Envel Facade’s High-Performance Mixing Advantage

Envel Facade is known for creating striking, high-quality building exteriors using ultra-high performance concrete (UHPC). Based in South Bend, Indiana, the company manufactures thin precast architectural wall cladding at its single facility and ships products across the country to specialized subcontractors. Their products can be found on Class A office buildings, universities, and healthcare facilities, anywhere architects are looking for a combination of durability and modern design.

A key factor in Envel Facade’s success has been its long-standing partnership with Mixer Systems, Inc., located in nearby Pewaukee, Wisconsin. For more than 12 years, Envel has relied exclusively on Mixer Systems equipment, beginning with a Skid-Mounted Batch Plant Model 21 (with 21 cubic feet of capacity) and upgrading three years ago to a skid mount plant Model 30.

This system, paired with an on-site material silo, has proven to be an incredibly durable and reliable piece of equipment. Over more than a decade of continuous operation, the batch plant has functioned with minimal issues, supported by Mixer Systems technicians with readily accessible replacement parts and responsive service.

Working with UHPC isn’t easy, though. Compared to traditional concrete, it places much greater stress on mixing equipment and requires longer batch times. The material goes through a demanding transition during mixing that can push standard equipment to its limits. To solve this, Envel Facade partnered closely with Mixer Systems to customize their Model 30 setup with an upsized motor.

That collaboration paid off. While a standard Model 30 might only achieve about two-thirds of its capacity when mixing UHPC, Envel’s upgraded system allows them to operate at nearly full capacity. The larger motor provides the extra power needed to push through the most demanding stages of the mix, helping the team produce more material without overworking the equipment.

This efficiency has become increasingly important as Envel Facade continues to grow. UHPC is gaining popularity quickly, and architects are specifying it more each year. To keep up, Envel needs equipment that works hard, stays reliable, and scales with their business.

Envel Façade’s work speaks for itself. One standout example is their contribution to the Obama Presidential Center in Chicago, where they produced custom UHPC lettering. Projects like this highlight not only the beauty and versatility of UHPC, but also the importance of having the right equipment behind the scenes.

With the support of Mixer Systems, Envel Facade is well-positioned to continue growing and delivering innovative architectural solutions for years to come.

Foundries across the country are rethinking how they handle spent foundry sand and baghouse dust. Traditional methods rely heavily on large, heavy-duty bulk bags to capture dry dust from multiple collection points throughout a plant. While common, this approach creates hidden costs in labor, safety, material handling, and landfill disposal that add up quickly. 

In a typical operation, spent foundry sand and baghouse dust are collected dry and loaded into 2-ton heavy-duty polypropylene bulk bags. These bags are then transported to a central area, staged, and ultimately loaded into roll-off containers for landfill disposal. A single roll-off may hold around 10 bags, but the process requires significant manual handling, ongoing bag purchases, and coordination. Beyond cost, dry material introduces environmental and safety concerns, including airborne dust exposure during handling and transport. 

DustMASTER® Enviro Systems from Mixer Systems Inc. eliminates the need for bulk bags entirely while improving efficiency, air quality, and sustainability. Instead of collecting dust in multiple decentralized points and packaging it, a pneumatic system conveys spent sand and baghouse dust to a centralized silo. From there, the material is processed through a mixer where water is added to condition the waste stream. 

This simple but powerful change transforms how foundries manage byproducts. By adding moisture, the material becomes stable, eliminating airborne dust and improving handling. The conditioned mixture can then be discharged directly into a roll-off container or dump truck. It’s ready for transport without the need for bags. 

The benefits are immediate and measurable.  

• Reduced material costs – Eliminating bulk bags reduces material costs and labor associated with handling, staging, and disposal.  

• Reduced material volume – Conditioning the material lowers its effective volume and allowing for better compaction, which can reduce the number of hauls to the landfill.  

• Reduced tipping fees – Eliminating bulk bags and reducing material volume directly impacts tipping fees, which can range widely depending on waste classification. 

• Operational control – Centralized storage in a silo allows foundries to control when and how material is discharged, creating flexibility in logistics and reducing reliance on constant hauling.  

• Environmental health – Adding water to spent foundry sand and baghouse dust helps keep facilities cleaner, improving overall plant conditions and reducing air quality-related health risks for employees. 

• Environmental sustainability – Conditioned sand and dust have the potential to be repurposed as daily cover material in landfills, which is a required layer used to contain debris and prevent it from becoming airborne. If adopted, this approach could further reduce disposal costs while giving new purpose to what was once waste. 

