30TPH-60TPH Dry Mortar Production Line Full Automatic Remote Monitoring
1. Product Introduction Dry powder mortar, also known as ready-mixed mortar, is made in the factory by precise batching and uniform mixing. It can be used directly by adding water on the construction site. Although different additives are added, it has different properties. The dry powder mortar ...
60TPH Dry Mortar Production Line
,30TPH Dry Mortar Production Line
,60TPH dry mortar production
1. Product Introduction
Dry powder mortar, also known as ready-mixed mortar, is made in the factory by precise batching and uniform mixing. It can be used directly by adding water on the construction site. Although different additives are added, it has different properties. The dry powder mortar plant has a production capacity of 15-150t/h. It can be fully automatic or semi-automatic. The plant structure type can be simple, automatic, or tower type. It depends on the customer workshop area.
The production line adopts a modular design, equipped with a high-precision weighing and batching system and a twin-shaft non-gravity mixing host. It features high mixing uniformity, low residue, and fast speed, ensuring stable and consistent product quality. The whole machine is equipped with an intelligent PLC control system, which is easy to operate and reliable in operation. It supports free switching of multiple formulas to meet the needs of multi-variety, small-batch or large-scale production.
With fully enclosed conveying from raw material drying and screening, metering and batching to mixing and packaging, together with a pulse dust removal device, the line effectively reduces dust pollution and meets environmental protection requirements. Featuring a compact structure, reasonable layout, small footprint, and convenient installation and maintenance, it is widely used in building materials factories, mortar stations, precast component factories and other scenarios. It is an ideal solution for improving production efficiency, reducing production costs, and realizing industrialized production of dry-mixed mortar.
The large dry powder mortar production line includes a sand dryer and vibrating screen, storage bin, conveying system, weighing batching system, mixer, packaging machine, dust collector, and control system. According to customer requirements, we can design individual production processes.
1. Dryer
Role:Dry sand and gravel raw materials, reduce material moisture content, avoid caking and failure of sensitive admixtures, and guarantee the flow and leveling performance of self-leveling mortar.
Key Selection Criteria:Adapt to dry mortar drying conditions with low particle degradation, precise temperature control, excellent air tightness and high thermal efficiency; equipped with wear-resistant inner liner to match overall production capacity.
2. Vibrating Screen
Role:Filter impurities and oversized particles, grade sand materials to optimize aggregate gradation, prevent coarse particles from affecting mortar quality and damaging subsequent precision equipment, and ensure raw material uniformity.
Key Selection Criteria:Adopt fully enclosed dust-proof structure, equipped with wear-resistant and anti-clogging screen mesh; feature high screening efficiency and stable grading accuracy to meet fine batching standards for self-leveling mortar.
3. Bucket Elevator
Role:Vertically transport dried and screened powders and sand to pre-mixing hoppers and silos, ensure continuous material supply; enclosed conveying effectively reduces particle degradation and segregation.
Key Selection Criteria:Adopt enclosed chain-type design with gentle low-speed handling to prevent particle damage; equipped with wear-resistant buckets, good sealing and anti-deviation & anti-blocking protection devices.
4. Silos
Role:Store bulk materials such as cement, gypsum and special fillers with moisture and dust protection, ensure continuous and stable material supply for the production line.
Key Selection Criteria:Capacity matches production volume; prioritize humidity control and anti-bridging devices for gypsum-containing materials; equipped with level monitoring and top dust removal system with anti-corrosion inner wall.
5. Screw Conveyor
Role:Complete horizontal material transfer between process stages, stably convey raw materials from silos to metering equipment and mixers, and realize uniform feeding with minimal segregation.
Key Selection Criteria:Adopt U-trough structure with Hardox 450 wear-resistant lining and anti-segregation design; stainless steel material for material contact parts with excellent sealing performance for powder conveying.
6.Weighing Scale
Role:Realize ultra-precise automatic batching for main materials (cement, sand, gypsum) and micro-additives (cellulose, superplasticizers, defoamers) to ensure consistent formula and batch-to-batch product stability.
