost?

In general, even when we consider the same type of concrete mixer batching plant series, the higher the production capacity of the plant, the higher will be the price. 

For example, let’s consider the stationary type – (models ranging from HZS35, HZS50, HZS60, HZS75, HZS90, HZS120, HZS150, HZS180, HZS240, etc.) The price of the HZS35 model concrete mixing plant will be lower than the price of the HZS240 plant due to the difference in the production capacity of the plant. 

Also Read: Dry Concrete Batching Plant

The same is applicable for mobile-type plants – models ranging from YHZS25, YHZS30, YHZS35, YHZS60, YHZS75, YHZS90, etc.

Models	Price range
HZS25	$18,000-$50,000
HZS35	$20,000-$100,000
HZS50	$25,000-$120,000
HZS60	$30,000-$150,000
HZS90	$50,000-$180,000
HZS120	$60,000-$250,000
HZS150	$70,000-$500,000
HZS180	$100,000-$500,000
HZS240	$150,000-$500,000

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Concrete Batching Plant Mixer Types

1. According to the working mode of the main mixer:

The main mixer of the concrete mixer batching plant can be divided into – forced intermittent mixing and continuous drum mixing, according to its mixing method.

In the forced batch mixing method, the three processes of feeding, mixing, and discharging of materials are carried out according to a certain time interval cycle. (which means that once a batch is in process, the next production batch will be carried out only after the feeding, mixing, and discharging is completed.) This is generally applicable to the forced intermittent mixing main machine.

The advantage of the batch type is that the concrete mixing is uniform and the produced concrete mixture is of good quality because the mixed materials are accurately weighed.

In the continuous drum mixing method, the feeding, mixing, and discharging of concrete are carried out continuously in a long drum.

Twin-shaft horizontal mixers are generally used in forced batching plants, so the batching plant is also called twin shaft mixer batching plant.

Types of Twin shaft concrete mixer batching plant

How many types of forced batch mixers are there?

• 0.5m3 double horizontal shaft forced concrete mixer, namely JS500 concrete mixer. This has a mixing capacity of about 25m3 concrete in one hour.
• 75m3 double horizontal shaft forced concrete mixer, namely JS750 concrete mixer, with a mixing capacity of about 35m3 concrete in one hour
• 1m3 forced concrete mixer with double horizontal shafts is JS1000 concrete mixer, which can mix about 50m3 concrete in one hour.
• 1.5m3 double horizontal shaft forced concrete mixer, namely JS1500 concrete mixer, which can mix about 75m3 concrete in one hour.
• 2m3 double horizontal shaft forced concrete mixer, namely JS2000 concrete mixer, which can mix about 120m3 concrete in one hour.
• 3m3 double horizontal shaft forced concrete mixer, namely JS3000 concrete mixer, which can mix about 180m3 concrete in one hour.
• 4m3 double horizontal shaft forced concrete mixer, namely JS4000 concrete mixer, which can mix about 240m3 concrete in one hour.

What are the advantages of JS double horizontal shaft forced concrete mixer?

• It comprises of double-helical blade shaft configuration with the benefit of – better usage of the cylinder space, better blade mixing energy release mode, and more uniform material mixing. This makes the mixing time in the working process shorter and provides uniform mixing and production efficiency is higher.
• Combined with a PLD series batching machine, it can be operated as a single machine to form a simple concrete mixing station, such as the HZS25 mixing station, which has good application in all kinds of large, medium, and small projects, prefabricated component factories, and industrial and civil construction projects.
• The shaft end is provided with multiple seal protection devices and a wind pressure seal protection device so that the whole stirring device operates continuously, providing stability, longer service time, and preventing dust.

2. According to whether water is added in the mixing process

According to when the water is added to the mixing process, concrete mixing stations are divided into dry mixing stations and wet mixing stations.

The dry concrete mixer batching plant does not require the main mixing machine because the operations of adding water and mixing of materials are carried out in the concrete tank truck during transportation. This saves the stirring time.

