At JA Plant we offer the latest technology with manufacturing expertise and tailor-make the best solutions for our clients on Mobile Batching Plant requirements.

In this article, we expand on some important and differentiating points regarding the electronic weighing and water system, and motor and gearboxes, used on our Mobile Batching Plants.

 

The Electronic Weighing function on our Mobile Batching Plants is driven by the latest technology and manufacturing excellence for best performance at all times

The Load Cells: 

Each mobile batching plant is fitted with two load cell shear beams. The load cell shear beams are fitted with permanent brackets which prevent them from moving around. This will enable the batching plant to be moved without damaging the load cells. Our process of calibrating and securing the load cells ensures that you will not be required to fasten them for use or movement, contrary to what is required when using ULP or bottle type load cells.

The fact that the load cells’ shear beams are fitted in a secure manner, means that this will prevent the load cells from any damage while in transport or loading the aggregate bin and will not require calibration to ensure the reading on the load cells are correct, each time after you have moved your mobile batching plant.

Each shear beam can take a maximum weight of 15 Tons. This makes provision for a 6m³ or a 9m³ load, depending on your mixer truck size.

The load cells are fitted in the front and back of the aggregate hopper, distributing the weight of the aggregate hopper evenly. The hopper is more balanced and gives a more accurate reading than the ULP or bottle type load cells, which are based on a 3-point reading basis. It is important to note that the slightest difference in the balance of the load cells can cause an inaccurate reading and have a negative impact on your mix design, often causing financial loss due to material loss.

The load cell shear beams are also more durable and shock durable than the ULP or bottle type load cells (which tend to be more sensitive and not as secured as the load cell shear beams.) Load cell shear beams also have an expanded lifecycle in comparison to bottle type load cells.

 

Other benefits of using load cell shear beams include:

• No re-adjusting or fastening of the load cell is required after each transportation of the mobile batch plant. This reduces the chance of damaging the load cells or the extra requirement to re-calibrate your load cells after you have moved your mobile batch plant. (Load cells are usually re-calibrated between one to two years, depending on your site requirements.)
• The load cell shear beams are easy to remove, should they need to be. Each load cell shear beam is fastened with four bolts only and is easily accessible.

 

Large Scoreboard For a TLB Operator

A manual mobile batch plant from JA Plant is fitted with a 5-digit LED large Scoreboard for easy access and visibility to the TLB operator.

The LED scoreboard is clearly visible during daylight and the TLB operator will be able to see how much material to load the aggregate hopper with.

JA Plant’s automated batch plants are fitted with a 6-Digit scoreboard, due to additional information required to operate the automated system.

Each scoreboard is conveniently fitted with a plug and play cable, making the scoreboard easy to remove and easy to store or secure the scoreboard during downtime.

 

Indicators for the Control Operator

The indicator is the brain of the load cells and the weighing system. JA Plant uses different types of indicators, depending on your requirements. For example, our Karoo Mobile Batch plant is usually fitted with a CAS or T-Scale indicator.

All our indicators are weatherproof, limiting the need to store the batch plant in a dry environment. Our indicators are easy to reset and operate.

With the use of an automated batch plant system or a more basic printer system, we use ICON 500 indicators, which have more functions available to accommodate the complexity of the system.  ICON 500 indicators are usually fitted and used in a wall-mounted or desk type control panel. It is either fitted on the plant or in an office control room, depending on your specific requirements.

 

JA Plant fit all our Karoo Mobile Batch Plants with a simple but essentially effective and durable Water System with key features

Our Karoo Mobile Batch Plants come equipped with an electronic water display that is easy to reset and ensures the plant is ready for each new load, by simply pressing the reset button.

The electronic water display can take a reading up to 9999L, while the mechanical water metre can either read to a maximum of 500L or 1000L per load, depending on selection. However, the limitations on the mechanical water metre can cause the incorrect loading of water quantity per cement load and we, therefore, recommend the electronic water metre.

The pulse wire, also known as a pick-up wire, on an electronic water metre, is connected to the water metre and the display. It provides the display with regular interval pulses from the water meter and displays each reading on the display screen.

Our 50mm electronic water metre can be measured in different quantities. Our batch plants are measured in litres to give a more accurate reading for each concrete mix design. The display and pulse wire on this metre is easily accessible and easy to replace, preventing long downtime of batching. This water metre is more cost-effective, more accurate and has easier availability of spares.

Mechanical Water Metres are only fitted on request from the client or on a diesel motor driven plant. However, the mechanical water metre must be reset manually and doesn’t come with an electronic display.

The mechanical water metre reset arm can also be easily damaged, causing a longer-term problem to reset the metre.

Regardless of the water system you choose, we fit the head shute with a water ring, which will allow the water to spiral into your mixer truck. This also assists with cleaning the loading hopper on your mixer truck.

Each of our mobile batch plants are fitted with a 220v water pump, which is connected to your water supply to feed your mixer truck.

 

Through years of experience the JA Plant choice of Gearbox and Motor for the Mobile Batch Plant is key to maximising performance:

At JA Plant we use a direct drive gearbox with a 7.5kw motor rather than a fenner type gearbox.

The key reasons why we use a direct drive gearbox are the following;

1. The direct drive gearbox is more durable.
2. The direct drive gearbox does not use V-Belts and therefore no spare V-Belts are required on site.
   • Due to the non-use of V-Belts, a direct drive gearbox repair is faster, reducing possible downtime.
   • No need to stress about a V-Belt slipping due to load on your conveyor belt.
   • Should your motor be damaged due to power outages or power surges, the motor is more cost-effective to replace than a larger motor. (This is usually prevented by our electronic switchgear fitted in our electrical control box as a normal safety precaution.)
3. The direct drive gearbox does not use oil unless a seal is broken or is damaged.
4. The direct drive gearbox has a stronger drive type, accommodating the weight of the material on the conveyor belt, better.
5. No adjusting of pulleys, gearbox or motor is required.
6. Our direct drive gearbox is fitted with an anti-run-back bearing, preventing the material from running in the opposite direction should you stop the plant with material on the conveyor belt, or in the case of a power outage.
7. The direct drive gearbox uses a smaller motor to operate than a Fenner type gearbox with V-Belts, due to the output of the gearbox.
8. A direct drive gearbox gives constant speed to the conveyor belt.

 

We can accommodate a client’s request for larger motors and different types of gearboxes as well, depending on the specific requirements or plant size. Different solutions are available depending on the conveyor requirements and type of plant required.

 

JA Plant is the leading manufacturer of mobile batching plants in South Africa, not only supplying South Africa but Sub-Saharan Africa as well.

We ensure our clients and their requirements are at the centre of all we do. Our batch plants deliver the best quality equipment, tailored to every client’s specific needs.

Contact us today for a consultation.