D-Beton focuses on larger projects and greater dimensions
Partnership with Progress Group
De Doncker chose Ebawe Anlagentechnik, Progress Software Development and Progress Maschinen & Automation, all subsidiaries of the Progress Group, as its suppliers. Indeed, the Belgian company uses a whole range of Progress Group machines and software in its production. Once all the technical and commercial details had been clarified, assembly began in Aalst in summer 2020.
Automation and innovative technology by the new carousel system
The scope of delivery includes a Form Master shuttering robot in combination with a fully automated pallet cleaning device. With the new pallet carousel system, D-Beton is taking another important step towards full automation of precast element production. The workflow has been optimized through a thorough planning of all product flows in the plant.
In addition, the new production line includes a concrete spreader in a bridge design complete with compaction equipment and interface to a fully automated mixing plant as well as a turning device with appropriate compaction equipment. The plant is also equipped with an automated pallet stacker, which, in combination with a demolding crane with demolding traverse, ensures the safe removal of the finished precast elements. An interesting feature of the demolding crane is that not only the usual lattice girder floors can be lifted but also double walls both in the horizontal and vertical position. Although D-Beton is also highly committed to manual quality control, the automation of the plant saves a lot of time and, thanks to the perfectly planned use of the space, can handle possible production issues swiftly by switching to alternative routes. The new production system guarantees an automated precast production of double walls, insulated double walls and floor slabs. The precast elements manufactured there are primarily used in housing and industrial construction. The plant also includes a master office with an optimized visual axis, which makes it possible to watch and monitor the entire production process.
Optimizing reinforcement preparation
Reinforcement processing was optimized by integrating the Wire Center. It comprises the multi-strand MSR 16/6 multi-rotor wire straightening and cutting machine, which permits fully automated wire diameter changes in just a few seconds, thus enabling all wire diameters to be provided just in time. Together with this, a wire laying robot with semi-automatic feed with (for the time being) externally sourced lattice girders ensures a wider range. Further features of the Wire Center include an automatic sorting and feeding system for plastic spacers, a bending machine for crimping the ends of the bars on one or both sides, as well as a magazine serving as a deposit and buffer storage for the bars which can be retrieved from the system and lifted onto the pallet automatically as needed.
Complete software solution with Ebos and Stabos
D-Beton chose ebos as its MES system, developed by Progress Software Development, also a Progress Group company. With ebos, all manufacturing processes are carried out in a single complete, user-friendly system. An innovative 3D visualization of the carousel plant makes it even easier to keep an eye on production. Machine and production data can be easily collected and evaluated with the integrated stabos software. Thanks to the unique web interface, analyzing and reporting for the whole carousel plant can be done from anywhere.
Dominique Zyde is very satisfied with the new production plant: “We cooperated very closely with our supplier. Progress has demonstrated a high level of efficiency. They developed an innovative production process to respond to all our needs. The quickness of their reaction was definitely a decisive factor.”
Thanks to the new production plant from the Progress Group, the Belgian company is able to make its product range more flexible. They are now producing a larger number of finished products to a high quality standard and with less manpower.