Stationary concrete batching plants
Production from 0.5 m³ to 2.5 m³
We build stationary concrete batching plants equipped with mixers with an output capacity ranging from 0.5 m³ to 2.5 m³. These are high-performance production units designed for intensive, continuous operation in demanding industrial and construction environments. The emphasis on dosing precision, component reliability, and operational cost optimization makes our batching plants the ideal solution for both precast concrete producers and companies executing large infrastructure projects.
Reliability and robust construction
Maximum efficiency and smoothness of the technological process are achieved thanks to the use of modern mixing systems, full automation, and proven industrial components. The entire structure is based on reinforced steel profiles, which, combined with a multi-layer anti-corrosion coating, guarantee long-term durability – even during intensive use in harsh weather conditions.
Intelligent control and automation
Operation of the entire production cycle is carried out by a single operator from an air-conditioned control cabin. The workstation is equipped with an industrial computer, an intuitive touchscreen panel, and an advanced SCADA system.
Aggregate loading and batching system (Skip Hoist System)
The modern aggregate loading and batching system in our stationary concrete batching plants has been designed for maximum reliability, precision, and optimal space utilization. In our structures, we focus on a proven and highly efficient skip hoist transport system (a skip bucket moving along a stable track), which guarantees trouble-free operation and allows for a compact design of the entire batching plant.
Key features and parameters of the system:
- Modular aggregate bins: We offer flexible 3- or 4-compartment configurations, where the capacity of a single bin ranges from 10 to 30 m³. This allows for an ideal alignment of raw material storage size with the actual production needs of your plant.
- Smooth and reliable batching: The operation of the bins is supported by precise electropneumatic valves and industrial vibratory systems (e.g., OLI vibrators). This ensures smooth material flow and eliminates the problem of aggregate bridging, even under high humidity conditions.
- High weighing precision: The raw material goes directly into a dedicated weigh hopper supported by advanced load cells. This guarantees pinpoint dosing accuracy for each component of the mix.
- Efficient skip transport: The weighed aggregate is transported to the mixer using a heavy-duty skip hoist. The skip, moving along a specially profiled track, ensures a fast charging cycle, minimizes the risk of downtime, and reduces dust and noise emissions.
Reliable twin-shaft mixers
For our stationary batching plants, we offer powerful twin-shaft mixers with a batch capacity of 0.5 m³ to 2.5 m³ of compacted concrete. This is a proven industrial solution that guarantees extremely fast and perfectly homogeneous mixing of even the most difficult concrete mixes within a short cycle time.
Highest execution standard and trouble-free operation:
- Output capacity: From 0.5 m³ to 2.5 m³ of ready-mix concrete per cycle.
- Extreme resistance: The interior is protected by replaceable 15 mm thick HARDOX 450 steel plate liners and blades made of NI-HARD cast iron with a hardness up to 600 HBW.
- Reliable drive and discharge: The system is equipped with powerful industrial motors and gearboxes. Discharge is hydraulically controlled with a built-in emergency manual opening system.
- Automatic lubrication: All key moving components and seals are automatically lubricated by a renowned LINCOLN (Germany) system.
High-precision planetary mixers
For plants requiring the highest accuracy and producers of precast elements, we offer advanced planetary mixers with a capacity from 0.33 m³ to 2.2 m³. Thanks to the unique, complex movement of the mixing blades, these devices eliminate so-called "dead zones" and perfectly handle special and colored concretes.
Advantages of planetary technology:
- Output capacity: A wide range from 0.33 m³ to 2.2 m³, ideal for precast production.
- Perfect homogeneity: The planetary movement trajectory of the arms guarantees full distribution of plasticizers, colorants, and cement throughout the entire batch volume.
- Armored protection: Just like in the twin-shaft versions, we use wear-resistant bottom and side liners, along with high-durability mixing arms.
- Full automation: Equipped with advanced LINCOLN pressure lubrication systems and hydraulic discharge gates ensuring clean and fast emptying.
Cement and fly ash silos
For the production of our silos, we use exclusively the highest quality steel, which guarantees full safety and long-term structural durability. The silo consists of three optimally designed parts: a cylindrical shell, a roof, and a conical hopper. Depending on logistical requirements and site conditions, we offer silos in fully welded versions or modularly assembled from components. The capacity of each silo is selected individually according to the technological needs of the plant.
