Baumaschinen GmbH
MIXING TECHNOLOGY
Editorial
Every day, new requirements concerning our work arise. New information and technologies offer possibilities that would have been unthinkable in the recent past. We take part in this fast-paced development. We check the advantages and create innovative products that take into account the latest methods and set standards for the future. Challenge and flexibility is our vision and our model. KNIELE Mischtechnik develops custom-made mixing plants of any kind. Based on our experience and use of state-of-the-art technologies, we supply systems which increase and secure productivity.
Dipl. Ing. (FH) Erwin Kniele Dipl. Ing. Harald Kniele Dipl. Ing. Alexander Kniele Managing Directors
Alexander Kniele, Erwin Kniele, Harald Kniele and Felix Kniele
Services
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KNIELE Mischtechnik represents decades of experience in mixing technology: grown with the customer’s requirements, planned and improved for the customer. KNIELE is always just a phone call away. If you have any questions or if you need spare or wearing parts, or if you need a service technician, please do not hesitate to get in touch with one of our engineers
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Highest quality as a base of success! KNIELE Mischtechnik can draw on many decades of experience in planning construction production and assembly
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of turnkey mixing plants for ready-mix plants mortar plants dry mortar plants prefabricating plants block plants ultra-high performance concretes special mixing plants of any kind such as: – special waste processing (dust, slurry, etc.) – soil processing (recycling) – dry mixing processes (e.g. chemistry, food) – brick and ceramics industry – glass industry – mixed gravel processing – farming – styrofoam concrete – plaster and clay – epoxy resin glue – floor screeds
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Innovative engineering and fast, flexible reactions to the market’s constant changing, to extended technical requirements, as well as our customer-oriented service has made us one of the leading international suppliers.
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Therefore, KNIELE Baumaschinen GmbH – Mixing Technology – is a sought-after partner for: new plants – standard solutions or custom-made plants modernisations expansions or complete conversions.
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We offer solutions at the latest state of the art – practical and economical:
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Needs-based and made to order KNIELE’s mixing technology offers plant designs for any tasks and for any required performance. – – – – – – –
tower batching plants step plants star-/scraper plants row-type plants pocket silo plants mobile mixing plants special mixing plants
tower batching plants
step plants The desired capacities of the plants have to be co-ordinated individually and the corresponding mixer sizes and types must be determined. All plants can be supplied with one or several mixers. Mixer sizes from 0.10 m3 to 3.0 m3 of hardened concrete, either as intensive mixer with mechanical or electrical infinitely adjustable stirrers, as counter current mixers, as cone-type mixer or as twin-shaft mixer. Special mixers can of course be integrated into all plants according to the customer’s individual wishes and requirements.
star-/scraper plants
row-type plants
We offer several ways to discharge the product, e.g. for truck-mixers, skip-type hoist as well as concrete spreaders and concrete buckets etc.
pocket silo plants
mobile mixing plants
special mixing plants
In consideration of the legally valid standards and regulations, our plants produce quality concrete for various applications. If requested, our plants can be equipped in such a way as to ensure continuous operation - even during the winter months.
KNIELE Mixing Technology your competent plant construction partner
SCC facing
Sleepers
Steirs of fair-faced concrete
Garden products
Accessories of UHPC
UHPC furniture
Bench of UHPC
UHPC roof-tile
Wet Cast slab Wet Cast slab
Wet Cast travertine
Wet Cast boards
Wet Cast slabs
Row-type/Pocket Silo Plants
The horizontal concrete station Loading by bucket loader or direct loading by truck The pocket row-type plant can be delivered as a semi-mobile or stationary model. Weighing of the aggregates is effected by a weighing belt or a mobile weighing-machine that delivers the materials to a skip loader or a belt conveyor which loads the mixer or an intermediate container.
Row-type plant: executed as high tower e.g. for block plants, because many different aggregates are needed. Loading by double belt or single belt conveyor, or special lift e.g. for double broken and double screened chips, to enable a sorted loading. Feed hopper over ground for rear dump trucks or underground with cover grating.