By replacing heavy-duty bulk bags with a centralized, conditioned material-handling system, foundries can significantly improve efficiency, lower costs, and create a safer, cleaner operation, all while moving closer to their sustainability goals. 

If your foundry could benefit from eliminating bulk bags entirely, contact us today.  

In modern concrete production, operational efficiency is driven by precision, consistency, and speed. As producers face increasing demand, tighter specifications, and ongoing labor challenges, automated batch controls have become essential infrastructure rather than a convenience. They enable producers to standardize processes, reduce variability, and maximize throughput while maintaining quality.

In 1979, Mixer Systems, Inc., launched its mission to design and manufacture technology for concrete products. Ten years later in 1989, Mixer Systems launched a proprietary automated batch control system to enable operators of all skill levels to unlock the true performance capabilities of their batch plants. Today’s Mixer Systems E-150 automated batch controls represent a modern approach to plant automation, one built on decades of operational insight, a fully integrated engineering philosophy, and continuous updates and upgrades.

At the most fundamental level, automated controls ensure accurate proportioning of cement, aggregates, water, and admixtures. Even small deviations in material quantities or sequencing can impact strength, workability, and yield. Automation eliminates much of the guesswork by executing programmed mix designs exactly the same way every time, improving batch-to-batch consistency and reducing the risk of rejected loads or product defects.

The current version of the E-150 features a large 22-inch industrial touchscreen, making the user experience intuitive while the system performs sophisticated tasks in the background. Full simulation mode, for example, allows operators to run real mix designs without using real materials, accelerating training while reducing waste. E-150 also provides highly accurate slump and yield control, automatic and manual batching modes, and remote diagnostics for faster troubleshooting and higher uptime.

Why OEM Batch Controls Matter

Mixer Systems is one of the only batch plant manufacturers in the U.S. that offers proprietary batch controls. Other manufacturers rely on third-party control vendors, which can create gaps between plant mechanics and software logic. These gaps begin when multiple vendors are needed to bring a plant online and continue as operators require technical support.

Automated batch controls are meant to create a more predictable and stable production environment. By improving accuracy, reducing downtime, and streamlining workflows, they help concrete producers lower operating costs while delivering consistent, high-quality products. However, this consistency, quality and efficiency can suffer when issues with third-party batch controls arise, or the automation controls become outdated, limiting a producer’s opportunities for growth.

Mixer Systems takes a different approach: controls are designed, built, tested, and supported in-house. This vertical integration enables tighter communication between mechanical systems and automation logic, faster innovation cycles, and direct support from engineers who understand the full batch plant environment.

The result is a unified system architecture designed to evolve with customer needs, not a patchwork of components.

See the following comparison chart to learn more about the difference between a batch plant manufacturer-supplied automation system and a third-party add-on system:

The Strategic Impact of Modern Controls

Automated batch controls enable a smarter production environment. They reduce the need for constant manual adjustment so operators can oversee production instead of controlling every step. By coordinating weighing, charging, mixing, and discharge sequences with precise timing, automated systems minimize delays between steps and keep production moving smoothly. This increased efficiency allows plants to produce more concrete in less time without sacrificing quality.

Newer automated batch controls provide real-time monitoring and data tracking, giving producers greater visibility in plant performance. Operators and managers can quickly identify inefficiencies, troubleshoot issues, and make data-driven decisions that improve productivity over time.

Control the Process, Control the Outcome

As concrete production becomes more data-driven, the plants that outperform will be those that treat automation as core infrastructure rather than an add-on, making automation one of the most impactful investments a plant can make to stay competitive.

The E-150 illustrates what’s possible when controls are engineered as part of a proprietary system: improved consistency, faster training, stronger support, and a technology roadmap shaped by real production environments.

For manufacturers evaluating modernization strategies, the key question isn’t simply which control system has the most features, its which approach provides the most control over the process, plant performance, and future growth.

If you are considering modern batch controls and the benefits of OEM-developed automation, contact us today.

For more than 50 years, Terry’s Precast Products Inc. in Holland Michigan, has been a family-run operation built on craftsmanship, reliability and a deep understanding of the masonry market. Founded in 1972 by Terry Bouwman, and now operated by his sons Chad and Ryan with a team of eight employees, the company specializes in dry cast architectural stone, wet cast underground utility vaults, retaining walls, and custom precast step treads.

