January 31, 2019

Twin-shaft batch mixer used for concrete pipe manufacturing in Indonesia

Precast concrete pipes

Precast concrete poses a challenge to mixing mechanisms due to its dryness

BHS-Sonthofen receives follow-up order from a player in the Indonesian precast concrete industry: Twin-shaft batch mixers from BHS-Sonthofen feature special drive technology that can handle even demanding tasks with ease. BHS supplied these types of mixers for a second time to a player in Indonesia’s precast concrete industry; two machines were sent to the company PT Calvary Abadi. This clearly demonstrates that twin-shaft batch mixers are suitable for use with precast concrete, contrary to popular opinion.

As an exclusive Indonesian cooperation and sales partner, PT Detede is authorized to advertise and sell BHS-Sonthofen products. The company produces complete concrete and asphalt mixing systems; BHS supplies the high-quality mixers required for concrete manufacturing. In March 2017, PT Calvary Abadi, the market leader for precast concrete in East Java/Surabaya, explicitly requested a BHS-Sonthofen twin-shaft batch mixer from Detede – a rather unusual choice for precast concrete.

BHS twin-shaft batch mixers are particularly powerful

Pan and planetary mixers have been dominating the precast parts industry for 30 years. This is mainly because it is widely believed throughout the industry that twin-shaft batch mixers would only be suitable for use in precast concrete under certain conditions. Industry players have assumed that the drive technology in these types of mixers would not be powerful enough for precast concrete applications, which place high demands on mixing technology. Precast parts require concrete with a lower water content than ready-mixed concrete, for instance. This relative dryness makes the concrete very tough, and poses a challenge to mixing mechanisms and drives.

BHS-Sonthofen integrates worm gears into its twin-shaft batch mixers of type DKX. As a result, these boast maximum operational safety and a long service life. The gears are pushed onto the mixer shafts without a firm connection to the mixing trough, which allows them to compensate for the changes in load that occur each time the mixer is loaded. BHS-Sonthofen is certain that this opens up a broad range of applications for its twin-shaft batch mixers. Philipp Parnitzke, Area Sales Manager for the Asia/Pacific region, selected the suitable mixer series for Calvary: “The mixer of type DKXS is highly versatile. It is suitable for all types of applications, from pumped and ready-mixed concrete, to wet mortar, to precast parts.”

Changing opinions through persuasion

Calvary specifically requested powerful BHS twin-shaft batch mixers from Detede. Previously, Detede had always supplied Calvary with a pan or planetary mixer. “We had to do some convincing when collaborating with the supplier on this project,” says Parnitzke. The mixers clearly convinced the customer. A follow-up order was placed very soon: In March 2018, two additional twin-shaft batch mixers of type DKXS 2.25 were supplied to the company.

Over the long term, Parnitzke wants to ensure that complete system manufacturers and end customers all around the world become more familiar with the high performance of BHS mixers and their areas of application. “We invented the twin-shaft mixer over 130 years ago and have continuously refined the technology ever since. Our special, technically highly sophisticated drive configuration makes it possible to produce all types of concrete.”

Mixers previously used for precast concrete were less efficient

The pan and planetary mixers which were previously the top choices for manufacturing precast parts cannot keep up with the efficiency and space-saving design of the BHS twin-shaft batch mixers. Thanks to their compact design, these twin-shaft batch mixers have a smaller installation footprint, and therefore fewer steel structures, yet enable the same production volume. Twin-shaft mixers can also be emptied more quickly, which shortens the mixing cycle and ultimately increases performance in m³/h, as compared to pan mixers. Due to their design, circular pan mixers take longer to empty. Meanwhile, the discharge of the BHS twin-shaft batch mixer, which is centrally positioned between the mixer shafts, empties within a very short period of time since the mixer shafts running opposite one another transport the concrete into the discharge shaft. Twin-shaft batch mixers also boast virtually complete emptying.

This means that they can produce more output when processing the same batch size, thereby increasing the efficiency of the entire process. As a result, this special mixing technology offers customers a wide range of benefits, made possible by BHS-Sonthofen’s 130 years of experience. This in turn represents a key advantage, one based on traditional engineering expertise and continuous optimization. Moreover, competitors in the twin-shaft mixer segment cannot fulfill the same types of demanding requirements as BHS mixers can.

Precast concrete production

BHS twin-shaft batch mixer used in precast concrete manufacturing

Hanny Avianto (CEO) from Calvary Abadi

Hanny Avianto, owner and CEO of Calvary Abadi, welcomes renewed collaboration with BHS-Sonthofen

Soerya Widjaja (Managing Director) and Romwell Sahata (Manager)

Convinced of the twin-shaft batch mixer’s high performance: Managing Director Soerya Widjaja and Manager Romwell Sahata of Calvary Abadi

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