Whereas, the wet concrete mixer batching plant (Central mixing plant 130) the main mixing machine is used to mix the prepared raw materials.

3. According to the scale of the concrete mixer batching station

According to the scale/volume, the concrete mixer batching plant can be divided into a large concrete mixing station and a small concrete mixing station. Mini concrete mixer plants are generally mini mobile batching plants

Also Read: Wet Concrete Batch Plant

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Technical Parameters Of Skip Hopper Type Concrete Mixer Plant

Model	HZS25	HZS35	HZS50	HZS75
Capacity	25m3/h	35m3/h	50m3/h	75m3/h
Mixing system	Twin-shaft concrete mixer
Aggregate feeder	Bucket (Skip hopper)
Discharging height	1500-3800mm		3800mm	3800mm
After-sale service	Erection & commissioning, operator training
Warranty	12 months after erection
Concrete mixer	JS500	JS750	JS1000	JS1500
Discharging volume	500L	750L	1000L	1500L
Charging volume	800L	1200L	1600L	2400L
Mixing cycle	72s	72s	72s	72s
Max. mixing size	80/60mm	80/60mm	80/60mm	80/60mm
Aggregate batching machine	PLD800	PLD1200	PLD1600	PLD2400
Storage bins quantity	2 or 3 or 4 sorts	3 or 4 sorts	3 or 4 sorts	3 or 4 sorts
Aggregate scale hopper	800L	1200L	1600L	2400L

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Technical Parameters Of Belt Type Concrete Mixer Batching Plant

Model	HZS60	HZS90	HZS120	HZS180
Capacity	60m3/h	90m3/h	120m3/h	180m3/h
Mixing system	Twin-shaft concrete mixer
Discharging height	3900mm	3900mm	3900mm	4000mm
After-sale service	Erection & commissioning, operator training
Warranty	12 months after erection
Concrete mixer	JS1000	JS1500	JS2000	JS3000
Discharging volume	1000L	1500L	2000L	3000L
Mixing cycle	60S	60s	60s	60s
Max. mixing size	100/80mm	100/80mm	100/80mm	120/80mm
Aggregate batching machine	PLD1600	PLD2400	PLD3200	PLD4800
Storage bins quantity	2 or 3 or 4 sorts	3 or 4 sorts	3 or 4 or 5 or 6 sorts	3 or 4 or 5 or 6 sorts
Aggregate feeding to mixer by	Belt conveyor

Main Components of the Mixer Plant:

1. Mixing machine

All the raw materials such as cement, sand and stone, water, and admixture are mixed in the concrete mixer, the equipment to produce concrete. The mixing machine mainly composes a motor, reducer, mixing barrel, and unloading mechanism. The domestic concrete production industry is mainly equipped with a double horizontal shaft JS series host.

2. Metering system

The metering system is the key component that affects the quality and production cost of concrete in concrete mixing stations. It is mainly composed of sand, water, cement, coal ash, mineral powder and admixture metering. At present, three-point metering is commonly used in China. The sensors sense the content and then the signal line is transmitted to the control computer to control the weight of the raw materials.

3. Storage System

The storage systems are mainly used to store the raw materials required to produce concrete. Generally, the storage system comprises four sand aggregate bins, cement bins, fly ash bins, mineral powder bins, water tanks, admixture barrels, and other parts. The volume of each part should not be different according to the size of the equipment model.

4. Conveying system

The conveying system is required to convey the various raw materials to the main mixer. Once the materials are metered in the storage bin, the conveyor belt conveys the sand and stone materials to the mixer. The cement, coal, fly ash, and mineral powder is transferred to the metering hopper by the screw conveyor and then unloaded to the mixer. The water is then pumped using a water pump to the metering hopper through the pipeline and then pumped to the mixer by the water pump. An anticorrosive admixture pump is used to deliver the admixture to the metering hopper through the pipeline and then unloaded to the mixer.

