Simpac 2000 Brochure
Simpac 2000 Modular Concrete Products Machine
SIMPAC 2000 DISCRIPTION
MODULAR CONCRETE PRODUCTS PRODUCTION SYSTEM
The SimTec Modular Concrete Production Machinery has been developed specifically to manufacture the Simbloc Mortarless Concrete Block Building System.
Mortarless concrete blocks have existed since the early 1900’s and have experienced limited success due to the inability to manufacture these products at accurate height tolerances productively . Most production machinery today can only achieve product height tolerances in a range of + or – 3mm. This variance creates an inability to place these mortarless blocks evenly and as a result the layers of block form uneven stacking. This creates both visual and structural difficulties in constructing walls. Constant adjustments by shimming blocks have to made to maintain consistency in the elevation of the walls.
The Simpac 2000 Concrete Press is a development that has resulted in achieving product height accuracy within a range of + or – 1mm. This type of consistency is unheard of in concrete block manufacturing equipment. The height control system is a patented design that through a combination of mechanical and computerized controls maintains accuracy while still being a highly productive system.
The machinery offered includes a complete manufacturing package with aggregate handling, cement handling, batch control, mixing, concrete press operation, automated pallet handling, material handling, cubing and curing systems. Generally in developing countries the amount of investment in machinery is balanced between lower cost labor functions that can be accomplished more economically manually than with automated production. An analysis can be done to determine the cost effectiveness of each component of the production package to adjust the investment according to labor value and the efficiency of the plant.
New Tec Building Products Inc. the owner of the Sim Machinery line and the Simbloc system and is prepared to work together with companies interested in our technology to establish production centers anywhere in the world. We can offer complete plant implementation by providing financing, installation, training and on going service. We have established many joint venture agreements that have resulted in successful companies that are manufacturing and using our technology.
Production capacity is determined by multiplying the cycles per hour of the Simpac 2000 concrete press with the number of products per cycle. 10cm blocks are 6 per pallet / cycle, 15cm are 4 per pallet and 20cm are 3 per pallet. Pavers are calculated at 0.25 sq meters per pallet.
The following pages provides details about the various components of a typical production concrete block system.
SIMTEC MACHINERY
MODULAR CONCRETE PRODUCTS PRODUCTION SYSTEM
SIMPAC 2000 CONCRETE BLOCK PRESS
This concrete block machine has a production area is 60 cm by 45 cm, production height is 5 cm to 25 cm and a capacity is 200 to 250 cycles per hour dependent on product difficulty and with or without face mix and automation.
The press package includes the following equipment
Table vibration
Two high and variable frequency ER 705 Dyna Pac vibrators in Tandem to provide synchronized vibration of high frequencies which is gives high intensity vibration for high density product requirements. Braking capacity for more efficient cycle time.
Head vibration
One independent variable frequency ER 705 Dyna Pac vibrators to provide synchronized vibration of high frequencies The vibrators is mounted in a separate head unit and provides braking capacity for more efficient cycle time.
Hydraulic system
One 15 hp high pressure Miller Vane pump with separate 200 liter hydraulic tank tank for large oil capacity. New Miller fluid power 5 station NFPA control valve manifold for press circuit. Control valving will provide smooth efficient operation of all press functions. All cylinders are Miller high pressure to provide quality operation.
Electrical system
Electrical system has Allen Bradley 1747 - L532 processor to control all press functions. Automated control of press made smooth and easy for complete control of the press operations and programming. Variable speed frequency Allen Bradley 1305 drives for vibrator controls. All motors protected by not fused circuit breakers and overloads. Control panel provided to for easy access for the operation of the machine.
OPTIONAL FACE MIX ATTACHMENT
This press attachment for the front of the press provide the capacity to add a layer of specialized concrete mix to the top surface of pavers and slabs. This provides a great cost reduction especially with color additives.
PALLET HANDLING SYSTEM
Automated pallet conveyor feeds pallets to the press pallet hopper, and a automated pallet discharge conveyor feeds finnished product on pallets to the a staging area..Pallet elevator indexes pallets into seven layers of 2 pallets ready for transporting with the forklift truck.
