Beton-Betz GmbH in Kirchardt near Heilbronn in Germany, a medium-sized company with a workforce of around 80 employees, has manufactured concrete products for building construction and agriculture for more than 85 years. The company delivers precast products for building construction and to construction sites within a radius of 150 km. Precast parts for the agricultural sectors are delivered to as far away as neighboring countries such as Austria, Switzerland, and France.
For many years,the company has invested in state-of-the-art production engineering to keep in step with the increasingly demanding requirements of customers. For this reason and others, the firm developed a concept for a new mixing plant in 2015. Following intensive negotiations with various manufacturers of mixing plants, Pemat subsequently won the contract for development, construction, and erection of the new mixing plant.
In-line silo plant with four compartments
Pemat can now look back on 40 years as manufacturer of high-quality mixing technology and individually designed mixing plants. The company was founded by Walter Stahl in 1977 and has remained to this day a medium-sized family business, now managed by the second family generation. Mixing technology and mixing plants from Pemat are sold worldwide. For development and production of the mixers and accessory equipment, however, the company has stayed loyal to its location in Germany.
The managing directors of the company Betz, Sascha Meiser and Bernd Betz, systematically cooperated with the Pemat Project Department, with the result that development of a final layout for the new mixing plant took place very quickly. The approval procedure, however, needed considerably more time than planned, with beginning of erection of the mixing plant only in 2017.
To afford the necessary flexibility, it was decided to build an in-line silo facility with four compartments. The in-line silo, including mixer platform, was erected from precast parts. To make good use of the generous space availalble it was decided to feed the in-line silo plant by two conveyor belts with a total length of 120 m – which, in turn, are fed by a truck-mounted hopper.
Mixer with moisture sensor and water batching
The individual compartments of the in-line silo are fitted with filling-level sensors, which enable data on further processing of the silo filling levels by the Bikotronic Plant Control System. The silos are discharged with continuous weighing via batching valves onto a weighing belt. A Pemat inclined hoist passes the aggregates to a PMPR 2250 Pemat planetary mixer with whirlers. The patented whirler technology results in fast and flawless homogenization of the material mix. The mixer is in addition fitted with a moisture sensor and water batching to ensure – in interaction with innovative control engineering from Bikotronic – very high repeatability exactness of every individual mix. The mixer has two discharge openings: through one, the material is discharged down a specially designed chute into a concrete distributor spreader – and through the other, into a skip conveyor system that supplies another building with concrete. The mixer, the concrete distributor, and the skip conveyor system are cleaned with a Pemat high-pressure system that is integrated into the Bikotronic plant control, as are all other components.
Plant operation was launched as scheduled in April of 2017, despite adverse weather conditions during installation. All participants constructively and highly effectively collaborated as partners, which allowed commissioning of a fault-free innovative and high-performance mixer plant.