5. Control system

The control system of the concrete mixer batching plant is the central nervous system of the whole set of equipment. The control system has different functions and comes in different configurations according to user requirements and the size of the mixing station. It adopts an industrial computer and according to the production process and mixing ratio of the required concrete, the data is realized through software and transmission signals.

Also Read: Compact Concrete Batching Plant

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Advantages of Concrete Mixer Batching Plant

Advantages of mixing system: The mixing system adopts a high wear-resistant lining plate with chromium content > 26%. Dust and shaft holding is reduced by the spraying device designed above the stirring shaft.

Advantages of the dosing system: The well-designed high wear-resistant thickened panel and large storage bin design help reduce the number of loader feeding in the future. The patent machine tool of double tile frame has the advantages of the convenient installation of the equipment, high precision, long service life, and noise reduction. The optimized blanking angle of the bin door and design intelligent blanking of the double-leaf door ensures smooth blanking and enables more accurate measurement.

Advantages of the conveying system: The conveying system has a smooth operation, quick and convenient installation, and easy maintenance. To minimize the belt loss, the conveyor undergoes five passes of cleaning and water cleaning. The frame adopts combined structure, standardized design, environmental protection, and is energy saving.

Metering system: The metering system has a large metering capacity and easy installation. The additive leak-proof device ensures the quality and safety of concrete. The metering is accurate, and only the functions of point compensation and intelligent weighing are carried out according to the flow. This ensures the accuracy of ingredient measured.

Environmental protection: The plant is equipped with a professional dust collector and the secondary dedusting collection design, making the dedusting more thorough and clean.

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Mixing Time of Concrete In Concrete Mixer Batching Plant

Concrete mixing time refers to the time taken by the mixer in a concrete mixer batching plant to mix all of the concrete mixture together. The based on the actual production requirement, the mixing time in the automatic control system can be modified. In general, the mixing time of a concrete batching plant is about 60 seconds.

The total time of the concrete mixer batching plant is the total time taken by the mixer to mix concrete per batch, which includes loading time, mixing time, and the discharge.

1. According to different concrete strength requirements

The table determines the mixing time according to the strength requirements of the concrete.

Strength grades/MPa	≤C30	C35	C40	C45	C50	C55	C60
Mixing time/s	30	35	40	45	50	55	60

2. According to particularity of the concrete

For strength ≤C30 – The mixing time of concrete with impermeability and various additives is increased by 10-15 seconds on the basis of 30 seconds.

For strength C30-C60 – The mixing time of concrete with impermeability and various additives is increased by 20-30 seconds on the basis of 60 seconds.

3. According to different slump of the concrete

If the slump is within the specified range (150mm-220mm), the mixing time is set according to the first article above.

For dry hard concrete the mixing time is increased by 20 seconds on the basis of the time specified in the first article above. 

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Concrete Mixer Batching Plant Process Flow Chart

An RMC concrete mixer batching plant has several parts and accessories that combine and work together to yield the right quality concrete as required.

The main components required for a fully functional concrete mixing station are:

1. Aggregate feeders

The feeder unit is one of the most important components of the concrete mixing station. These are feeder hoppers built side-by-side for storing and feeding coarse aggregates and sand.

The different hoppers bins are made to hold aggregates of different sizes or sand into each individual compartment. The purpose of storing each material (size-wise) into separate bins is so that each material can be weighed separately as per desired mix ratio.

2. Aggregate weighing conveyor

The weigh conveyor is generally located below the aggregate feeder. The purpose of the weighing conveyor is to weigh the aggregates one by one and then transfer them into the mixing unit.

This is suspended and hung on load cells. Weighing systems are crucial and an essential part of the mixer design. They are periodically calibrated to ensure the quality and grade of the concrete produced.

3. Charging conveyor / Skip

The function of the charging conveyor or skip is to carry the weighed aggregates to the mixing unit.

4. Cement weigh scale

The cement weigh scale weighs cement from the cement silo in the required quantity which is then transferred to the mixing unit via a screw conveyor. This is to weigh the cement before dispatching it into the mixing unit.