PRODUCTION PALLETS
2000 Baltic birch 13 ply hardwood plywood production pallets 48 x 73 cm
PALLET RACKS
75 Steel pallet racks designed for durable long term handling, storage and curing of product. Two pallet transfer racks to move pallets from the elevator to curing racks
PRODUCTION MOLDS
These molds are manufactured from high strength durable Swedish steel. Each mold is made within a tolerance of one millimeter for accurate product delivery
Block molds are 10 cm, 15 cm and 20 cm, 25cm & 30cm widths. Paver, Curb,floor block molds are also available.
SIM MIX 1000 MIXING AND BATCHING EQUIPMENT
MIXER
Sim Tec 1000 twin shafted 30 hp mixer, with a capacity to deliver 1000 kg of homogenous zero slump concrete in four minute cycles. Air operated mixer gate for easy operation of mixer gate.
BATCH PANEL
Includes mixer control and feed control panel for complete batch control. Allen Bradley PLC controller automated batching concrete with water dispensing and sensing, timer controlled volumetric conveyor feeders and mixer feed conveyor.
PRESS CONVEYORS
One 6 meter long and 60 centimeter wide belt incline conveyor to transfer from the mixer to the press hoppers complete with 20 degree troughing idlers and 2 HP gear drive unit.
One 2 meter long with 45 centimeter wide belt conveyor to feed the face mix hopper or face mix hopper complete with 20 degree troughing idlers and 1 HP gear drive unit.
AGGREGATE CONVEYORS
One 10 meter long with 60 centimeter wide belt with 20 degree troughing idlers and 2 HP gear drive unit incline transfer conveyor delivering 1000 kgs. per minute to the mixer.
Two 3 meter long with 45 centimeter wide belt with 20 degree troughing idlers and 2 HP gear drive unit horizontal hopper conveyors delivering 500 kgs. of aggregates per minute to weigh hopper.
AGGREGATE HOPPERS
Two 20 tonne hoppers designed for ground loading and easy access. Modular bolt together container sized hoppers compatible for transfer conveyors.
AIR COMPRESSOR
10 HP Ranger / Ingersoll Rand 80 gal tank air compressor
MATERIAL HANDLING EQUIPMENT
FORKLIFT TRUCKS
Competitively priced 5000 LB capacity pneumatic tires, propane powered, inside outside forklifts
with side shift and block handling forks.
The SimTec Modular Concrete Production Machinery has been developed specifically to manufacture the Simbloc Mortarless Concrete Block Building System.
Mortarless concrete blocks have existed since the early 1900’s and have experienced limited success due to the inability to manufacture these products at accurate height tolerances productively . Most production machinery today can only achieve product height tolerances in a range of + or – 3mm. This variance creates an inability to place these mortarless blocks evenly and as a result the layers of block form uneven stacking. This creates both visual and structural difficulties in constructing walls. Constant adjustments by shimming blocks have to made to maintain consistency in the elevation of the walls.
The Simpac 2000 Concrete Press is a development that has resulted in achieving product height accuracy within a range of + or – 1mm. This type of consistency is unheard of in concrete block manufacturing equipment. The height control system is a patented design that through a combination of mechanical and computerized controls maintains accuracy while still being a highly productive system.
The machinery offered includes a complete manufacturing package with aggregate handling, cement handling, batch control, mixing, concrete press operation, automated pallet handling, material handling, cubing and curing systems. Generally in developing countries the amount of investment in machinery is balanced between lower cost labor functions that can be accomplished more economically manually than with automated production. An analysis can be done to determine the cost effectiveness of each component of the production package to adjust the investment according to labor value and the efficiency of the plant.
New Tec Building Products Inc. the owner of the Sim Machinery line and the Simbloc system and is prepared to work together with companies interested in our technology to establish production centers anywhere in the world. We can offer complete plant implementation by providing financing, installation, training and on going service. We have established many joint venture agreements that have resulted in successful companies that are manufacturing and using our technology.
Production capacity is determined by multiplying the cycles per hour of the Simpac 2000 concrete press with the number of products per cycle. 10cm blocks are 6 per pallet / cycle, 15cm are 4 per pallet and 20cm are 3 per pallet. Pavers are calculated at 0.25 sq meters per pallet.
The following pages provides details about the various components of a typical production concrete block system.
