A concrete batching plant is crucial in construction to produce concrete for building projects. However, people often grasp concrete production superficially, lacking a profound comprehension of its complexities. How does the concrete batching plant work? The working principle coordinates various parts to guarantee the concrete output meets quality standards. This article will show how a concrete mixing plant works, so let’s learn together!
What Are The Key Components and Their Functions in a Concrete Batching Plant?
Aggregate Batching System
The system includes aggregate storage hopper, metering hopper, and belt conveyor for accurate proportioning.
Inclined Belt
It transfers aggregate from flat belt to storage hopper; a steep belt conveyor can save space.
Control Room
It has a precise manipulator and microcomputer system for monitoring and controlling the mixing process.
Measuring System
Including measuring equipment for aggregate, cement, fly ash and water, etc. to ensure the accuracy of concrete batching.
Mixing System
Adopts forced mixer to ensure uniform concrete mixing.
Gas Circuit System
Provide gas control for each branch circuit to ensure the normal operation of each part.
Supporting Powder Storage And Supply System
Including cement silo, fly ash silo and screw conveyor to ensure the storage and supply of powder.
Therefore, all the components play an important part in the inner works of a beton batching plant. Now that we know the function and komponen batching plant, let’s learn more about how a batching plant works next!
What Is The Working Principles Of Concrete Batching Plant?
Concrete plant is the equipment used to produce concrete, and the working principles in the concrete batching plant involves a number of links, including aggregate batching, powder metering, mixing, conveying and so on. There is the batch plant working principle of a mixer batching plant in detail below.
Aggregate Metering and Conveying
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Aggregate metering and conveying is the first step in a concrete mixing plant, which ensures the accuracy and stability of concrete batching. This step usually includes the following stages.
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Aggregate Storage and Metering Hopper
Aggregate storage hoppers are usually provided in concrete batching plants for storing aggregates. Each hopper contains a metering hopper to measure aggregate weight precisely. Sensors and devices monitor the hopper to maintain measurement accuracy.
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Flat Belt Conveying
The measured aggregate is discharged from the metering hopper onto a flat belt. The flat belt is a common conveying equipment, which conveys the aggregate from the metering hopper to the inclined belt conveyor by driving the belt to run.
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Inclined Belt Conveyor
Aggregate is conveyed to the inclined belt conveyor through the flat belt. The inclined belt conveyor is an inclined conveyor that transports the aggregate from below to the aggregate storage hopper above. The operation of the inclined belt conveyor ensures smooth transportation of the aggregate between different heights.
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Aggregate Hopper
The aggregate hopper on the concrete plants’ roof stores measured aggregate. Once the aggregates are in the hopper, they are ready for further processing, such as being fed into the mixer for mixing.
Through the above steps, the batching plant indonesia can realize the accurate measurement and smooth delivery of aggregates, which lays a reliable foundation for the subsequent mixing work.
Powder Metering and Conveying
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Powder metering and conveying is an important part of a concrete batching plant indonesia to ensure the accuracy and stability of concrete batching. The following are the main steps of this process.
- Powder storage and metering hopper: Pabrik batching plant typically has silos for cement, fly ash, and other powders to provide sufficient storage. Each powder storage bin has a metering hopper to measure powder weight accurately. Sensors and devices monitor and control the hopper for accurate measurement.
- Screw Conveyor Conveying: Powder (e.g. cement, fly ash, etc.) is conveyed through a screw conveyor. Screw conveyor is a common conveying device that transports the powder from the storage bin to the respective metering hopper through rotating screw blades.
- Powder metering: Powder is accurately metered once it enters the respective metering hopper. Hoppers have sensors and devices to monitor powder flow for accurate metering.
- Water and Admixture Metering: In addition to powder, water and admixtures also need to be metered. Water and admixtures are fed by pumps into their respective metering hoppers for metering to ensure the accuracy of the batching.
- Conveyance to the mixer: After metering the powders, water, and admixtures, feed them into the mixer in a set order for mixing. Usually, materials will mix uniformly into concrete paste in the mixer.
Through the above steps, the batching plant di indonesia is able to realize the accurate measurement and smooth delivery of raw materials such as powder, water and admixture, which provides a reliable guarantee of raw materials for the subsequent mixing and stirring work.
Batching Process
Readiness
Before starting the batching process, it is necessary to make sure that the mixer is in proper working condition and that the hoppers for the various raw materials are ready and accurately measured according to the pre-set ratios.
Sequential Feeding
according to the pre-set proportion and feeding order, put the raw materials such as aggregate, cement, fly ash, water and additives into the mixer in sequence. Usually, the feeding order is according to the sequence of aggregate, cement, fly ash, water and additives to ensure the homogeneity and stability of mixing.
