Selecting the right concrete batching plant for block production is just as important as choosing the concrete block machine itself. A high-capacity block machine cannot deliver its expected performance if the batching plant supplies concrete too slowly, produces inconsistent mixtures or cannot adapt to different product recipes.
In concrete block, paving stone and kerbstone production, the batching plant is not merely a raw material preparation unit. It directly affects:
For this reason, the batching plant, mixer and block machine should be designed as parts of the same production system.
The correct plant must prepare the required concrete quantity within the available cycle time while maintaining consistent moisture, aggregate distribution and cement content from one batch to the next.
Concrete blocks and paving stones are generally manufactured using a low-moisture, stiff concrete mixture commonly described as zero-slump concrete. This type of mixture behaves differently from conventional ready-mixed concrete.
Because the mixture contains limited water, it must be blended intensively to distribute:
evenly throughout the batch.
An unsuitable batching plant may create variations in moisture and material distribution. These variations can cause:
The batching plant must therefore do more than prepare concrete. It must supply a stable and repeatable mixture that supports the vibration and pressing process of the block machine.
Ermak has produced professional concrete batching plants and its registered Milano Mixer systems since 2000. The company designs its batching plant solutions for integration with concrete block, paving stone and other precast concrete production lines.
The first step in selecting a batching plant is to determine how much concrete the block machine consumes during real production.
This calculation should consider:
The block machine manufacturer should calculate the approximate concrete consumption for the selected products.
For example, a machine producing standard hollow blocks may consume a different volume of concrete per cycle than the same machine producing thin paving stones. Even when the cycle time is similar, the product volume and required batch quantity may change substantially.
The batching plant must supply enough concrete to prevent the block machine from waiting. However, selecting a plant far above actual requirements can create unnecessary investment, energy use and maintenance costs.
The target should be a controlled capacity margin rather than excessive oversizing.
Mixer models are often described using two numbers, such as:
The first value generally represents the input or charging capacity, while the second represents the approximate compacted concrete output per batch.
However, mixer capacity alone does not determine hourly production.
The real output depends on the complete mixing cycle:
A nominally large mixer may deliver less concrete per hour if charging, mixing or discharge takes too long.
The hourly output should therefore be calculated using:
Net concrete per batch × completed batches per hour
For example, a mixer that delivers 1 m³ per batch and completes 30 full cycles per hour has a theoretical output of 30 m³ per hour. In practice, plant efficiency, recipe changes, cleaning and material supply must also be considered.
The batching plant should be selected according to realistic hourly output rather than the largest number printed in a catalogue.
The mixer and block machine must operate in rhythm.
If the block machine completes production cycles faster than the mixer can prepare concrete, the following problems may occur:
The mixer does not necessarily need to prepare concrete for every individual machine cycle. A properly sized buffer hopper can hold mixed concrete and supply several cycles.
However, the buffer hopper must not be used to hide a serious capacity mismatch. Concrete should not remain in the hopper long enough to begin losing workability or consistency.
The correct configuration depends on:
A capacity study should show how many block machine cycles can be supported by each mixer batch.
Mixer type has a direct impact on concrete homogeneity, mixing time, maintenance and investment cost.
Two common options for concrete block production are pan mixers and planetary mixers.
In a pan mixer, mixing arms rotate inside a circular mixing chamber. The system can be suitable for a wide range of concrete block and precast applications.
Potential advantages include:
A pan mixer can be a practical choice for facilities producing standard hollow blocks, brickets or paving products at controlled capacities.
Ermak’s 1500/1000 Pan Mixer uses a 45 kW motor and is designed for difficult zero-slump concrete used in precast elements and interlocking paving stone production. Its published design includes replaceable arms and blades, wear-resistant lining options and a wide discharge opening intended to support fast emptying.
Planetary mixers use rotating mixing tools that also move around the mixer chamber. This movement can provide intensive coverage of the mixing area and help distribute materials rapidly.
They are frequently considered for applications requiring:
Planetary mixers may require a higher initial investment, but they can provide important advantages where surface appearance, pigment distribution and recipe consistency are critical.
Ermak’s Milano Mixer range includes a 750/500 Planetary Mixer with 37 kW power and a 2250/1500 Planetary Mixer with 75 kW power. Both are presented as systems designed for zero-slump concrete used in paving stone and precast product manufacturing.
The final selection should be based on product requirements, not mixer labels alone. Blade design, mixing coverage, discharge speed, wear protection and maintenance access must also be evaluated.
The required batching plant configuration changes significantly when double-layer paving stones are planned.
Single-layer products use one concrete mixture throughout the product body.
Double-layer paving stones usually consist of:
The base mix and face mix typically require different:
A double-layer production line may therefore require:
The base concrete mixer is normally sized according to the main material demand of the machine. The face-mix mixer may be smaller because the surface layer uses less material per cycle.
