Bouter Betonexport e.K., 77889 Seebach, Germany Increased … · 2015. 11. 10. · Bouter...

CPI – Concrete Plant International – 6 | 2014 www.cpi-worldwide.com102

CONCRETE PRODUCTS & CAST STONE

Mark Küppers, CPI worldwide, Germany

Eifeler Betonbauteile GmbH was foundedin 1993 and began manufacturing con-crete products for Deutsche Bahn at a pro-duction site in Cologne. Due to local condi-tions, the production was later moved toMechernich, approximately 50 km south-west of Cologne. Just like the old produc-tion site, the new site also possesses a con-nection to the railway network, which is oneof the prerequisites for being at all takeninto consideration as a supplier to DeutscheBahn.

Since the turn of the year 2001/2002,Eifeler has had a second production site inEast Germany. Its production facility inCalau, to the west of Cottbus, simplified

transport logistics for supplying DeutscheBahn on a national scale and the compa-ny’s overall capacities were expanded sub-stantially. At the current time, the companyhas its headquarters in Hellenthal/Losheim.Only sales and distribution are managedfrom this site; production is carried on sole-ly at Mechernich and Calau. The managing partner of Eifeler Beton -bauteile GmbH, Mr Thomas Manderfeld,additionally possesses a second strong pre -sence in the concrete sector with “ThomaBeton” in Cologne.

Certified and monitored

As supplier to Deutsche Bahn, Eifeler doesnot just meet the stipulations of ISO 9001with its corresponding certification. Eifeler

has been named a Q-1 supplier byDeutsche Bahn as one of only two manu-facturers of this type of concrete products inGermany. With this quality competenceclassification for a supplier, Deutsche Bahnis documenting the fact that the prerequi-sites have been met for satisfying their highquality requirements with such products.

However, Deutsche Bahn does not simplyrely on their certified suppliers deliveringthe necessary quality. All products fromEifeler are closely inspected and their pro-duction monitored.

If a company is able to fulfil such strict qual-ity guidelines, it is hardly surprising that itsproducts arouse great interest outside ofDeutsche Bahn. Eifeler has already made

Increased efficiency in manufacture and improved product quality

Bouter Betonexport e.K., 77889 Seebach, Germany

Eifeler Betonbauteile GmbH from Hellenthal/Losheim has one well-known customer, Deutsche Bahn, that at the same time takes delivery ofthe major part of the concrete products the company produces. Eifeler manufactures concrete cable ducts, precast foundations, platformedges and supporting brackets at two production sites. These products are installed in the national network of the Federal German Railway- Deutsche Bahn. Others customers are, of course, also supplied with these types of products by Eifeler. However, Deutsche Bahn is withoutdoubt this German company’s major customer. Eifeler previously relied on an egg-layer and a small stationary machine for manufacturingcable ducts and their appropriate covers, which have to be produced in very great numbers due to continual high demand. It was occasion-ally possible for bottlenecks to occur since the quantities needed were not always able to be covered in normal scheduled operations. Anypotential undersupply has now been averted without problems on a permanent basis after commissioning a new stationary manufacturingsystem from Bouter-Krobo in the summer of last year.

An undercover bucket conveyor wasinstalled for the new production line

Transferring the concrete - the new stationary system’s concreting bucket travels directly underthe bucket conveyor

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www.cpi-worldwide.com CPI – Concrete Plant International – 6 | 2014


deliveries to railway projects in Belgium,Luxembourg and Switzerland, for example,with concrete products for new railway plat-forms.

Other buyers for Eifeler products essentiallyinclude Telekom and general industrial con-struction companies. Amongst their ranksare to be found firms purchasing cableducts, precast foundations up to 10 tonnesand supporting brackets.

Pure “railway products” include e.g. rail-way platform edges, which are manufac-tured complete with foundation accordingto Deutsche Bahn specifications as well asconcrete cable ducts, which can be pro-duced still more efficiently on the newBouter-Krobo system.

Stationary Bouter-Krobo MP-F-405-RTconcrete machine brings new momentum to the production line

The new MP-F-RT system enables a varietyof reinforced or unreinforced concreteproducts to be manufactured that can bedemoulded immediately. These productsinclude, for example, reinforced concreteposts for fences, reinforced concrete piles,kerbstones, bank revetments, cable ducts,manholes for drainage and grease separa-tors, beams,lintels, piling boards for chan-nels, wall base elements (e.g. for noiseabatement), gullies, reinforced base slabs,concrete products for traffic engineering,slatted floors for cattle and pig slats.