SIMTEC MACHINERY
MODULAR CONCRETE PRODUCTS PRODUCTION SYSTEM
SIMPAC 2000 CONCRETE BLOCK PRESS
This concrete block machine has a production area is 60 cm by 45 cm, production height is 5 cm to 25 cm and a capacity is 200 to 250 cycles per hour dependent on product difficulty and with or without face mix and automation.
The press package includes the following equipment
Table vibration
Two high and variable frequency ER 705 Dyna Pac vibrators in Tandem to provide synchronized vibration of high frequencies which is gives high intensity vibration for high density product requirements. Braking capacity for more efficient cycle time.
Head vibration
One independent variable frequency ER 705 Dyna Pac vibrators to provide synchronized vibration of high frequencies The vibrators is mounted in a separate head unit and provides braking capacity for more efficient cycle time.
Hydraulic system
One 15 hp high pressure Miller Vane pump with separate 200 liter hydraulic tank tank for large oil capacity. New Miller fluid power 5 station NFPA control valve manifold for press circuit. Control valving will provide smooth efficient operation of all press functions. All cylinders are Miller high pressure to provide quality operation.
Electrical system
Electrical system has Allen Bradley 1747 - L532 processor to control all press functions. Automated control of press made smooth and easy for complete control of the press operations and programming. Variable speed frequency Allen Bradley 1305 drives for vibrator controls. All motors protected by not fused circuit breakers and overloads. Control panel provided to for easy access for the operation of the machine.
OPTIONAL FACE MIX ATTACHMENT
This press attachment for the front of the press provide the capacity to add a layer of specialized concrete mix to the top surface of pavers and slabs. This provides a great cost reduction especially with color additives.
PALLET HANDLING SYSTEM
Automated pallet conveyor feeds pallets to the press pallet hopper, and a automated pallet discharge conveyor feeds finnished product on pallets to the a staging area..Pallet elevator indexes pallets into seven layers of 2 pallets ready for transporting with the forklift truck.
PRODUCTION PALLETS
2000 Baltic birch 13 ply hardwood plywood production pallets 48 x 73 cm
PALLET RACKS
75 Steel pallet racks designed for durable long term handling, storage and curing of product. Two pallet transfer racks to move pallets from the elevator to curing racks
PRODUCTION MOLDS
These molds are manufactured from high strength durable Swedish steel. Each mold is made within a tolerance of one millimeter for accurate product delivery
Block molds are 10 cm, 15 cm and 20 cm, 25cm & 30cm widths. Paver, Curb,floor block molds are also available.
SIM MIX 1000 MIXING AND BATCHING EQUIPMENT
MIXER
Sim Tec 1000 twin shafted 30 hp mixer, with a capacity to deliver 1000 kg of homogenous zero slump concrete in four minute cycles. Air operated mixer gate for easy operation of mixer gate.
BATCH PANEL
Includes mixer control and feed control panel for complete batch control. Allen Bradley PLC controller automated batching concrete with water dispensing and sensing, timer controlled volumetric conveyor feeders and mixer feed conveyor.
PRESS CONVEYORS
One 6 meter long and 60 centimeter wide belt incline conveyor to transfer from the mixer to the press hoppers complete with 20 degree troughing idlers and 2 HP gear drive unit.
One 2 meter long with 45 centimeter wide belt conveyor to feed the face mix hopper or face mix hopper complete with 20 degree troughing idlers and 1 HP gear drive unit.
AGGREGATE CONVEYORS
One 10 meter long with 60 centimeter wide belt with 20 degree troughing idlers and 2 HP gear drive unit incline transfer conveyor delivering 1000 kgs. per minute to the mixer.
Two 3 meter long with 45 centimeter wide belt with 20 degree troughing idlers and 2 HP gear drive unit horizontal hopper conveyors delivering 500 kgs. of aggregates per minute to weigh hopper.
AGGREGATE HOPPERS
Two 20 tonne hoppers designed for ground loading and easy access. Modular bolt together container sized hoppers compatible for transfer conveyors.
AIR COMPRESSOR
10 HP Ranger / Ingersoll Rand 80 gal tank air compressor
MATERIAL HANDLING EQUIPMENT
FORKLIFT TRUCKS
Competitively priced 5000 LB capacity pneumatic tires, propane powered, inside outside forklifts
with side shift and block handling forks.