Boosting efficiency and optimizing quality: Eirich modernizes concrete production at Plötner

German concrete producer Betonwerk Carl Plötner GmbH, a renowned provider of high-quality concrete products, has taken further steps to boost the efficiency and quality of its concrete mixing lines. In the project to modernize the face concrete mixing line at its Plaidt plant, Plötner has relied on the expertise of Eirich to optimize production processes and reduce reject rates. The introduction of a new face concrete mixer has not only helped the concrete plant to improve product quality, but also to shorten downtimes and noticeably reduce cleaning efforts and costs.

Manufacturing of concrete products demands the highest precision during preparation of a batch. High reject rates and inefficient cleaning processes were restricting production capacity and productivity at Plötner. The goal of the modernization process was to enhance mixing quality, improve mix homogeneity, and minimize machine downtimes. In addition, the amount of cleaning required on the paving stones machine was to be reduced, as the facing concrete was often stuck to the pressure plates, leading to production downtimes and unwanted interruptions of ongoing operations.

State-of-the-art face concrete mixer for optimized processes

Eirich has modernized the machine inventory in the mixer line. As well as the new face concrete mixer of type RV12 500, the existing line technology (balance, skip hoist, mixing and weighing platform etc.) was adapted accordingly. The face concrete mixing line is equipped with a new, powerful dust removal system as well as a PU apron for the product transfer. In addition to installing the technical components, Eirich also took care of engineering services and ran the functional tests on the line.

Improved mixing results:

• Improved moisture distribution: Considerably less residue stuck to the die, which significantly reduces downtimes and cleaning requirements.
• Consistent coloration: Uniform distribution of the cement and pigments ensures vibrant and uniform coloration of the products.
• More efficient cement preparation: The cement is broken down and incorporated in the mixture much better, leading to higher quality of the end products.
• Reduced reject rates: High homogeneity with uniform moisture distribution and consistent mixture quality lead to a drastic reduction in rejects/scrap and therefore to lower costs associated with disposal.

“Inventory modernization always goes hand in hand with certain challenges, but thanks to our close coordination with Plötner we were able to master these challenges together. For us it is important to utilize and supplement existing components a way that optimizes not only the immediate mixing result, but also the entire process all the way up to the end product,” explains Stefan Berberich, Project Engineer at Eirich.

Project flow: close coordination and timely implementation

The project was launched in October 2022 when initial contact was made at the bauma trade fair. After detailed planning and discussions on site and the submission of conversion plans, Eirich was awarded the contract to carry out the modernization project in December 2022. Conversion of the facilities and lines was closely coordinated with Plötner. Installation of the new line components and the functional tests were all completed with no problems whatsoever, allowing the modernized mixing line to be taken into operation in March 2024. 

Major efficiency boost and high customer satisfaction

Thanks to the modernization of its production systems, concrete producer Betonwerk Plötner has been able to make significant improvements in production and is now perfectly set up for future
challenges.
Christoph Plötner, CEO of the company, is clearly very happy: “Our reject rates are almost down to zero now, and we have been able to reduce our cleaning cycles by half. When it comes to replacing further mixers in the future, we already know that Eirich mixers will definitely be a leading contender.”

The project at Plötner highlights how the use of state-of-the-art mixing technology in combination with close coordination with the customer can lead to significant improvements in terms of efficiency and quality.