The system is supplied by Bouter-Krobo inthree different standard sizes for product

Filling the mould with concrete is carried out using a concreting bucket which can travelfreely above the entire mould.

Specialist for concrete machinery

BOUTER-KROBO automatic discharging machine

BOUTER-KROBO flexible filling machine

Krobo Machinery B.V. Zompstraat 23 | NL-8102 HX RaalteNetherlands | www.krobomachinery.nl

International agent for Krobo Machinery B.V: Bouter Betonexport e. K. / A. Th. Bouter. Sommerseite 45 | D-77889 SeebachTel.: +49-7842-994411 | Fax: +49-7842-994419 E-mail: [email protected]

BOUTER-KROBO stationary production line

concrete machinery and moulds




lengths of maximum 3.20 up to maximum5.20 m. At Eifeler, a type MP-F 405 RTmachine was installed that permits productlengths up to 4.0 m. The company makesuse of this production width in order to man-ufacture several products simultaneously inone cycle.

All procedures utilised in this machine havebeen tried and tested over many years inthe precast concrete component industry.The MP-F-RT is rated as a powerful, diversi-fied machine with low running costs despiteits high output.

One of the system’s essential components isa travelling concrete spreader, which is sup-plied by a bucket conveyor at Eifeler. Thisconveyor was installed specifically for thenew production line. The concrete spreaderhas a pneumatic gate which enables thequantity of concrete and filling width to becontrolled precisely. Filling can be adjustedand adapted to any product.

A dosating box ensures that the entiremould is filled uniformly. A trowelling discattached to the concreting bucket movescontinually over the mould to create asmooth surface. This trowelling disc can be

moved both manually and automaticallyover the mould.

One other core component is a gantryframe which travels on rails and is driven bytwo electric motors with an automatic stopmechanism. This part of the system takescare of demoulding the fresh products. Thegantry frame is equipped with an electri-cally driven turnover device whose speedcan be regulated.

Production is carried out on a vibratingtable with high-frequency motors. Mouldchanges are easy to perform. The vibratingtable is additionally equipped with an elec-trically driven lifting device.

The electrical control panel with PLCenables automatic operations to be moni-tored or else manual operations to be con-trolled directly.

Manufacturing on the wet side with the MP-F-RT

Mould preparation is the initial stage of aproduction cycle. The mould is first cleanedto be subsequently sprayed with releaseagent on its inner areas. If necessary for a

particular product, in the next stage rein-forcement can be positioned in the mouldbefore it is filled with concrete.

Filling the mould with concrete is carriedout using a concreting bucket, which cantravel freely above the entire mould. Thisallows the concrete to be discharged intothe mould in a very targeted manner. Itspneumatically operated flaps permitdosage according to need. If the concretein the concreting unit’s storage container iscoming to an end, replenishment is orderedfrom the main mixing unit and the bucketconveyor brings fresh concrete to the pro-duction line on time.

Then vibration is commenced to compactthe concrete. The concrete settles in themould and some more concrete is addeduntil the mould has been completely anduniformly filled. The trowelling disc, as hasbeen previously mentioned, ensures that theoverall surface is smooth and even.Production is carried out “upside down”.The visible concrete surface will later on bethe concrete products’ lower part.

The fresh concrete products are now readyand can be immediately demoulded. The

The trowelling disc ensures that the overall surface is smooth and even. Production is carried out “upside down”. The visible concrete surfacewill later be the concrete products’ lower part.

For demoulding, both the mould and the pallet are brought with a rapid feed mechanism to the demoulding station whilst the whole unit isturned at 180°. The locking devices are now released and the mould slowly lifted off.




system positions a steel pallet on the mould for this purpose. The pal-let is then locked together with the mould by means of a pneumaticlocking cylinder. The following stage involves lifting this unit com-posed of mould and steel pallet from the MP-F-RT’s vibrating stationand conducting it to the turnover procedure. Both the mould and thepallet are brought with a rapid feed mechanism to the demouldingstation, whilst the whole unit is turned at 180°, and set down. Thisturning results in the mould now being positioned on top of the steelpallet at the demoulding station.

Once demoulded, fresh concrete products remain on the steel pallet.

With each completed stack of pallets on the wet side, all pallet stacks are shifted forward by a pallet’s width until pallet stacks with hardened products are ejected at the system’s end.

