ELKON- The First and The Biggest Mobile Concrete Batching Plant Manufacturer in Turkey

The studies for creating more economic or technological solutions for the increasing demands of human beings, are variable and increasing. This situation is not different for construction equipment manufacturing in construction sector. ELKON who has been manufacturing construction machineries ( concrete batching plants ) and presenting important technological solutions to the sector since 1975. Definitely, one of these solutions is Mobile Concrete Batching Plants.

Traffic jam in crowded metropolises and it’s consequences like ; losses in time and work while transporting the concrete from the manufacturing points to the construction sites; small projects which is not worth to set up a concrete batching plant, increasing demands like finding concrete whenever it is needed in construction site were the main reasons for ELKON to start the Mobile Concrete Batching Plant project in 1999. With his great experience and technological background, R&D, project and prototype studies were completed in 2000. In 2001, Elkon manufactured ELKON MOBILE MASTER-100 Fully Automatic Mobile Concrete Batching Plant which is the first mobile concrete batching plant in Turkey and exported it to Mezamet, France. These studies were improved and Elkon started manufacturing of another model ELKON MOBILE MASTER-60 Mobile Concrete Batching Plant in 2002.

ELKON MOBILE CONCRETE BATCHING PLANTS (MOBILE MASTER SERIES)

Manufacturing a fully functional mobile concrete batching plant requires a serious experience, technological production and design facilities and engineering ability. Because It should be accomplished to fit all units of a concrete batching plant in a limited area  while they fulfill all functions that are required for the concrete production and work harmoniously. Moreover the mobile concrete batching plant should fulfill all all safety requlations. A mobile concrete batching plant which is manufactured by ignoring the above mentioned features, will not be a real mobile concrete batching plant. It will be mobile just in appearance. Up to 2005, Elkon was the only mobile concrete batching plant manufacturer in Turkey and by today Elkon is not only the biggest mobile concrete batching plant manufacturer in Turkey but also one of the biggest mobile concrete batching plant manufacturers in Europe.

In Elkon Mobile Concrete Batching Plants, the mentality of esthetic and functional design is considered while manufaturing all units from aggregate silo to concrete discharging chute. In other words Elkon Mobile Concrete Batching Plants weigh and transfer the aggregates with the same conveyor (cycle time gets shorter, the angle of the conveyor stays at the proper angle and capacity increases), platforms that are need for the maintenance of the weight batcher and conveyor are equipped with ladders, conveyor is cleaning by the means of belt cleaner driven with the motor of  transfer conveyor, the transfer of the cement from integrated cement silo is made by the means of semi-open cement screws which are at the same length with the integrated cement silo. (This application exists in only Elkon Mobile Master-60 Mobile Concrete Batching Plant). In most of the mobile concrete batching plants, the transferring of the cement from the built-in cement silo is made from just 1 point. In this case the problem is, 40 % cement will remain (can not be transferred)  in the integrated cement silo because of the geometric structure of it.) Moreover  Elkon concrete batching plants are equipped with centralised lubrication system (which is also exist in only Elkon Concrete Batching Plants)  and  integrated cement silo is equipped with paraphets to provide maintainence easiness. Mixer is surrounded by galvanized maintenance platforms in order to provide full Access to all maintenance points. Operator cabinets of concrete batching plants are equipped with necessary furnitures, heater and air conditioner and  is manufactured from polyurethane material in order to provide isolation even at  – 30 C°. Also It’s designed to provide a wide view to operator during the production. According to type of the concrete which will be produced, Elkon manufactures his mobile concrete batching plants with Twinshaft or Pan Type Mixer. In Elkon Concrete Batching Plants, world wide known-realible components are used.

ELKON MANUFACTURING TECHNOLOGIES

It is not easy at all for the customer to choose the most appropriate supplier among many of them. Because concrete batching plants are investment products and it is necessary to be very careful in this subject. Choosing the wrong supplier causes irremeable consequences. So that there is need to make the decisions according to evaluation of the parameters like experience, technical sources, skills, manufacturing technologies, components and engineering solutions.

COMPUTER AIDED DESIGN

ELKON, who has wide R&D and project design departments, uses CAD programmes in all his designs. Through this way, error rate is decreased to zero and millimetric accuracy is reached in manufacturing. Simulation, static and dynamic analysis of new designed products can be actualized by these programmes. Also, accurate components are produced by special machineries using CAM.