Tower Plants
The vertical concrete mixing plant Between 100 m3 and 1000 m3 of material can be stored in the distinctive tower plant aggregate silo with a diameter from 5.75 to 10.5 m. Loading can be effected at 16째 by conveyor belts (even), by steep-incline conveyor belts (napped) at 30째, by bucket-type elevator or by an S-conveyor. The design allows for loading without additional staff. Processing of the aggregates is possible even at extremely low temperatures if the silos are equipped with an insulated cladding and an integrated heating. The installation of several mixers ensures a very high effectiveness of the plant. An independent shipping of transit-mixed and ready-mixed concrete for a construction site as well as an independent production of transit-ready concrete and mortar or flowing screed (if an anhydrite mixer is integrated into the plant) is possible.
Step plant Due to its low design height this low tower type is used wherever officially predefined height limitations must be observed.
Durchdacht bis ins kleinste Detail
Mixing Systems Mixers for any application KNIELE Annular Tray Mixer (Type ZE) with two mechanically driven stirrers. Also available with an infinitely adjustable stirrer.
Intensive Annular Tray Mixer KNIELE’s annular tray mixer is excellently equipped with two agitators which are mechanically driven by the main drive for particularly difficult mixing tasks. The good mixing effect especially results from the good break-up of the material due to the two stirrers which rotate contrary to the direction of the agitator. A very intensive mixing effect – even in a shorter time – is achieved by the relatively narrow mixing canal. This also offers a great advantage for the mixing of small quantities.
Conversion of conventional mixers Conversion of conventional mixers without stirrer to mixers with a mechanically driven stirring system.
Investing in a KNIELE intensive mixer means: – – – – – – – –
high concrete quality low operational costs easy maintenance and cleaning high reliability low noise level easy and flexible installation high adaptability to individual needs high yield
Mixing systems in figures
I
250
375
500
750
1000
1250
1500
2000
2250
2500
3000
Unmixed batch capacity I
375
550
750
1125
1500
1850
2250
3000
3375
3750
4500
11
15
22
30
30
45 (37)
55 (45)
55 (75)
75
90
90 (110)
22
30
30
45 (37)
55 (45)
55 (75)
75
90
90 (110)
22
30
30
45 (37)
55 (45)
55 (75)
Nominal volume
Three-phase motor * ZE type
kW
ZE type (without stirrer)
kW
Type GM
kW
15
* Standard drives; for extended mixing times more powerful drives (400V | 50Hz) may be required; special voltages possible
Type ZE
Type ZE (without stirrer)
Type GM
Constant-flow mixer A specially equipped batch-type mixer with a special device and control panel is used as a constant-flow mixer, e.g. for the production of mixed gravel, concrete, etc.
Cone Mixer
The cone mixer for your application! Mixing re-invented! Successful application since 2000! KNIELE has chosen a fully new path and developed and patented a cone-type mixer with impressive features. Thanks to a completely new technology, a never before seen performance can now be achieved.
* A B
100/150 820 360
250/375 1420 560
375/550 1420 560
500/750 1800 560
750/1125 1800 560
1000/1500 2100 660
* A B
1250/1875 2100 660
1500/2250 2400 660
2000/3000 2400 660
2500/3750 2700 660
3000/4500 2700 660
4000/6000 3000 760
* Change of dimensions reserved
The cone mixer and its properties: – Optimal mixing effect thanks to the new mixing principle! – Reliable break-up of cement agglomerates! – Bar-free addition of colours! – No loss of quality when mixing small quantities! – Entire discharge within the shortest time! – Conical, space-saving design! – Low pollution level – easy and quick manual or automatic cleaning! – Absolutely low noise! – Start with fully loaded mixer is possible without any problems! – Versatile application! Mixing of concrete of any texture, steel fibre concrete, SCC and UHPC, air-entrained concrete, polystyrene concrete, mortar, any dry bulk products, sludge, dusts, etc.
High efficiency through: – – – – – –
short mixing and discharge cycles short cleaning times cement and pigment savings reduction of waste low maintenance effort reduced wear and tear surfaces
With the independent speed control of the two agitators, especially the inner agitator, liquid and earth-moist concrete can be produced by the cone mixer. It is ideally suited for special concrete such as UHPC and SCC, fibre concrete, lightweight concrete, heavy concrete, etc. The indefinitely variable control allows for precise adjustment for the respective mixing product. These optimisations significantly reduce the mixing time of such special concrete. Dry materials from dry mortar to food are also no problem for the cone mixer. Many educational establishments, material test centres and research institutes use this mixer as a laboratory mixer for the development of new special concrete.
