Hollow-core slabs are the core products Milbank Concrete Products Ltd, operating in Colchester Essex from 3 large factories over an 8 acres site. It is a family run business that prides itself on a strong reputation for reliability. The company currently employs 164 full time personnel 44 of which make up 11 teams of directly employed highly skilled fixing teams that have a wealth of experience and training, this along with it’s engineering and contracting departments make sure that all of its projects are carried out by in house personnel.
MCT Italy preferred supplier of choice
Milbank spoke to several potential suppliers of batching plants and MCT Italy were the only company able to offer a complete solution to meet all the demands and requests given by Milbank. It was this flexibility of approach and solution offered that allowed Milbank to select MCT Italy as their preferred supplier of choice.
Minimum factory closure for the retrofit
The challenge on the project development was even harder since the production demand at Milbank couldn’t allow the smallest amount of downtime to the factory for the comprehensive retrofit. Here MCT came up with a very flexible solution which involved the supply of MCT’s very own smart mobile plant type MCR ‘on the road’ to ensure the concrete production manufactured/batched alongside their existing factory and then moved by conveyor belt into the existing flying bucket over the 8 week period allocated for the removal and retrofit of the plant and distribution system.
After the quick installation of the MCR plant and integration into the ‘old’ distribution system, Milbank within days switched off the main batching plant, commenced the dismantling and safe removal of the ‘old’ plant and associated equipment.
A massive advantage of the MCR was that the mixer operators were initially trained on the operation of the MCT ‘Compumat’ automation software and this was a great advantage as ALL MCT plants operate on the same structure and this saved an enormous amount of time, once the commissioning of the main plant got underway.
True partnership with the customer
In this provisional layout, the MCR mobile plant was engineered to feed the existing flying bucket in phase 1, while MCT crews were installing the first of the 2 new ‘lines’ feeding the production hall whilst the main plant was also being erected. Then, in phase 2 the MCR mobile plant and feeding system was switched to the new flying bucket line, while dismantling the old one and re-install the second new line, before finally switching to the new plant. Once the commissioning of the new fixed batching plant was completed and all its parts operating, the ensured a great level of confidence on the processes and without any possible blackout.
Opportunity to upgrade
The plant not only had the mixing group and concrete distribution system replaced, Milbank also took the opportunity to comprehensively upgrade the entire plant: new aggregate extractions, dosing systems for aggregates, cement, admixtures and water along with a complete automatic washout system for mixer and flying buckets. They also had a customized control room, and the integration of Milbank’s existing water recycling plant into the new software. The final upgrade was the cement silos layout, this has been redesigned to meet with the new demands and regulations, this included the replacement of 2 silos and the refurbishment of 3rd existing one with new accessories.
Optimum utilization of production sheds
“Concrete consistency and quality exceeded all our expectations, and this was apparent within a couple of days of the mobile plant starting and has continued with the completion of the main plant,” says Andy Mayne, Milbank’s Managing Director. “The flexibility of the MCT system ensures optimum utilization of our production sheds. Automation and plasticity control have enabled us to significantly reduce cycle times and increase finished concrete strength with no additional cement or admixtures.”
MCT Italy are represented in the UK & Ireland by PUK Services who also worked closely with Milbank and assisted with project management during the design and installation phases of this complex project and continue to support with aftersales and parts from their offices and warehouse in the UK.
MCT Italy S.R.L.
Via Perugia, 105
06084 Bettona (PG)/Italy
Milbank Concrete Products Ltd
Earls Colne Business Park
CO6 2NS/United Kingdom
Unit 1, Stratford Agri-Park
Stratford upon Avon, Warwickshire
CV37 8LP/United Kingdom
+44 (0) 1789 721 655