However, the face-mix system must still prepare concrete quickly and consistently. A small mixer with slow discharge can become a bottleneck even when the required volume is limited.
Aggregate bunkers must store and separate the different materials used in production.
A typical block production plant may require separate compartments for:
The number of bunkers depends on the number of recipes and the required product range.
A plant producing only one standard hollow block may operate with fewer aggregate types. A facility producing coloured pavers, kerbstones, grass stones and special blocks may require more compartments.
Bunker capacity should be determined according to:
Very small bunkers require frequent loader filling. This increases equipment movement and may interrupt material supply.
Excessively large bunkers increase structural cost and occupy more space.
The correct design should keep the plant supplied without creating unnecessary construction or handling costs.
Aggregates may be loaded into the batching plant using:
The selection depends on site conditions and production scale.
Wheel-loader-fed bunkers are common because they provide flexibility and can handle several material types.
However, the layout should minimise loader travel and prevent cross-contamination between aggregates.
The feeding system should also maintain a consistent flow. Fine or wet materials may bridge inside the bunker, while lightweight aggregates may behave differently from crushed stone.
Useful equipment may include:
The bunker and gate design should match the physical properties of the aggregate rather than relying on one standard arrangement for every material.
Accurate dosing is essential for repeatable block production.
The plant should weigh or measure:
Small variations can affect moisture, colour, strength and compaction behaviour.
Aggregate weighing systems may use:
The correct system depends on production speed and required precision.
Important points include:
The control system should account for material that continues falling after a gate begins closing. Without this compensation, repeated overfeeding can alter the recipe.
High weighing accuracy is especially important for:
Aggregate moisture is one of the most influential variables in concrete block production.
Sand and fine aggregates can retain significant amounts of water. If the control system adds a fixed water quantity without accounting for existing moisture, the final mixture may become too wet.
Excess water can cause:
Insufficient water can lead to:
Moisture probes can be installed in aggregate bunkers, weighing systems or mixers. The automation software can then adjust the added water according to the measured moisture level.
Moisture control should not be treated as an optional luxury in high-quality production. Inconsistent water content quickly becomes inconsistent product quality.
Water dosing should provide both accuracy and speed.
The system may use:
A two-stage system can add most of the required water quickly and then complete the dose more slowly for accuracy.
The water system should also account for:
The automation system should store separate water settings for each product recipe.
Operators should not need to manually guess the water quantity for every batch. Manual correction may still be useful, but it should be controlled and recorded.
Cement storage must support the plant’s daily consumption and delivery schedule.
The required silo capacity depends on:
A plant using different cement types may require more than one silo.
The cement system may include:
The screw conveyor must supply cement quickly enough to support the mixing cycle.
A slow cement transfer system can lengthen every batch and reduce hourly plant capacity. This is a classic hidden bottleneck: the mixer receives all the attention while the screw conveyor quietly steals the shift.
Ermak states that its batching plants use specialised components from established suppliers, including WAM equipment for elements such as screws, gates and vibrators. The company also offers standard or project-specific automation depending on the production line.
Coloured paving stone production requires controlled pigment dosing.
Pigments may be added through:
Manual pigment addition may be acceptable for limited production, but it increases dependence on the operator.
Automatic dosing can improve:
Chemical additives may also be used to influence compaction, strength development, water demand or surface quality.
The additive system should provide:
Pigment and additive systems should be planned at the beginning of the project. Adding them later can require significant changes to the plant structure and software.
Zero-slump concrete is abrasive. Mixer blades and internal wear plates are therefore exposed to continuous mechanical wear.
When comparing mixers, examine:
Worn blades increase the distance between the mixing tools and the chamber. This can reduce mixing efficiency and increase batch time.
Adjustable arms allow the position of the blades to be corrected as they wear.
Ermak states that Milano Mixer blades use Ni-hard cast material with a published hardness of 54 HRC. Its mixer pages also describe optional Ni-hard or Hardox wear plates, replaceable blade assemblies and adjustable mixing arms.
Wear parts should be viewed as planned operating components. Their cost, expected lifetime and replacement time should be included in the investment assessment.
A mixer may prepare concrete quickly but still limit plant capacity if discharge is slow.
The discharge opening should be large enough to release stiff concrete without prolonged waiting.
The receiving conveyor or skip must also be positioned correctly to prevent:
The discharge gate should open and close reliably under dusty and abrasive conditions.
Useful features may include:
Milano Mixer product information describes wide discharge covers and optional quick-discharge systems. A manual hydraulic opening method is also provided for power-loss situations.
Discharge time should be included in the full batch-cycle calculation. Ignoring it can produce an overly optimistic capacity estimate.
A buffer hopper is installed between the mixer and the block machine to maintain a controlled material supply.