In order to produce UHPC, the mixer can be equipped with a special agitator tool and a special drive with a speed of up to 1000 rpm. As a result, the mixing time can be reduced to as low as approx. 2 minutes.
Another patent pending: “System for rinsing the mixer within a few seconds!
Laboratory Mixer Optimal mixing effect thanks to the proven 4-dimensional mixing principle Laboratory mixer KKM 30 and KKM 100
Special design with special tool + high speed
suitable for special concrete, SCC, UHPC, dry mixing products, etc.
KKM 100/150 mobile
Special Mixer for UHPC
Small plant for testing and production, extendible with Big-Bag stations, bag feeding hoppers, day-silos, etc.
st r i f d l r o w
KKM-RT 15/22,5 (stainless steel) Laboratory intensive mixer KKM-RT 15/22,5 with integrated rheometer and tribometer The Kniele KKM-RT 15/22,5 combines a laboratory intensive mixer with a rheometer that provides the rheological properties of the mixture in either relative or absolute units. A mixer probe for moisture analysis and a dosing unit for addition of liquid components expands the scope an enables automated parameter studies of mix development. Samples of various concrete types, of any quality and quantity, can be produced with this mixer to carry out classic fresh concrete tests such as slump spread, slump flow measure, VdZ/ German Cement Plant Association) funnel, LCPC box, etc. Material discharge and mixer cleaning – Almost all of the mixture drops into a previously positioned container beyond the mixer under the influence of gravity. – Following the discharge of the mixture, the flap is closed, the drum is filled with water and the mixing tools are run at high speed. Deposits on the mixing tools come off and are carried out with the water when the closure flap is reopened.
Overview with lifting tool
Mixing tool To increase mixing intensity, minor improvements were made to the conical mixer’s mixing tool. The disagglomeration of fine materials and the separation of fine fibres will be significantly improved and accelerated with the arrangement of short pins on the outer edges of the mixing paddles. Drives and function as a rheometer (relative measured values) – Synchronous torque drive for low speed / torque control – Oscillating measurements with quick changes of the sense of rotation Function as a rheometer for the determination of measurement values in absolute units – Speed-controlled mode – Torque-controlled mode – Oscillating measurements with sinus shaped change in rotation direction
Quick-change rheometer
Function as a tribometer – To determine the pumpability of a concrete Mixer - composite view
Mixer probe – To check and control the average water/binder ration, even when using materials with variable inherent moisture Camera to observe the mixing procedure
Quick-change mixing tool
Special Plants, e.g. in stainless steel design
Production of UHPC and suspensions
e.g. for food and pharmaceutical pre-products, chemical industry, EXX protection
UHPC plant
Mixtures, e.g. with epoxy resin, cold bitumen, etc.
Mobile Mixing Plants
Mobile train plants
Production of concrete and glass terrazzo
Mobile mixing plants and special mixing plant construction KNIELE mixing plants in mobile and partly mobile design are the solutions for concrete production at any time and any place. Even if designed the same way, stationary and semi-mobile plants differ because of the specific techniques of connecting the parts of the plant, which enable an easy assembly and disassembly of the semi-mobile plants. This is also true for the electronics, water supply and pneumatics. With semimobile plants, the transport dimensions for problem-free road transport are of course observed. Entirely mobile plants can be mounted onto railway wagons and can thus be transported to their destination every day. Some data: – Output of the plant 30 – 100m3/h – Storage of 3 x 60 t of cement – Storage of aggregates in row-type silos, 4 – 6 chambers, 10 – 30 m3 each Thanks to the integrated steel foundations of our mobile mixing plant, the foundationrelated and installation-related work can be reduced to a minimum.
We develop the right solution for each and every individual case. Expertise and the co-operation with the customer are what is needed here.
Dry Mortar Plants
Dry and wet mixing plant
Sack filling unit
Bag feeder with screening unit
Conversion, Reconstruction, Modernisation Today and in future, securing the location of existing plants is very important. Conversion, reconstruction, expansion or modernisation performed by KNIELE raises the standard of the plant and, thus, increases competitiveness. Our flexibility, know-how and our qualified staff enable us to perform disassembly, conversion or expansion of an existing plant as well as the putting into operation of a new plant in a very short time. These are our strengths!