5. Water and additive weigh scale

The water weigh scale gets water from the water pump, which holds and weighs the water according to the recipe preset in the control panel. The weighed water is then transferred into the mixing unit.

Additive weigh scales are suspended on load cells. They are meant to weigh the additive material and dispatch it into the mixer.

6. Cement silo/hopper with screw conveyor

A cement silo is to store large volumes of cement brought by the bulk trucks. The silo is usually provided with safety accessories. A screw conveyor placed at the bottom of the cement silo, of suitable diameter and length, is provided to enable the transfer of cement into the cement weigh hopper.

Some small capacity plants are installed with a cement hopper, whose opening is big for enabling adding cement from bags. Screw conveyors are provided to transfer cement from the cement hoppers into the weigh hopper.

7. Main mixer

The main mixer is the most crucial central part and heart of an RMC batch plant. This is where all the weighed ingredients are batched/mixed thoroughly for a fixed time. The concrete produced is then discharged into the transit mixer or a concrete pump.

8. Air compressor

Another important component of the mixing station is a compressor. All the pneumatic operations of the RMC plant are controlled using a compressor. Some of the operations are –

• Opening and closing of cylinders – control the feeder gates
• Opening and closing of the mixer gate
• Opening and closing of butterfly valves fitted with weigh hoppers

9. Control system

The control panel helps control the working of the machine. Modern machines are equipped with a PLY panel for ease of use. The print mix material recipes can be saved in the PLY control panel.

Fast and accurate measurements of the ingredients required for batching can be achieved by the control system. The growing demand for high-quality and accurate concrete makes it important to produce the right quality concrete efficiently without wastage. The control systems process and devices are designed to achieve more accurate measurements continually.

Also Read: Ready Mix Concrete Plant Setup Cost

Four Main Points to Consider Before Buying a Concrete Plant

1. Study and evaluate the estimated total demand of the local concrete market.
2. Understand the total number of local concrete stations already existing and define the proportion and scale of commercial concrete stations.
3. Understand the local policies and regulations on the concrete industry.
4. Evaluate the capital investment required for the project and calculate the return on investment.

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How can I choose the right concrete mixer station?

Three basic points to consider when you are planning to invest in a HZS concrete mixing station. They are –

1. Scale of production: The equipment of large and small HZS series concrete mixing plants is the same with the only difference being the size of the model. When choosing the station, it is important to note that it does not mean the bigger the better or the smaller the better.  Customers should decide the size of the equipment considering the estimated production scale.
2. Auxiliary equipment: Selection of the working size and specification of the concrete mixer should be according to the conditions of the auxiliary equipment. For example, you should match the loading capacity of the mixer truck with the discharge capacity of the mixer. If the matching is not suitable, it will impact the work efficiency. Similarly, the loading height of the loader shall match the loading height of the batching station of the HZS concrete mixing plant.
3. Technical performance of the equipment: It is important to consider the reliability of the equipment, advanced features, and universality of the equipment. The equipment should have the characteristics of advanced working principle, high degree of automation, powerful management function, and good environmental protection performance.

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Find right Concrete Mixer Plant Manufacturer, Luton Group？

Luton Group is a leading concrete mixer batching plant supplier in China. It is a professional concrete plant manufacturer; integrating research and development, production, and sales.

Our company has outstanding performance in equipment quality, production technology, industry experience, and market reputation and has been unanimously recognized and praised both inside and outside the industry.

Luton Group machinery has performed extremely well in mixing high-quality concrete with the production exceeding our expectations. Thanks to our design and manufacturing department, we are able to produce high-quality concrete mixing equipment to serve our customer requirements better.

If you are looking to purchase a concrete mixer batching plant, all you need to do is tell us your requirements, and we will provide the best model, equipment, and configuration to choose from. Our professional engineers and the after-sales team are always available to provide all-round support.

Interested in knowing more about our company and our products? Do not hesitate to contact us. We are here at your service and would love to hear from you.