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2.1 MAIN FRAME WITH AGGREGATES STORAGE AND DOSING BINS

• *Steel frame designed to carry the load of 30 m3 aggregate storage bins and contain the aggregate dosing devices, equipped with lower skid for installation on precast sleeper foundations.
• *Aggregates storage hoppers total storage capacity 30 m3 divided in 4 equal compartments (compartment bins), with hopper walls made of corrugated steel thickness 4 mm.
• *4 bottom dosing openings with 4 gates made of steel thickness 10 mm., driven by double acting pneumatic cylinders diameter 100 mm. with electro valves; possibility to adjust the distance between the gates and the bottom part of the cones to reduce the wear of steel.
• *1 no. adjustable electro vibrator power 311 Kgf. installed on sand compartment.
• *Aggregates weighing hopper volume capacity 1.5 m3 made of steel thickness 5 mm, divided into 2 compartments for cumulative weighing and fixed with adjustable electro vibrator power 311 kgf.
• *Electronic aggregate weighing system with 4 Nos. alloy steel load cells of capacity 2000 Kg. each. The reading is displayed on a digital display installed on the control panel, located in Control cabin.
• *Extracting belt conveyor length 5 mtrs installed under the weighing hopper, with 3 ply rubber belt 800 mm. wide, driven by shaft-mounted gearbox with electric motor power 5.5 Kw.; belt speed 60 m/min, production 60 m3/hr.
• *Self adjustable belt scraper provided with a special double-sided rubber bar.
• *Protection panels bolted inside the aggregate dosing cones.
• *Protection panels bolted inside the aggregate weighing hopper.

2.2 AGGREGATE LOADING SYSTEM

Aggregates loading system by Belt Conveyor, driven by electric motor power 15 Kw.

2.3 CEMENT DOSING DEVICES

• *Cement weighing container capacity 800 l installed above the mixer, complete with bottom discharge valve driven by electro pneumatic cylinder and adjustable electro vibrator power 182kgf.
• *Electronic cement weighing system with 3 Nos alloy steel load cell of capacity 500 Kg. each. The reading is displayed on a digital display installed on the control panel, located in Control cabin.

2.4 SCREW CONVEYOR

• *Screw Conveyor for Cement capacity 60TPH, driven by electric motor power 9.2 Kw with ball type connection flange on the inlet and cylindrical outlet. (Max inclination 45deg.)
• *Cement Screw Conveyor model: CS 219 x 10m.: 2 No.

2.5 CONCRETE DISCHARGE CONE

• *Concrete Discharge cone installed under the mixer discharge gate, with round outlet diameter 500 mm, suitable for a discharge height of 4.1 m into truck mixers, complete with rubbersock.
• *Protection panels bolted inside the cone.

2.6 WATER DOSING DEVICES

• *1 no. complete water dosing set provided, comprising of following,
• *Water weighing container capacity 300 l installed above the mixer, made of steel, complete with bottom discharge valve driven by electro-pneumatic cylinder.
• *One water feeding valve butterfly type with rubber seals, driven by electro-pneumatic cylinder.
• *Electronic water weighing system with 2 No. alloy steel load cell of capacity 500 Kg. The reading is displayed on a digital display installed on the control panel, located in Control cabin.

2.7 ADMIXTURE DOSING SYSTEM

• *1 no. admixture dosing system provided, each comprising of following,
• *Dosing unit with acrylic cylinder capacity 10 l equipped with load cell and preload connected. The reading is displayed on a digital display installed on the control panel, located in Control cabin.
• *Admixture loading and unloading cycle with 2 valves driven by pneumatic cylinders and reversible pump.

2.8 PNEUMATIC SYSTEM

• *Air compressor with single stage head driven by electric motor power 7.5 Kw. for a suction capacity of 700 l/min.; air tank capacity 280 l.
• *Air distribution box with FRL and manual valves for the different air destinations.

