We offer you KOCMO plant for dry mortar production.

This equipment ensures manufacturing of top-quality products at minimum financial investments.

The advantages of purchasing the given plant are as follows:

• Using the plant for sand preparation, you will be able to obtain raw material for production of top-quality dry mortars. Thanks to automatic screen changer, screening process can be modified or optimized in any moment.  

• At adverse weather conditions with hard frosts condensation is reduced to minimum even in unsealed silos.

• During drying and cooling process fine fractions (flour / adjuvant) are separated from gross ones in the so-called «separation zones». After that by means of air blowing fine fractions are discharged into fine dust filter to be separated from air.

• Our drying system as an alternative to a more expensive air separation system ensures deriving of high-quality adjuvant at minimum costs. 
 
• Due to use of by KOCMO developed technology and qualitative equipment, screening, dosing and mixing processes are fully automated and high accurate.

• Module plant for raw material preparation makes it possible to increase the number of silos in any moment, thus, providing for use of other additives – high-grade broken stone (marble) and light additives (perlite, pumice, polystyrene).

• Equipment for raw material preparation and dry mortar production is installed inside, thus ensuring 100% protection from adverse weather conditions, preventing corrosion and guaranteeing long service life.

• Automatic weighing system of raw materials prevents any dosing errors. Operation process is displayed on PC. Dosing process is not to be carried out manually in order to prevent extra costs resulting from possible dosing errors. 

• Our equipment makes it possible to prevent demixing of finished product during its conveying from mixer to packing machine. This is a guarantee for products of top quality which traditional dry mortar plants cannot ensure.

• KOCMO dry mortar plants are very compact. Required manufacturing area including the integrated raw material preparation covers only 400 m2.

• Utilizing the experience built up through years of manufacturing and updating own dry mortar plants, KOCMO is able to meet the individual demands of every client.

• KOCMO dry mortar plants are made of the component parts produced by the leading German engineering plants, thus guarantying a long service life of the dry mortar plant.             

Description of raw material preparation process
 
Use of sand (silica sand) in production process:

Silica sand with grain size from 0 up to 3 mm is discharged into loading hopper by means of bucket loader.  From hopper raw material is dosed into dustproof bucket elevator and than discharged into gas or fuel oil dryer.

In drum dryer silica sand is dried by hot air and afterwards cooled by the air supplied from outside. Temperature of dried sand is 40 – 50°C. After drying silica sand can immediately be used in production process.
Humidity percentage of dried sand is 0, 2 %. By means of air venting material bulk with grain size up to 90 mм is discharged into filter. This filtered dust proves to be a perfect raw material.
Equipment for raw material preparation provides for manufacturing of top-quality products at minimum energy costs, thus proving its economic benefits.
By means of bucket elevator dried material (silica sand) is charged into tumbler screening machine for sifting. Fractions derived after screening are stored in separated steel silos. If needed, single fractions can immediately be used in dry mortar production process.

Sand preparation process, which consists of drying, cooling, dust-eliminating and screening, is carried out constantly and controlled automatically. Electronic control system monitors operation of metering and dosing devices, controlling the temperature of preparation process.

All silos for silica flour and cement are equipped with air suction and blowing system to ensure regular material feed from silo and high accuracy in dosing.

Additives delivered in silo vehicles or big bags (marble flour, perlite, pumice) are conveyed into special buffer silos by means of pneumatic conveyor or elevator. Silos for additives are equipped with all required devices – squeezing valves, external filters, safety valves, silo filling level sensors. 

Basic model of dry mortar plant is equipped with 6 silos for raw materials. The dry mortar plant ensures possibility of using additional silos for raw material provided they are respectively equipped. Metering and dosing system and scales can simply be re-adjusted regarding the greater number of silos. Thus, basic number of silos can be increased. 

Capacity of the plant for raw material preparation

Capacity of the plant is 7 t/h (wet sand, initial humidity 7%). All the units of the plant complied with the given capacity.

The plant for raw material preparation can be operated in 3 shifts, provided that maintenance works are to be carried out timely.

Raw material storage

Binders for dry mortar production (cement, lime) are delivered in silo vehicles and conveyed into special steel silos by means of pneumatic conveyor. Silos have the volume 60 m3 and are equipped with all required devices – squeezing valves, external filters, safety valves, silo filling level sensors. 

Basic model of dry mortar plant is equipped with 6 silos for raw materials. If needed, respectively equipped additional silos can be used. Metering and dosing system and scales can simply be re-adjusted regarding the greater number of silos.

Steel silos are to be mounted on concrete foundation and fixed by special rods. Steel supports are not required.

Silos are to be made on site, according to our drawings and taking into account calculated static load. Our specialists control manufacturing process and its compliance with the set parameters.

Basic model is provided with the following silos:

 Silo 1  Portland cement
 Silo 2  slaked lime/non-staining cement  
 Silo 3  silica flour  
 Silo 4  silica sand fractions   
 Silo 5  silica sand fractions 
 Silo 6  silica sand fractions 
 
• If needed, automatic dosage system can be equipped with additional small-size silos (volumetric capacity up to 1500 l) and big bags that are emptied by discharge conveyor. Thus, raw materials and chemical additives seldom used in manufacturing are weighed and mixed with high accuracy.

Description of dry mortar production process
 
 From steel silos required amount of raw materials and binders is dispensed into scales by means of screw conveyors and metered-dose valves. After weighing raw materials and additives in batches are fed into conoid mixer.
 Dosing process is carried out according to the formulation, pre-set in control system. In this way any dosing and mixing errors are excluded.
 If needed, chemical additives can be pre-dosed and added manually to raw materials. This possibility is provided in basic model of the plant. The process is controlled through handshake key.
 
 In conoid mixer raw materials are mixed according to the formulation during specified period of time. 
 Than mixer is dropped into buffer silo and a new batch of raw materials from scales container is charged into mixer.
 
 From buffer silos dry mixture is charged into turbine packing machine with one connection pipe to fill bags with finished products.
 Bags are to be put on connection pipe manually. Bag-weighing and filling processes are carried out automatically. On belt conveyor filled bags are conveyed to pallets.
 
 Dry mortar production process is carried out automatically, controlled and monitored by PC.
 
 Each stage and operation of production process is completely visualized. If needed, production control can be carried out semi- or fully manually.
 
 The plant is provided with metering and dosing device, software for control of plant operation and production according to pre-set formulation.
 
 Computer is provided with built-in modem which ensures remote access to computer system of service firm for immediate error diagnostics. 
 
 
 Capacity of the dry mortar plant
 
 Capacity of the dry mortar plant is 7 - 15 t/h.
 All the units of the plant are complied with the given capacity.
 
 Packing capacity is 7 - 15 t/h (400 - 800 bags/h).
 
The plant can be operated in 3 shifts, provided that maintenance works are to be carried out timely.
 
 
 Dry mortars
 
 Our plant makes it possible to produce top-quality dry mortars of every art.
 All equipment complies with special requirements for raw material and finished products.