Dry Mortar Production
- System configuration: Two 2m³ mixers, each equipped with three packaging machines with robotic palletizing system
- Raw materials: red cement, grey cement, calcium carbonate (CaCO₃), medium sand, fine sand, multiple additives
- Automation level: silo storage, automatic weighing and batching, automatic mixing, automatic discharge, automatic packaging, automatic palletizing
- Project location: Malaysia
- Installation requirement: Production line to be installed within an existing plant building
Raw Material Feeding
- When the powder tanker arrives at the unloading station, operators connect the unloading hose to the inlet pipeline to initiate pneumatic conveying into the silos.
- Sand is delivered in jumbo bags (ton bags). A forklift discharges the sand into a bucket elevator at ground level, which transports the material to the top-level storage.
- An electric hoist lifts 25kg-bag pallets from the ground to the additive dosing platform, where manual charging is performed. Each silo is equipped with a top-mounted jet pulse dust collector and high/low-level indicators.
Batching
Production recipes are pre-configured in the PLC control system. Upon mortar batching system activation, materials are automatically discharged from respective silos into weighing hoppers according to the programmed sequence. The feeding is done through screw feeders and gravity chutes.
Once the batching is completed, materials are transferred sequentially into the mixer for processing.
Simultaneously, the next weighing cycle begins in parallel to ensure continuous production.
Mixing
The dry mortar mixing system utilizes premium WAM brand mixers to ensure high-performance blending. Each batch cycle takes approximately 2-3 minutes. Upon completion of the mixing process, the pneumatically controlled bottom discharge gate opens, and the homogenized product is discharged into a collection hopper. During the mixing cycle, operators can manually add functional additives through a dedicated inspection and manual feeding port if required.
Packaging & Palletizing
The collection hopper features three discharge outlets, with each outlet connected to an independent valve-bag packaging machine. Utilizing a pneumatic forced-flow bagging method, the finished bags automatically drop onto a belt conveyor upon completion and are transported to the palletizing station. At this station, a robotic arm stacks the bags onto pallets in a predefined pattern with high precision. Once the palletizing is complete, the pallets are sequentially transferred to a stretch wrapping machine for film enclosure, before being moved to a discharge roller conveyor for manual forklift removal.