Advanced protection and aeration systems:
- Eco-friendly dust extraction system (2300 m³/h): We use advanced mechanical filters with a 200 W electric vibrator. Polyester pocket filter inserts effectively clean the airflow, meeting strict emission standards. The robust design allows stable filter operation at high temperatures and high pressure, and the mechanically shaken dust falls freely back into the silo.
- Active cone aeration: Silos are equipped with a mechanized system of aeration nozzles (distributed on the hopper and the silo shell). This system effectively prevents cement bridging and guarantees a smooth, uninterrupted flow of material.
- Point level measurement (Rotary sensors): For electrical signaling of the minimum and maximum material levels in the silo, we use reliable, rotary paddle level indicators. The system works automatically: the presence of cement blocks the rotation of the paddle, sending a signal to the controller, while the drop of raw material below the sensor line restarts the rotation.
Complete equipment of the set includes:
- Supporting structure: A solid steel frame with a standard clearance height of 4 meters.
- Loading system: A silo filling pipe, ending with a Cam-lock coupling for quick connection to a cement truck.
- Pressure protection: A pressure relief safety valve that protects the silo structure during dynamic filling.
- Shut-off system: A heavy-duty butterfly valve with a manual lever, mounted at the hopper outlet.
- HSE Infrastructure: A safe maintenance ladder with a safety cage and service railings on the silo roof, allowing comfortable filter maintenance.
Intelligent automation and Command Center
The heart of our concrete batching plants' control system is an advanced industrial automation cabinet cooperating with an ergonomic, three-monitor operator workstation. The entire technological process has been reduced to a single, clear interface, giving full control over production in automatic, semi-automatic, or manual modes. Two monitors handle the digital process management and synoptic visualization of the plant, while the third – divided into four independent zones – provides a continuous live feed from cameras positioned at key sections of the concrete plant.
Key capabilities of the automation system:
- Full cycle automation: The processes of raw material weighing, chemical admixture dosing, discharge of ready-mix concrete, and the opening and closing of all technological gates are 100% automated. The system eliminates the risk of human error, guaranteeing perfect repeatability for each batch.
- Intelligent recipe management: Mix production is based on precise recipes entered and modified by the user. All recipes are securely collected and archived in an integrated database.
- Active moisture control (Optional): The option to equip the plant with advanced moisture sensors (e.g., in the mixer and under the bins). This allows the system to automatically adjust the amount of added water on the fly to achieve the perfect, targeted final concrete moisture.
- Comprehensive reporting: The automation continuously monitors the consumption of raw materials (cement, aggregates, water, additives) and enables instant generation and printing of detailed reports from each batch, facilitating plant cost and logistics management.
Barbatus – Comprehensive turnkey execution from design to completion
As a direct manufacturer of stationary batching plants, we take full responsibility for every stage of the investment. We do not use half-measures or unverified subcontractors. By choosing our company, you gain the certainty that the entire production line is built based on strict engineering standards, a modern machine park, and years of experience of the Barbatus team in the industrial market.
Why trust us? Our key advantages:
- In-house engineering and design office: Our engineers will develop full documentation, and the designer will individually draw and adapt foundation plans to the specific terrain layout and geotechnical conditions of your site.
- Formal support and advisory: We will comprehensively assist you in the permitting process. We will precisely indicate what documents you must hold and what requirements need to be met to smoothly obtain official building approval for the batching plant.
- Certified materials and components: For structural fabrication, we use only the highest quality steel with full mill certificates. All key components – from precise weighing systems (load cells) and electric vibrators to actuators – hold strict industrial certifications.
- In-house factory and CNC technology: The entire manufacturing process takes place in our modern production facility. The use of advanced CNC machinery guarantees perfect repeatability, ideal fitting of elements, and the highest quality execution of details.
- In-house installation, service, and spare parts base: We provide professional installation and commissioning of the batching plant by our technical teams. We maintain a richly stocked, in-house spare parts warehouse, which, combined with the experience of the Barbatus company, guarantees lightning-fast service and exceptionally short turnaround times.