The base platefor the concrete and

pumice-stone industry

Eckart Holz GmbHHolzbe- und -verarbeitungKallbachstraße 4836088 Hünfeld-Michelsrombach, GERMANYTel.: +49 (0) 66 52 - 25 77 · Fax: +49 (0) 66 52 - 55 55E-Mail: [email protected] · www.eckart-holz.de

Available in all dimensions, max. length 1800 mm,max. width 1430 mm, max. 80 mm thick.

Version with or without tongue and groove.

Pine or larch from best forest stands.

With throughgoing twisted round steel 10 mm (special steel III a) or with threaded rods M 8 and M 10 mm, U disks and self-locking nuts.

Edge protection with galvanized profiles in differentdimensions and forms.

The base plates are planed on both sides, impregnated with colourless biodegradableforming oil.

Technical wood drying guarantees that wood humidity can be adjusted to the local conditions.

We consider customer’s requirements in production.

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The locking devices are now released andthe mould slowly lifted off. Fresh concreteproducts are demoulded by this means andremain on the steel pallet. The mould is lift-ed off, again automatically turned and setdown once more in the vibrating station.The next production cycle can begin.

These steel pallets have legs and so can bestacked with their products on top of eachother. The leg height thus, of course, prede-termines maximum product height. When

several pallets have been stacked to anappropriate height, the whole stack is thenconducted for hardening to the system’stransport route and subsequent packaging.The curing area can accommodate anentire day’s production. With each com-pleted stack of pallets on the wet side, allpallet stacks are shifted forward by a pal-let’s width until pallet stacks with hardenedproducts are ejected at the end of the cur-ing section.

Packaging on the dry side

The hardened concrete products can nowbe hoisted from their steel pallets with theproduction line’s packaging crane and setdown on wooden Euro pallets. At Eifeler,three wooden pallets are always packed atthe same time. An employee places threewooden pallets next to each other atdefined positions. The packaging crane isequipped with grabs covering a productionpallet’s entire width. This means that it can

The packaging crane is equipped with grabs covering a steel pallet’sentire width.

At Eifeler, three wooden pallets are always packed at the same time.

Packaged concrete cable ducts on the dry side.

Eifeler also manufactures concrete products for Deutsche Bahn at its second production site in Calau.

Once the hardened products have been removed, the empty steelpallets are hoisted, automatically turned through 180° and set downon a roller conveyor.




hoist all products from one steel pallet at a time and then set themdown on Euro pallets.

The next Euro pallets are always positioned ready in a furtherdefined row to maintain a continuous packaging process. Whilst thefinished packages are being transported to outside storage bymeans of a forklift, or even if there should be delays in their removal,the system can still continue packaging and thus create space forfresh products moving up from the wet side. Roller conveyors have been set up at both outer bays on the trans-port line for the pallet stacks. Once the hardened products havebeen removed, the empty steel pallets are hoisted, automaticallyturned through 180° and set down on these roller conveyors.Uniform gradients over the entire length of the roller conveyorsallow the pallets to be conducted by the force of gravity back to thewet side, where they are again available for use in production.

System running to complete satisfaction

The new Bouter-Krobo system was ordered in February 2013 andEifeler was already able to start manufacturing in August. MrManderfeld, whose life’s work is concrete, was delighted with theinvestment in the new production line from the outset. The system hasmade manufacturing substantially more efficient at one go.Downtimes due to repairs are now a thing of the past when com-pared with the old production method using an egg-layer. And –another essential factor – concrete product quality has beenimproved still further. Indeed, alongside the strict outside monitoring,the company’s own continual in-house checks provide clear evi-dence that this quality is not just a matter of appearance. In thiscase, too, Eifeler leaves nothing to chance… !

Eifeler Betonbauteile GmbHAm Goldenbach 2a53940 Hellenthal / Losheim, GermanyT +49 6557 92920F +49 6557 [email protected]

Bouter Betonexport e.K. Sommerseite 4577889 Seebach, GermanyT +49 7842 994411F +49 7842 [email protected] www.betonexport.com

KROBO Machinery B.V.Zompstraat 238102 HX Raalte, The NetherlandsT +31 572 [email protected]

FURTHER INFORMATION


Bouter Betonexport e.K., 77889 Seebach, Germany Increased … · 2015. 11. 10. · Bouter...

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