2.9 MIXER: BHS MAKE MAO 1500/1000 TWIN SHAFT HORIZONTAL MIXER, VOLUMETRIC CAPACITY 1500Ltrs.

• *Dry filling capacity 1500 l compacted concrete output 1000 l.
• *Two high efficiency gearboxes driven by electric motor power 37.5 Kw. through elastic transmission; one sacrificial syncro shaft installed between the gearboxes; two articulated joints between gearboxes and main shafts.
• *Two mixing shafts made of forged steel, supported by double rollers bearings.
• *Labyrinth type seals on the shafts, with grease injection from electrical pump, max. grease pressure 200 bar; grease tank capacity 4 Kgs.
• *Lateral liners made of Hardox steel, hardness 400 brinnell.
• *Mixing arms, bolted on the shafts.
• *Mixing paddles made of Ni-Hard cast iron hardness 600 brinnell.
• *Pneumatic Discharge gate with 2 proximity sensors for operation of discharge gate.
• *Tank protection hood with inspection doors with rubber seals and safety switch.
• *Ring type water distribution pipe placed above the tank, with inlet flange.
• *Electric junction box.
• *Provision of platform for easy maintenance.
• *Mixer bottom wear plates made of Ni-Hard Cast Iron hardness 600 brinnell.

2.10 CONTROL SYSTEM

• *Set of electrical wirings from the various devices to the control board. Location of control cabin shall be not beyond a distance of 3 m from standard layout.
• *Electric control panel for manual operating cycle, power control panel contained inside waterproof steel box with synoptic panel, lights and buttons.
• *Table for System computer.
• *Power required at 415 VAC +/-5%, 50 Hz+/-3%.
• *Control cabin placed with steel chassis dimensions 3 m L x 2m W x 2.1 m H and heat insulated sandwich panels for walls and roof construction; floor covered with wooden panels and linoleum surface; viewing windows provided.

System Description:

• *Modular PLC based PC driven control system with real-time SCADA for control and data management. Programmable Digital display units installed on the control panel connected to load cells for direct indication of the weights.
• *Manual control of the plant with buttons and switches installed on the control panel with changeover key for automatic and manual control. Automatic cycle execution through PC.
• *PC interface for storage of recipe archives and cycle data. The command for transferring recipe or production schedule is executed through PC. Availability of cycle data records on the basis of daily, weekly and monthly basis as well as recipes. Printing of cycle data is possible online or as and when required.
• *Printing of cycle data records and consumption reports is possible.
• *PC, UPS and printer (80 col. Dot matrix: 1 no.) required for the above system are included in scope.

2.11 SOFTWARE DESCRIPTION:

• *This is a fully compatible system with the Windows environment. It is designed to manage all types of concrete batching plants.
• *The interface is developed in a user-friendly way to make every operation simple. With Order management, at every moment, the user is provided with a complete view of the work schedule of each day or week and can access all needed information about the work progress of the plant.
• *The operator is able to start the automatic production and eventually, the system can be interfaced with any sort of Invoicing & Accounting program through CSV file interchanges. In this format, all the information can be managed in Access or Excel format to obtain all types of reports requested by the customer. Rich choices of statistics are available inside the program itself, so production analysis or consumption monitoring is always at the customer's disposal.
• *PC interface for recipe archives, cycle data storage. Execution of auto-cycle program transfer through PC.
• *Design recipes are stored on the basis of 1 m3 with a multiplier up to 99.9 m3. Each recipe stored with number, code, and name for easy search. There is no limit on the storage capacity. Limit is the capacity of PC-HDD.
• *Automatic batch-wise data printing and cycle data storage at the end of each cycle. Cumulative consumption records of each component for control over material consumption with provision to reset the records.
• *Cycle data stored can be viewed or printed on the basis of daily, weekly, monthly, or total reports. Also, can be set to view the reports on the basis of mix recipes.
• *Advanced control on alarms generated with inbuilt help and specific indication.
• *Database for consumption and possibility to calculate consumption on recipes and periods of production.

Plant Maximum Configuration:

• *4 Scale system Extractors
• *4 Aggregate extractors
• *1 Cement extractor
• *1 Fresh & Reclaim water
• *1 Additives batchers
• *1 Water Scale + Additional Flow meter for manual addition
• *1 mixer
• *Belt management

Batching Features:

• *Automatic in-flight/proportional open close management
• *Net tolerance monitoring
• *Intelligent & flexible discharge sequence
• *Manual batch by mouse
• *Water set point correction by mouse click
• *System pause
• *Automatic restart after power supply break-down
• *Changing extractor during auto batch
• *Online set point modification before auto batch start

Archive & Reporting:

• *Statistical report
• *Consumption report
• *Data cycle analysis
• *Report by destination
• *Recipe statistics
• *Incoming delivery notes report & statistics
• *Delivery note reporting
• *Analysis of the batching accuracy
• *Material consumption from the batch reports

Security & Assistance:

• *Automatic data backup
• *Remote backup in workstation unit
• *Multiple level password