Key Selection Criteria:Main material batching accuracy: ±0.2%; micro-additives adopt loss-in-weight feeders and anti-bridging micro-screw feeders with ±0.1% high precision; full stainless steel structure for multi-formula precise batching.
7. Mortar Mixer
Role:As the core equipment of the production line, it homogeneously blends all ingredients, preserves the functional integrity of sensitive components and particle size distribution, and ensures the excellent flow and leveling performance of finished mortar.
Key Selection Criteria:Adopt high-shear twin-shaft paddle structure with gentle yet intensive mixing effect; optimized blade design for special mortar formulations; Hardox 500 carbide overlay wear-resistant parts with complete discharge capacity and homogeneity coefficient CV ≤ 2%.
8. Finished Product Silos
Role:Serve as buffer storage before packaging, maintain finished product uniformity, avoid secondary material segregation, and ensure continuous and stable packaging operation.
Key Selection Criteria:Equipped with fluidized bottom and anti-segregation cones, with real-time level monitoring device for continuous automatic production.
9. Packing Machine
Role:Automatically fill finished self-leveling mortar into valve bags with precise weighing, realize automatic packaging, and avoid material segregation and dust pollution during packaging.
Key Selection Criteria:Valve bag packing capacity: 25-40 bags/hour with ±0.1% weighing accuracy; integrated dust collection and anti-segregation feeding design to ensure consistent product quality after packaging.
10.Palletizing Equipment
Role:Automatically stack filled mortar bags on pallets in standard and precise patterns, facilitate storage and transportation, reduce labor cost and maintain bag integrity.
Key Selection Criteria:Robotic palletizer is suitable for high-volume lines with capacity of 400-800 bags/hour; gentle handling design to avoid bag damage with accurate and stable stacking effect.
11. Steel Structure
Role:Serve as the overall supporting frame of the production line, carry all main equipment such as silos, mixers and conveying equipment, fix equipment layout, ensure stable operation and accurate installation, and provide safe operating platforms.
Key Selection Criteria:Adopt national standard load-bearing section steel with high safety factor, suitable for tower-type production line layout; overall anti-corrosion and weather-resistant design with complete anti-slip platforms and safety protection facilities to meet industrial safety production standards.
12. Dust Collector
Role: Collect dust generated from each production process, prevent dust leakage, purify working environment, reduce material loss and meet environmental emission standards.
Key Selection Criteria: Adopt pulse bag type with high dust removal efficiency. Match air volume of production line, wear and corrosion resistant filter bags. Good sealing performance, convenient ash cleaning and qualified exhaust emission.
2. Core Highlights
- High-precision Intelligent Batching System: Equipped with imported digital weighing sensors, the batching accuracy is controlled within ±0.3%. It supports storage of 50+ production formulas, realizing one-click switching between tile adhesive, wall putty, insulation mortar and other products, avoiding material waste caused by manual proportioning errors.
- Zero-dead-angle Twin-shaft Gravity-free Mixer: The core mixing host adopts bidirectional spiral stirring structure. The mixing cycle is only 3-5 minutes per batch, with mixing uniformity up to 99.7%. No material residue inside the mixing bin, effectively preventing raw material cross-contamination between different mortar products.
- Full-process Environmental Protection Dust Removal Design: Matching pulse bag dust collectors at feeding, mixing and packaging positions. The overall workshop dust emission concentration is far below international industrial environmental protection standards, meeting EPA, CE and local construction machinery environmental inspection requirements in Europe, Southeast Asia and other regions.
- Low Operation Cost & High Stability: Optimized power distribution reduces overall energy consumption by 18% compared with peer equipment. Key wearing parts adopt wear-resistant alloy steel, with service life extended by 2 times. The whole line only needs 2-3 operators to complete full production monitoring, greatly cutting labor costs.
- Customized Flexible Configuration: Free matching of small-batch simple type, medium-standard automatic type and large-scale intelligent centralized type production lines. Supporting automatic palletizing machines, bulk delivery systems and sand drying systems according to customer site conditions.
