1. Raw Material Supply Bin

• Compartmentalised raw material supply bin for sand and stone
• Capacity:
  • Sand - approx. 7000 kg (15500lbs)
  • Stone - approx. 9000 kg (20000lbs)
  • Dimensions approx. 4.5m x 2.1m x 3.2m (hgt) (15"x7"x10")
  • NB Capacity increase possible via height extension
    
• Bins supported by high- strength, RHS steel box-section frame.
• Hydraulically operated slide drawers for raw material flow.
• Optional 3-position raw material bin location to suit outside plan.

2. Raw Material Discharge Conveyor

• Discharge conveyor with mini-containment hopper
• Automated ditigal material weighing system.
• Accurate measurement of both sand and stone
• Heavy-duty three ply rubber belt with electric direct-drive motor. Complete with hopper, scraper blades and support stand.
• Plastic-covered gravity roller sets
• Power for hydraulics, air and weigh-cell power routed internally through steel RHS box sections for safety and improved maintenance.
  

3. Supply Conveyor

• Heavy-duty three-ply rubber belt with electric direct-drive motor. Complete with hopper, scraper blades and and support stand.
• Plastic-covered gravity roller sets.
• Power, hydraulics, air and weigh-cell power routed internally through steel RHS box sections for safety and improved maintenance.
• Includes safety stop-switching.

4. Mixer Platform

• Operation access platform with safety rails and galvanised safety-tread steps.
• Steel chequer-plate. Slip resistant working surface.
• Perimeter chequer-plate up-stand for cleaning water containment.
• Support platform for pigment weighing scales.
• Power control centre located below platform for protection and access.
• Electronic control panel for mixer, hopper and conveyor operation (sited beside mixer)
• Supporting, heavy duty, box section steel stand
• Vibration table support structure
• Electronic panel for raw material weigh-cells, power and hydraulics.

5. Concrete Batching Mixer

• High-durability, 16 cubic ft (0.45 m3) capacity barrel, ribbon-type mixer with long-life replaceable wear plate liners and blades.
• Hydraulically operated wear plate discharge door.
• Water supply pipe and volume control meter
• Galvanised top cover grid with safety cut-out switching.
• Direct-drive, heavy-duty gearbox with 3 phase electric motor.
• Mix operator platform and cement bag stand.
• Drive system safety cover

6. Concrete Supply Hopper/Bin

• Conical discharge hopper
• Discharge-adjustable auger-feed to moulds.
• Direction-adjustable flow spout.
• Direct drive variable speed motor.
• Heavy-duty, synchronized vibration motor (mounted on hopper).

7. Mould Ejector

• Steel, powder-coated, height adjustable mould ejector.
• Hydraulic automatic / semi-automatic foot control operation with emergency stop return button.
• Enclosed control panel for operational components.
• Gravity roller tracks and supports stands. Adjustable width guides and positional stops for mould cassettes.

8. Vibrating Table

• Powder-coated steel table, set on eight rubber isolation mounts with levelling and height-adjustable supports.
• Wear-resistant mould runners and overflow discharge slots.
• Heavy-duty, reliable, vibrating motor.
• Control panel for operation of:
  • Vibrating table
  • Mould ejector
  • Auger
  • Stacking system
  • Gravity roller track with spray system support stand and mould guides
  • Hydraulic mould despatch ram.

9. Automated Mould Stacking System

• Steel, powder-coated automated stacking system.
• Pneumatic and electric product stacking apparatus.
• Pneumatic and hydraulic pallet, mould and tray transfer.
• Mould trays x 750.
• Gravity roller track sections for tray cassettes/timber pallets.

10. De-Moulding Table 2

• Steel powder-coated box framed tables.
• Flatbed conveyor feed with direct drive motor.
• Gravity roller track sections and support stands.
• Roller vibration isolation sleeves.

11. Mould Cassettes 19

• Steel, powder-coated mould cassettes 19
• Sizes to suit 400m x 400m and 300m x 300m (16" x 16" and 12" x 12") sized moulds
• Aluminium edged timber trays to suit mould selection

12.Plant Protection Barriers

• Steel-braced fork hoist barriers for mould ejector and roller tracks.

13. Spray System

• High pressure cycle integrated operating system with inline filter
• Stainless steel containment enclosure with over spray support tray
• High efficiency height adjustable spray gun

14. Waste Bins 2

• Steel waste containment bin for vibration table discharge and cleaning water access

15. Management and Control Systems

• All electrical systems are enclosed in waterproof housing and sited for maximized protection and safety.
• Programmable logic control systems (PLC) used for:
  • Mould ejector
  • Mould spraying systems
  • Hopper/bin auger
  • Stacking apparatus
    
• Semi-automatic control system used for:
  • Raw material measurement
  • Raw material transfer
  • Concrete batching mixer and dispatch
    
    NB: these functions subject to full automation if required.

16. Moulds 2180

• Proprietary polyurethane paving and coping moulds
• Mould features:
  • Wear-resistance / long-life
  • Dimensional precision manufacture
  • Distortion-resistant
  • Pattern colour-coded to assist manufacturing and identification processes.
  • Five different surface textures.
    
    NB:
• All steel system components are sandblasted, anti-corrosion undercoated and finished with industrial-quality paint topcoat.
• Where indicated powder-coated components are similarly prepared by sandblasting treatment
• Where possible, all hydraulic, pneumatic and power cabling are routed internally for protection, safety and maintenance purposes.
• All electric motors are 3-phase design.

Supplementary Features of Flexipave™ Systems

• Unlike various other automated paving manufacturing systems, The Flexipave™ Systems provides for a low-noise operationing enviroment. The built-in ease of operation of the Flexipave™ System allows for the employment of basically unskilled labour, reducing production costs.
• Production downtime is minimised with there being no requirement for mould changes, system reconfiguration or the on-site presence of an engineering technician. (NB: Manual mould cleaning is required)
• All aspects of Flexipave™ Systems plant design incorporate a high-safety element, minimising the risk of injury to operating personnel
• Design and process engineering of Flexipave™ Systems plant design minimises repair and maintenance costs.

NB: Although an additional outlay is required for industrial capacity surface grinding machinery, the surface-ground products are anticipated to command a premium retail value, offsetting this concomitant capital expenditure. The same criteria and value proposition apply to any additional labour costs in the manufacture of these products.

Requirements for system installation:

Flexi pave System components and machinery will require lifting apparatus onsite for placement and installation. 2 x labouring staff are required to be supplied by purchasers, in addition to Flexipave™ Systems staff, for assistance with system installation. The system purchaser will meet these costs.

Set-up and Training

Included in the price is a site system set up and training service. This will involve one of our manufacturing specialists at the customer's premises to install and commission test the plant. An additional specialist will then take over in order to train staff in the manufacture, handling and storage of the different products. . The customer will meet all costs for local cartage and other installation costs

System Delivery

All Flexipave™ Systems are wholly manufactured in New Zealand. A delivery time frame of approximately three months is required on all System orders.
Please note that this schedule may be subject to some variation.

Additional Items Supplied with Flexipave™ Systems

• Pigment storage drums
• Pigment weighing scales
• Plastic pigment weighing containers
• Fibreglass mould cleaning container

Items NOT Supplied with Flexipave™ Systems

• Fork hoists
• Raw Material front loader
• Timber pallets
• Optional Extras
• Production surface-grinding equipment (approx. cost $USD 35,000 - 40,000)
• Bulk cement silo and weighing equipment