Reconstruction
Block plant conversion Block plant conversion – cone-type mixer for pipe production
Elevators KNIELE elevators: bucket hoists (standard), alternatively buckets with bottom dump discharge!
Standard equipment of an elevator: – quality drive separately borne cable reel with track grooves, automatic valve for feeding of the mixer, all required switches, incl. emergency-stop and slackline switch. Material elevator with selectable inclination (25° to 90°)
Special equipment: – – – – –
elevator with pole-changing motor or frequency controlled double diversion valve for distribution into two mixers plunge-protection designed as an aggregate weigher extended track – straight or buckled
Fall protection for material elevators: (for bucket hoist elevators) The abrasion and overload protection is designed to prevent falling during elevation. This newly developed device will – in case of overload or abrasion of the cable – switch off the driver or provoke a signal to prevent the bucket falling.
Modification Elevator with bottom dump discharge bucket
Elevator with bucket hoists
The many different adaptation options enable us to meet the highest demands and requirements.
Weighing Systems
Row-type silo with mobile batcher
Cone mixer with water batcher
Cement batcher – additional container for white cement – – double distribution valve for aggregates –
to weigh
Batcher for additives – 2 chamber design –
Colour dosing for granulate with temporary silo
The fully automatic weighing system for aggregates, binders, water and additives can be officially certified and ensures a constantly high productivity. Aggregate batchers
Row-type silo with weighing belt
– as container or belt batcher, or mobile batcher – can be equipped with an Cement batchers additional container for white cement Water batchers – for fresh water and sewage, alternatively available as negative weighing system with coarse/fine dosing Mixer weighing system – for weighing additives directly inside the annular tray mixer AFE mixer weighing system – anhydrite mixer designed as a weigher Batchers for additives – in 1 to 4 chamber design Steel fibre dosing plant – designed a weigher Colour dosing weigher – simple design for granulate and powder
Weighing belt
Dosing Exact dosing of the aggregates is normally effected by dosing valves; alternatively, coarse or fine dosing is possible. Dosing can also be effected by belts or vibrating chutes.
Control system
Container weigher for gravel/sand
The computer control system of the plant allows for a fullyautomatic operation. Thanks to the user-friendly design, the operation of the plant requires very few workers. The highly sensitive sensors deliver all information on the plant states at any time. This includes, for example, moisture probes for the sand chambers and the texture measurement in the mixer or also the filling level monitoring of the binder and aggregate silos.
Components Production of prefabricated flowing screed The individual components of prefabricated flowing screed are weighed automatically in the mixing plant, thus a constant quality can be achieved. A special mixer with a fast agitator – designed as a weigher – was developed for the mixing of the glue. Mixing tray, agitator and cover of the mixer are entirely made of high-grade steel. In series, the cover of the mixer is equipped with an automatic cleaning system. A specially designed recycling plant (AFE) was developed for the utilisation of the remaining water.
B
øA
Dimensions:
Type
FL 1800
FL 1800S
FL 2500
A (mm)
1600
1300
1600
B (mm)
2550
2995
2900
Accessories – automatic mixer cleaning at the push of a button! – forced dust extraction – cement silos with complete accessories – aggregate silos of any type and size – day silos for special aggregates – Big-Bag discharge stations – conveyor belts, dosing belts – elevators – remaining water utilisation in the concrete products industry (RC plant) – steel fibre dosing plants – PP fibre dosing – steam injection in the mixer
Camera mounting
Central cement silo filling station
Cornering waggon
Row-type silo with hydraulic cover
Day silos with vibro chute
Fibre dosing
Mixer deduster
Equip
Bucket for SCC and UHPC
Big Bag station
Concrete pump with pigging station and cone mixer with squeeze valve
Material feed hopper
KNIELE Baumaschinen GmbH
MISCHTECHNIK
Industriegebiet Kappel Gemeindbeunden 6 D-88422 Bad Buchau Germany
Phone +49 7582 9303-0 Fax +49 7582 9303-30
email: info@kniele.de web: www.kniele.de
How to find us
For detailed information on our products, please contact us. The information contained in this brochure is nonbinding. Only the provisions stipulated in the contact of delivery are applicable. We reserve the right to change the systems and mixing plants described in this brochure without notice.
MIXING TECHNOLOGY