Control the Feeding Speed
Control the raw material feeding speed based on mixer condition and production needs during feeding. Variations in feeding speed impact mixing and production; thus, adjust and control it appropriately.
Monitoring the Feeding Process
Constantly monitor multiple raw material feedings for accuracy and stability during the feeding process. Monitoring equipment and control system quickly address feeding issues to maintain production.
End of Feeding
When all the raw materials are finished feeding, the feeding process can be ended. At this time, the concrete mixer mixes raw materials into concrete paste for the next work cycle.
Through the above steps, the feeding process can ensure that all kinds of raw materials are put into the mixer according to the precise proportion. Besides, it supplies quality raw materials for mixing, ensuring smooth production and stable concrete quality.
Mixing Process
Starting the Mixer
Prior to mixing, the operator verifies mixer functionality by starting it. A mixer is a machine with agitators or mixing blades for blending raw materials.
Inputting Raw Materials
Different raw materials are measured, conveyed, and placed in the mixer as per prescribed ratios. The feeding process needs precise control of sequence and speed to maintain mixing uniformity and stability.
Mixing Process
Once all the raw materials are put into the mixer, the mixer starts to mix. The agitator or mixing blades spin, blending raw materials to create a uniform concrete paste. The mixing process usually takes a certain amount of time to ensure that the mix is adequate and homogeneous.
Monitoring the Quality of Mixing
During mixing, operators monitor quality in real time using monitoring equipment and control systems. They monitor concrete indicators and adjust mixer settings promptly for stable mixing quality.
End Mixing
When mixing meets time or uniformity targets, the operator stops the mixer to end the process. At this time, the formed concrete slurry can be unloaded for subsequent construction or other uses.
By mixing raw materials thoroughly, the process creates a stable concrete paste, forming a reliable foundation for concrete product production.
Unloading Process
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Unloading is the last key step in concrete batching plants for sale. Besides, it refers to the unloading of the mixed concrete from the mixer, ready for transportation or use. The following are the main steps in the unloading process.
- Stopping the mixing: Before unloading can take place, the mixer must stop. Usually, the mixer will have a control system to stop rotation for safe unloading.
- Open the discharge opening: After the mixer stops, operators typically open the discharge outlet, located at the bottom or side. By opening the discharge opening, the mixed concrete can flow smoothly out of the mixer.
- Controlling the discharge rate: During the discharge process, control the concrete discharge rate promptly. Excessive discharge speed can lead to spills or equipment damage, while slow speed may hamper productivity.
- Monitoring the unloading process: Constant monitoring is essential during concrete unloading to ensure smooth operations. The operator watches near the discharge opening and monitors concrete flow to address any issues.
- Collecting Concrete: During the unloading process, the concrete will flow into a pre-prepared container or concrete mixer truck. The operator must efficiently collect and store concrete for later transport or use.
- Cleaning the discharge opening: Clean the discharge opening and surrounding area promptly after concrete discharge for smooth subsequent discharges. It also helps to keep the equipment clean and functioning.
Following these steps ensures smooth discharge of mixed concrete from the mixer. Therefore, it provides a reliable raw material base for subsequent transportation or use.
Different Types of Concrete Batching Plant
AIMIX, a professional manufacturer, provides both stationary and mobile concrete batching plants. Below are the main product and service features offered by AIMIX.
- Multiple models available: We offer a variety of concrete batching plants with different capacities, configurations, and options. Customers can select concrete batch plants that fit their needs and project requirements for optimal productivity and quality.
- High-quality manufacturing process: Our batching plants use high-quality materials and advanced manufacturing, ensuring stable performance and lasting durability. Each concrete batching plant machine undergoes strict quality control and inspection to ensure that the product quality meets international standards.
- Stationary Concrete Batching Plants: AIMIX provides various sizes and models of stationary batching plants for projects needing stable long-term production. These plants usually have large production capacity and high concrete production efficiency to meet the needs of large-scale projects.
- Mobile Concrete Batching Plants: We provide mobile batching plants for projects needing frequent changeovers or temporary construction, alongside stationary plants. The batching plant mobile is convenient and flexible, easily set up and removed for various sites and construction environments.