MATERIAL PREPARATION

Human factor has a great effect on final product. Because concrete batching plant manufacturing is an effort based sector. Minimizing this effect means making the process indepented from human effect as much as it’s possible and standardizing the parts. Laser technology is applied to cut and to pierce the parts which will be used in manufacturing process. Thus it’s possibile to get sensivity. After this process, chemical surface cleaning operation is applied to these parts they will be ready to be used in manufacturing process.

 
MANUFACTURING AND CONTROL PROCESSES

As we mentioned before, human factor has an effect on final product. This issue is also valid for equipment preparation and manufacturing processes. Elkon succeded not only isolating the manufacturing process from human factor but also to reach high sensitivity in the production with the special moulds and tools that he designed. For instance the mixers, the panels of aggregate silos, cement silos, manufacturing of the metal construction of winterized covering. Moreover Elkon mostly prefers bolted type connections in his production. Bolted type connections is not only proof of the sensitive production but also provide resistent structure which can be easily interfered. Also there will be no defection in the materials on the connection points as it’s in the welding technic. In addition to this It provides great advantage to the customer during the transportation. (It’s possible to make more reliable and cheaper packaging)

The control system is very important to continue the manufacturing process in a high quality. Many local or foreign manufacturers work with subcontractors to reduce the costs. In this method, responsibility of some processes are being assigned to other manufacturers so that the control chain is broken. ELKON takes over all responsibility thereby producing all units from aggregate bunkers to cement silos. With this specialty Elkon becomes the only manufacturer in Turkey and one of the biggest manufacturers all over the world.

PAINTING AND GALVANIZATION

Parts manufactured in special moulds and tools, are being galvanized and painted to have protection against corrosion. Processes which are seen as optional in Europe, are presented to customer as standard by ELKON. For example water weight batchers, additive wieght batchers, walking platforms, maintenance gates, paraphets, stairs and conveyor chassises are galvanized as a standard. Also ELKON uses JUTON brand epoxy primers and top coatings which have great resistance against corrosion. Dyeing process is being done in modern painting cabins. Each ELKON factories has two painting cabins.

COMPONENTS

ELKON goes on his technological, quality and reliable concrete batching plant manufacturing principle thereby using 2 parallel ways. 1. High manufacturing culture and 2. Choosing reliable, quality and proper components. Component selection requires serious experience and feedbacks. At the same time it is an optimization problem. For example if you manufacture a conveyor which will transfer a certain capacity sand, you should solve these problems: selecting the correct drum and roller, appropriate conveyor angle, type of conveyor, conveyor belt wideness and drive system.

ELKON prefers properly designed, high productive, reliable, and widely serviced components in his concrete batching plants. Also, this components’ reliability have been tasted by ELKON since 1975. For example ELKON uses world’s famous brands like: Brevini (Italy), WAM (Italy), FARBO (Italy), Duplomatic (Italy), Pirelli (Italy), Siemens (Germany), Beckhoff (Germany), Lincoln (Germany), Beka – Max (Germany), Telemequanic (France), Atlas Copco (Sweden), Jotun (Norway) etc. in his own concrete batching plants.

CONFORMITY WITH STANDARDS

Increasing numbers of concrete batching plant manufacturers creates competition. Manufacturers who is in cost-based mentality, want to reduce the cost thereby ignoring standards during the production. In other words, a designer has to consider safety of workmen, maintenance and repair easiness. For example, mixer gates should be equipped with safety switches; cement, water and additive weight batchers should be reached by stairs and should be equipped with platforms and paraphets. Unfortunately, ignoring these standards to reduce the cost is becoming widespread among European manufacturers. All regulations which required by CE and GOST-R standards are being applied to ELKON concrete batching plants carefully.

COMPLETENESS

If an investor hasn’t invested in concrete batching plant sector before, he may not have enough knowledge about this subject. This situation is being abused by many manufacturers. During the commercial offer preparation period, manufacturer convinces the customer that customer can produce many parts of the plant by himself  to reduce the cost. But for example, production of upper panels of aggregate silo, cement silos,supporting structures by customer is a completely wrong application. Because it would be the first time for the customer and it would be very difficult to produce the items at  reasonable costs,on time, with required quality and guarantee. However ELKON directs his customers, shows possible alternatives and helps about the scope of business. Furthermore ELKON carries out analysis for his customers for free.