The hopper must:
A hopper that is too small may empty before the next mixer batch arrives.
A hopper that is too large may allow concrete to remain inside too long, particularly during production interruptions.
The interior shape should promote material flow. Vibrators or agitators may be required for difficult mixtures, but uncontrolled vibration can also cause segregation.
Level sensors should inform the plant automation when another batch is required.
The batching plant control system should coordinate:
Recipe management is especially important when the plant manufactures several products.
Each recipe may contain different:
The control system should store recipes securely and prevent unauthorised changes.
Useful automation functions include:
Ermak states that its concrete batching plants can use standard market software or project-specific automation. This allows the control system to be adapted to the requirements of the associated block production line.
A modern batching plant should communicate with the block machine rather than operating as a completely independent island.
The systems may exchange information such as:
When the block machine stops, the batching plant should avoid preparing unnecessary concrete.
When the product recipe changes, the correct mixture should be selected automatically or through a controlled operator command.
Integrated communication reduces the risk of:
The batching plant and block machine should ideally be planned by teams that understand both systems.
A technically capable batching plant can still perform poorly when installed in a bad layout.
The site plan should consider:
The distance between the mixer and block machine should be kept practical. Long conveyor routes increase:
However, the batching plant should not obstruct production, curing or forklift traffic.
The layout must also allow safe access to:
A compact layout is useful only when maintenance can still be performed safely.
The total installed power of the batching plant may include:
The electrical design should consider both installed power and simultaneous demand.
The plant may also require:
Compressed air is commonly used for gates and valves. Compressor capacity must be sufficient for peak demand.
Water pressure and supply must remain stable throughout production. If the plant depends on a storage tank, the tank and pump should be sized for the maximum production rate.
Concrete batching plants operate in dusty and abrasive conditions.
Daily and periodic maintenance may include:
The plant should be designed so that these tasks can be performed without dangerous or time-consuming disassembly.
Mixer cleaning is especially important. Hardened material reduces effective capacity and may contaminate future batches.
Optional washing systems can reduce cleaning time, but they do not eliminate the need for inspection.
Milano Mixer product pages describe optional pump-and-nozzle washing systems and safety switches on maintenance covers. These features are intended to support cleaning access and maintenance safety.
The batching plant contains moving conveyors, rotating mixers, pneumatic gates and elevated equipment.
Required safety measures may include:
Maintenance covers should prevent the mixer from operating while open.
Platforms and stairs should provide stable access for inspection.
The manufacturer should supply operating manuals, electrical diagrams and maintenance instructions. Operators must be trained before production begins.
A batching plant should support current production without preventing future growth.
Possible future requirements include:
Expansion planning may affect:
Leaving suitable connection points and physical space during the original installation is usually less expensive than rebuilding the plant later.
However, expansion potential should remain realistic. Paying for a plant twice the required size based only on vague future hopes is not planning; it is expensive optimism wearing a hard hat.
The lowest-priced batching plant is not necessarily the most economical option.
The total cost should include:
A plant with poor weighing accuracy may increase cement consumption.
A slow mixer may reduce block machine utilisation.
A weak discharge system may lengthen every batch.
An unreliable moisture system may increase rejected products.
These costs are often less visible than the original quotation, but they continue throughout the working life of the plant.
Before finalising the plant design, confirm that:
The best concrete batching plant for block production is not simply the plant with the largest mixer or the highest theoretical output.
It is the system that delivers the correct concrete:
Mixer type, batching accuracy, moisture control, automation, material storage and discharge speed must all work together.
Ermak develops concrete batching plants, Milano Mixer systems, block production machines, moulds, curing racks, transport systems and packaging equipment. This allows the batching plant and block machine to be evaluated as a coordinated production line rather than as unrelated equipment.
For a new block production facility, the batching plant should be sized according to the actual products, target capacity, operating hours and planned automation level. A properly balanced system improves product consistency, reduces unnecessary production interruptions and helps the entire investment operate closer to its intended capacity.
A plant designed for stiff, low-moisture or zero-slump concrete is required. It should provide accurate aggregate, cement and water dosing together with intensive mixing and fast discharge.
Capacity is calculated using the mixer’s net concrete output per batch and the number of complete batches produced per hour. Charging, mixing and discharge times must all be included.
Neither option is automatically better for every plant. Planetary mixers are often selected for intensive mixing, coloured face concrete and demanding recipes. Pan mixers can provide a reliable and economical solution for many standard block products.
In most applications, separate mixers are preferred for the base concrete and face concrete because the two layers use different aggregates, pigments, quantities and recipes.
Aggregate moisture changes the real water content of the mixture. Without correction, products may become too wet or too dry, causing compaction, strength and surface-quality problems.
Bunker size should be based on hourly consumption, production shifts, loader operation and material delivery frequency. The bunkers should prevent supply interruptions without being unnecessarily oversized.