Concrete Batching Plant Specifications
In the following, there are these concrete batching plant specifications. Then you can learn more about them and choose your suitable products here.
| Model | Belt type | |||
|---|---|---|---|---|
| AJ-60 | AJ-90 | AJ-120 | AJ-180 | |
| Theoretical Productivity (m³/h) | 60 | 90 | 120 | 180 |
| Mixer Model (Mixer Output L) | JS1000 | JS1500 | MAO3000/2000(SICOMA) | MAO4500/3000(SICOMA) |
| Mixer Power (kW) | 2×18.5 | 2×30 | 2×37 | 2×55 |
| Mixing Cycle Period (s) | 60 | 60 | 65 | 65 |
| Max.Aggregate Size (mm) | Φ60 | Φ80 | Φ80 | Φ80 |
| Standard Aggregate Bin Capacity (m³) | 4×7 | 4×15 | 4×15 | 4×20 |
| Kind of Aggregate | 3/4/2002 | 3/4/2002 | 3/4/2002 | 3/4/2002 |
| Max. Discharging Height (m) | 4.1 | 4.1 | 4.3 | 4.3 |
| Overall Weight (ton) | ≈40 | ≈68 | ≈93 | ≈101 |
| Installation Power (kW) | ≈110 | ≈160 | ≈220 | ≈290 |
| Model | Belt Type | ||
|---|---|---|---|
| AJY-25 | AJY-35 | AJY-50 | |
| Theoretical Productivity (m³/h) | 25 | 35 | 50 |
| Mixer Model (Mixer Output L) | JS500 | JS750 | JS1000 |
| Mixer Power (kW) | 18.5 | 30 | 2×18.5 |
| Mixing Cycle Period (s) | 72 | 72 | 72 |
| Rated Input Volume (Model of Batching Machine L) | 800 | 1200 | 1600 |
| Max.Aggregate Size (mm) | Φ60 | Φ60 | Φ60 |
| Standard Aggregate Bin Capacity (m³) | 2×3 | 2×5 | 2×5 |
| Kind of Aggregate | 3/4/2002 | ||
| Powder Storage Silo (ton) (Optional) | 1×50 | 2×50 | 1×100 |
| Max. Discharging Height (m) | 3.8 | 3.8 | 4.1 |
| Weighing Range & Accuracy of Aggregate (kg) | （300~1500）±2% | （300~1500）±2% | （300~3000）±2% |
| Weighing Range & Accuracy of Cement (kg) | （100~300）±1% | （100~300）±1% | （250~900）±1% |
| Weighing Range & Accuracy of Water (kg) | （60~150）±1% | （60~150）±1% | （80~300）±1% |
| Weighing Range & Accuracy of Additive (kg) | / | （8~20）±1% | （8~20）±1% |
| Overall Weight (ton) | ≈15 | ≈22 | ≈26 |
| Installation Power (kW) | ≈61 | ≈73 | ≈92 |
| Power Supply | 380V/220V/415/440V, 50/60HZ, 3Phase | ||
| Model | Bucket type | |||
|---|---|---|---|---|
| AJ-25 | AJ-35 | AJ-50 | AJ-75 | |
| Theoretical Productivity (m³/h) | 25 | 35 | 50 | 75 |
| Mixer Model (Mixer Output L) | JS500 | JS750 | JS1000 | JS1500 |
| Mixer Power (kW) | 18.5 | 30 | 2×18.5 | 2×30 |
| Mixing Cycle Period (s) | 72 | 72 | 72 | 72 |
| Max.Aggregate Size (mm) | Φ60 | Φ60 | Φ60 | Φ80 |
| Standard Aggregate Bin Capacity (m³) | 3×3 | 3×5 | 3×8 | 3×12 |
| Kind of Aggregate | 3/4/2002 | 3/4/2002 | 3/4/2002 | 3/4/2002 |
| Max. Discharging Height (m) | 3.8 | 4.1 | 4.1 | 4.1 |
| Overall Weight (ton) | ≈15 | ≈18 | ≈23 | ≈30 |
| Installation Power (kW) | ≈65 | ≈75 | ≈100 | ≈140 |
| Power Supply | 380V/220V/415/440V, 50/60HZ, 3Phase | |||
All in all, we, as a professional batching plant manufacturer, offers high-quality products and services for diverse engineering projects. Contact us today to make your concrete production more efficient and reliable! Whether you need a stationary concrete mix plant or a mobile concrete mixing plant, AIMIX has you covered. Various models are available to suit projects of any size, ensuring a solution for everyone.
Choose AIMIX, Choose Concrete Mixing Plant
AIMIX concrete mixing plants deliver exceptional quality through advanced manufacturing and premium materials, ensuring lasting performance and durability. What’s more, we provide comprehensive after-sales services for your production, including installation, training, technical support, and spare parts supply.
Contact us today and let our professional team customize the optimal solution for you! No matter where you are, we can provide you with timely and efficient service. Act now to get concrete batching plant prices, let us work together to create a better future!
