How to do Maintenance for Batching and mixing system for block making plant?

How to do Maintenance for Batching and mixing system for block making plant?

Maintaining the batching and mixing system of a block making machine is critical for consistent concrete quality and efficient block production. This system includes weighing hoppers, conveyors, mixers, water dosing units, and control panels. Poor maintenance here leads to inconsistent mixes, lower block strength, and downtime.

Batching & Mixing System Maintenance Guide

✅ Daily Maintenance

1. Clean Mixer and Hoppers

• Remove leftover concrete or cement from the mixer blades, walls, and hoppers.

• Use a scraper or water (low-pressure wash) before the concrete sets.

2. Check Mixer Blades and Liners

• Look for signs of wear or bending.

• Blades must be sharp and properly aligned for uniform mixing.

3. Inspect Batching Accuracy

• Monitor whether aggregates, cement, and water are being dispensed correctly.

• Verify load cells (weighing sensors) are not obstructed or dirty.

✅ Weekly Maintenance

1. Lubricate Moving Parts

• Grease the mixer shaft bearings and conveyor rollers.

• Oil the gear reducer or gearbox if needed.

2. Inspect Conveyors and Belts

• Check for tears, misalignment, and material buildup.

• Clean and adjust tension.

3. Check Water Dosing Unit

• Ensure water flow meters or valves are clean and functional.

• Clean strainers or filters in the water line.

✅ Monthly Maintenance

1. Calibration

• Calibrate weighing systems for aggregates, cement, and water using standard weights or reference measurements.

• Ensures batching precision and consistent concrete mix quality.

2. Inspect and Clean Load Cells

• Clean off dust, cement, and concrete buildup.

• Ensure no foreign objects are affecting load cell performance.

3. Check Mixer Motor and Gearbox

• Listen for unusual noise.

• Check oil levels and seals in the gearbox.

✅ Every 6 Months

1. Replace Worn Mixing Blades or Liners

• If blade edges are rounded or liners are thinning, replace them to maintain mix uniformity.

2. Inspect Electrical Panel & Sensors

• Clean and tighten connections in control boxes.

• Test emergency stops and interlock systems.

3. Test Overall Mixing Time and Homogeneity

• Run test batches and inspect concrete consistency.

• Adjust timing settings if needed.

��� Tools & Supplies Needed:

• Grease gun and lubricants

• Water hose or low-pressure washer

• Calibration weights (or known batch)

• Wrenches, scrapers, and cleaning tools

• Replacement blades, liners, and seals