It may be possible if mixer output, storage, conveyors and automation are designed for the combined concrete demand. A detailed cycle and capacity study is required.
Common causes include an undersized mixer, slow aggregate feeding, low-capacity cement screws, slow discharge, insufficient buffer storage and inaccurate automation timing.
Integrated communication is strongly recommended. It allows the batching plant to receive concrete requests, respond to machine stops and coordinate product recipe changes.
The quotation should clearly identify aggregate bunkers, weighing systems, mixer, cement silos, screw conveyors, water and additive dosing, automation, moisture control, conveyors, installation, training, warranty and spare parts.
Your personal data; It is one of the leading principles of our Organization to protect the privacy of visitors to the website (www.ermakmakine.com.tr) operated by the Ermak Makine (“Ermak Makine”) as the data controller. This Cookie Usage Policy (“Policy”) explains to all our website visitors and users which types of cookies are used and under what conditions.
Cookies are small text files stored on your device or network server by websites you visit on your computer or mobile device.
They are generally used to provide you with a personalized experience during your use of the website you visit, to improve the services offered and to improve your experience, and may contribute to ease of use while browsing a website. If you do not prefer the use of Cookies, you can delete or block Cookies in your browser settings. However, we would like to remind you that this may affect your use of our website. Unless you change your Cookie settings in your browser, we will assume that you accept the use of cookies on this website.
Cookies on websites, depending on their type, collect data about your browsing and usage preferences on the device you visit the site. This data includes information about the pages you access, the services and products you review, your preferred language option and other preferences.
Cookies are small text files stored on your device or network server through browsers by the websites you visit. These small text files, which contain your preferred language and other settings on the site, help us remember your preferences the next time you visit the site and make improvements to our services to improve your experience on the site. Thus, you can have a better and personalized usage experience on your next visit.
The main purposes of using cookies on our Website are listed below:
Session cookies ensure that the website functions properly during your visit. They are used for purposes such as ensuring the security and continuity of our sites and you during your visit. Session cookies are temporary cookies, they are deleted when you close your browser and come back to our website, they are not permanent.
These types of cookies are used to remember your preferences and are stored on your device via browsers. Persistent cookies remain stored even after you close your browser or restart your computer from which you visited our site. These cookies are kept in subfolders of your browser until they are deleted through your browser’s settings.
Some types of persistent cookies may be used to provide you with special suggestions, taking into account issues such as your purpose of using the Website.
Thanks to persistent cookies, if you visit our Website again with the same device, it is checked whether there is a cookie created by our Website on your device and if there is, it is understood that you have visited the site before and the content to be transmitted to you is determined accordingly and thus a better service is provided to you.
These cookies are essential for the website you visit to function properly. The purpose of such cookies is to provide necessary services by enabling the website to function. For example, it allows you to access secure parts of the website, to use its features, to navigate on it.
They collect information about the way the website is used, the frequency and number of visits, and show how visitors navigate to the site. The purpose of using such cookies is to increase performance by improving the way the site functions and to determine the general trend direction. They do not contain data that could enable the identification of visitors. For example, they show the number of error messages displayed or the most visited pages.
It saves the choices made by the visitor within the site and remembers them on the next visit. The purpose of such cookies is to provide ease of use to visitors. For example, it prevents the site user from re-entering the user password on each page they visit.
They enable the measurement of the effectiveness of advertisements served to visitors and the calculation of the number of times the advertisements are viewed. The purpose of such cookies is to serve ads customized to the interests of visitors.
Likewise, they enable the detection of visitors’ interests specific to their browsing and the presentation of appropriate content. For example, it prevents the advertisement shown to the visitor from being shown again in a short time.
To change your preferences regarding the use of cookies or to block or delete cookies, simply change your browser settings.
Many browsers allow you to control cookies by giving you the option to accept or reject cookies, accept only certain types of cookies, or be alerted by the browser when a website requests to store cookies on your device.
It is also possible to delete cookies that have already been saved in your browser.
If you disable or refuse cookies, you may need to set some preferences manually, and some features and services on the website may not work properly because we cannot recognize and associate your account. You can change the settings of your browser by clicking on the relevant link in the table below.
Website Privacy Policy …./…./…./…. . is dated. In case all or certain articles of the Policy are renewed, the effective date of the Policy will be updated. The Privacy Policy is published on the website of the Authority (www.ermakmakine.com.tr) and made available to the relevant persons upon the request of personal data subjects.
Ermak Makine
Address Organize Sanayi Bölgesi Mah. 27.Sokak. No:1/1 Dilovası/Kocaeli
Telephone: (+90 262)263 02 70
E-mail: kvkk@ermakmakine.com.tr
Web Address: www.ermakmakine.com.tr
You can type below the product you want to search for