3. Detailed Technical Specifications
| Item | Mini Type (5-10t/h) | Standard Type (15-30t/h) | Large Automatic Type (30-60t/h) |
|---|---|---|---|
| Hourly Output | 5-10 tons | 15-30 tons | 30-60 tons |
| Total Installed Power | 75KW | 132KW | 215KW |
| Mixing Cycle | 4-5min/batch | 3-4min/batch | 2.5-3min/batch |
| Batching Accuracy | ±0.5% | ±0.3% | ±0.2% |
| Operation Mode | Semi-automatic | Full automatic | Full automatic + remote monitoring |
| Packaging Mode | Valve bag manual auxiliary packing | Automatic valve bag packing | Automatic packing + automatic palletizing |
| Occupied Area | 600㎡ | 1200㎡ | 2000㎡ |
| Working Voltage | 380V/50Hz | 380V/50Hz | 380V/50Hz |
Product Parameters
| Item | Fully automatic dry mix mortar production line |
| Capacity | 15-150 tons per hour |
| Application | Bonding mortar, Masonry mortar, Decorative mortar, Protective mortar, waterproof mortar |
| PLC | Siemens |
| Electric parts | Siemens |
| Weighing sensor | Toledo |
| Number of Silo | 2-5 sets |
| Bucket elevator | Plate chain bucket elevator |
| Screw conveyor | Italy brand, or Sicoma brand |
| Silo capacity | 100 tons |
| Additive system | Automatic control |
| Weighting tolerance | aggregate within +/- 1%, additives: within 20g |
4. Application Scenarios
- General Construction Mortar Production: Masonry mortar, plastering mortar, waterproof mortar, crack-resistant mortar for residential buildings, commercial buildings and infrastructure projects.
- Decoration Special Mortar: Tile adhesive, tile grout, wall putty powder, interior and exterior wall thermal insulation mortar for home decoration and engineering decoration project
- Floor Engineering Materials: Floor self-leveling mortar, ground hardener, repair mortar for industrial workshops, parking lots and commercial floor construction.
- Supporting Production for Building Material Factories: Standardized finished dry mortar supply for local construction markets, building material distributors and engineering contractors.
- Prefabricated Building Supporting Projects: Special dry mortar matched with precast concrete components to meet high-standard assembly construction requirements.
5. Operation & Maintenance Precautions
5.1 Daily Operation Notes
- Strictly prohibit hard foreign matters (iron blocks, stones, steel bars) from entering the mixing host to avoid damage to mixing blades and cylinder lining plates.
- Check the weighing system zero calibration before starting the machine every day to ensure accurate batching data and avoid unqualified mortar proportion.
- Do not open the mixing cabin door during equipment operation to prevent material splashing and personal safety accidents.
- Feed materials in strict accordance with the preset formula; do not arbitrarily add excessive water-retaining agents, adhesives and other additives.
5.2 Regular Maintenance Notes
- Clean residual materials inside the mixer and packaging machine after daily shutdown to prevent dry powder caking affecting next mixing effect.
- Replace dust filter bags every 3-6 months regularly to guarantee stable dust removal efficiency and unobstructed ventilation of the whole line.
- Add lubricating oil to reducers and bearing parts every 15 days to reduce mechanical wear and extend equipment service life.
- Cut off the total power supply during long-term shutdown, and cover the whole equipment with waterproof cloth to avoid moisture erosion of electrical components.
5.3 Site Environment Requirements
The production workshop shall keep dry and ventilated; avoid working in high-humidity and rainy environment for a long time to prevent raw material damp caking. The ground of the workshop needs to be hardened with concrete to bear the weight of silos and main equipment.
6. Frequently Asked Questions (FAQ)
1: What kind of terms of payment can be accepted?
A: L/C, T/T, Western Union could be accepted.
2: Can I visit your factory and your customer factory?
A: Yes, You can come by yourself or ask your friend in China to come to our factory or customer's factory.
3: What about the delivery time?
A: 7-35 days after receiving the deposit. According to the number of non-standard parts.
4: What about the warranty time?
A: 12 months after shipment or 2000 working hours.
5. What about the Minimum Order Quantity?
A: The MOQ is 1 pcs.
6. I don't have the formula, can you send me one?
A: Yes, we have more than 500 customers through these years, and our customers are willing to tell us their formulas.
