In-line fix pallet with New Mobile Tilting Shuttle (New concept: Highly flexible & Low / Scalable investment) An alternative to High-tech Pallet circulating system By combining stationary production lines & mobile m/c technology
We have worked out a new concept for Stationary Production, as the investment of circulation system is too high.
An alternative to computer-controlled, High-tech’ rotation plant the in-line pallet production plays a decisive role.
By combining stationary production lines and mobile machine technology a level of automation is achieved, reaching a high efficiency for a certain production capacity.
In the existing System of Stationary Tilting Tables each production stage is normally equipped with a hydraulic tilting device. This leads to a high investment, especially if a larger number of tilting tables are used. Also Rails and power supply for the machines are connected separately to a complex rail system in the precast hall foundation.
Most Economical, Expandable & Simple technical Start-up solution with low level of automation & expand as per requirement for Precast Wall, Slabs, Sandwich elements or any Flat elements with New Mobile Tilting Shuttle.
The main advantages of Production Plant with New Mobile Tilting Shuttle are: -
- No of hydraulic tilting device for individual Tilting table is reduce to one Mobile Tilting Shuttle. Hence less investment & less in maintenance.
- Plant can also be set-up Open to sky, just in a month for immediate production of Wall / Slabs & can be Naturally Cured under our hot & humid climate. (set-up on the main road of housing colony & leave it on Completion of project.)
- Start with lowest investment initially, than upgrade the plant to highest capacity. Initially can use swing setter for concreting or for more convince use speedy casting truck, upgrade to mobile concrete spreader, mobile leveling & trowelling/ floating device.
- Outstanding wall & slab quality due to factory production (by Machines) – directly at site.
- You can also Bid for more on-site remote projects & Reduce hassle & cost of Transport of precast element.
- Site Batching plant & other equipment installed for above can be used for other work.
- Saving on taxes & govt. duties as production is on site.
- Produce other precast element on site like staircase etc.
- Minimize cash out, as No investment in expensive land & Fast Return on Investment with minimal capital.
- Very less wiring required hence less complication.
- Very less power required.
- Spares required is very less as fewer equipment’s are used compared to standard carousal system.
- Very easy to move Dismantle & Transport plant as there are fewer equipment etc. like Pallets, mobile Tiling shuttle gantry crane and rails can be easily removed.
- Expansion for more production is very easy.
Requirements to set-up Precast Concrete Element Plant: -
For Maximum annual production capacity of say 2,50,000 m2 / year of Precast Concrete elements like Solid load bearing External walls, solid floors, Double layer walls or precast elements with core insulation, Partition walls / Internal wall panel, Composite slab panel, Beam, Column, Staircase, Double Tee, Balcony compound wall etc.For best production facility with expansion plus in future setting –up of Hollow core slab production & storage, a good size of Precast Concrete factory area Totally required is about 70,000 – 1,00,000 square meters. (Say 25 acres).
About 170 meter x 25 meters - 2 bays are required for Precast Concrete elements production workshop. One line is the ‘standard part production line’ for standard parts; the other is the ‘special part production line’, which caters for the time-consuming operations such as fitting special reinforcement, required for special precast elements. Where jobs require an especially flexible response the pallet can be moved across to the other production line. On one line pallet circulating system is fitted & on other bay is for Special elements, Beam & Column, Double Tee, Tilting Tables & Battery mould etc., (Based on pallets with dimensions of 12 x 4 meter & At an utilization rate of 60 to 80% this allows the manufacture of approx. 25 to 30 m2 precast concrete parts per pallet per hour)
Attached with above plant 5,000 m2 for Concrete Batching & mixing plant (Approx. 180 m3/hr.) with storage of aggregates, sand & having 2 - 4 nos. of Cement silos etc., Steam boiler plant, Area for Reinforcing preparation workshop with Tools for cutting & forming steel reinforcement along with Steel fabrication & general workshop machinery for repair & maintenance, general store area plus finish good storage area 30,000 – 50,000 m2, Quality control dept., beside this, it also need to consider Administrating Building with all utilities, Staff Quarters.
Other requirements are Drinking Water storage tanks & pump house, Transformer sub Station for 1500 - 2000 KVA, Weighbridge - 60T, Good internal Road etc. plus vehicles, Trucks, Wheel Loader, forklift & Cranes etc. Full load production personnel required is approx. 200 - 400 nos. And roughly construction period required for above is 4 - 6 months minimum.
This allows the company to cater to Residential housing, commercial and Industrial construction needs, including modular products for schools, and many speciality products in addition to floor slabs and walls.