Their work is often highly customized and designed to achieve the exact aesthetic the customer envisions.

“Our business is really built around what the mason needs,” said Chad Bouwman, owner at Terry’s Precast Products. “When they come to us with a print or even just a phone call, we figure out how to make it happen.”

Over the years, demand for Terry’s Precast Products has steadily increased but scaling up was difficult. Every time the company took on more custom dry cast and wet cast projects, they would run into the limitations of their original batching and mixing setup. Before 2019, the plant relied on a single Mixer Systems Inc. mixer that was fed manually using a hopper system the team had engineered themselves. Only Chad or Ryan could operate it consistently.

“It was old school,” Chad said. “We had to watch every batch closely. There were no meters or automation, just experience and a good eye.”

A Turning Point: The First Mixer Systems Upgrade

In 2019, Terry’s Precast Products invested in its first Mixer Systems skid mount batch plant for dry-cast production. The impact was immediate. The simplified, automated batching and mixing system delivered consistent batches, reduced labor demands, and made training new operators far easier.

“It was a game changer,” they said. “It gave us peace of mind. If we train someone to run the machine, we know we’ll get the same concrete every day.”

With the upgrade, the company increased dry cast output to around 3 yards per day in a steady, controlled and efficient manner. Chad and Ryan could step back from production to focus on other areas of the business.

Growth Leads to the Next Step

As business accelerated through 2020 and beyond, Terry’s Precast Products saw an opportunity to expand its wet cast production as well. To do that, Chad and Ryan needed a solution that could increase capacity without requiring them to redesign the existing floorplan or take on major construction costs.

Chad and Ryan met with Steve Nelson of Mixer Systems to discuss a second Mixer Systems batch plant investment.

“When Steve came out, he was able to design the new system to fit right inside the building we already had,” Chad said. “We didn’t have to rebuild our plant to make it work. It fit our workflow.”

The new automated wet cast batch plant arrived as a palletized, skid-mounted system easy to install and connect.

“All you do is hook up water, electric and air and you’re ready to go,” Chad said. “It’s simple.”

Mixer Systems technicians ensured the installation was complete, and then spent one week training employees. Moving forward, if they have any questions, Chad and his team can directly contact Mixer Systems for guidance.

With the new plant online, Terry’s Precast Products was able to increase its entire production to between 9 and 11 yards per day of wet and dry cast products. Splitting production into two dedicated lines, one for dry cast, one for wet cast reduced bottlenecks and stress while increasing quality and consistency.

The Results

• Higher daily production capacity
• Reduced labor intensity and easier operator training
• Safer material handling and workflow
• Reliable batch consistency for both dry and wet cast mixes
• Opportunity to bid larger and more complex jobs

“Before, we were limited by how labor-intensive the work was,” Chad said. “Now, we can expand as much as we feel comfortable. The new batch plant has opened the door for bigger projects.”

In addition to bigger projects, the second batch plant opened up capacity for Terry’s Precast Products to serve Western Michigan businesses and residences as a source for Novum Wall, a medium format retaining wall system.

Looking Ahead

With two dedicated production lines, a growing skilled team, and the right automation in place, Terry’s Precast Products is positioned for continued expansion without sacrificing the craftsmanship and reputation they’ve built over decades.

“We’re a small business with high standards,” they said. “This equipment gives us consistency, peace of mind, and the ability to grow at our pace. It’s been a great investment for our company.”

Power, Precision and Performance: Selecting Batch Plants for UHPC

Ultra-High-Performance Concrete (UHPC) is an advanced class of concrete known for its exceptional strength, durability and resilience compared to conventional mixes. UHPC boasts compressive strengths above 22,000 psi (150 MPa), more than double the performance of high-strength concrete.

UHPC is dense and impermeable, thanks to a mix-design that includes fine powders such as silica fume and quartz flour, a very low water-to-cement ratio, high range-water reducers, and steel or polymer fibers. So, it may come as no surprise that UHPC producers require a specialized approach when investing in mixing technology and batch plants.

In this article, Mixer Systems, Inc., experts weigh in on the unique specifications and options producers should consider when UHPC production demands power, precision and performance.

High Shear Mixing Technology

At the heart of UHPC production is high shear mixing technology. Because UHPC is typically used in large infrastructure and complex architectural applications, high volume is an important factor as well. Traditional drum mixers simply cannot provide the energy or precision required to thoroughly combine dry powders with water and superplasticizers, or to evenly disperse fibers throughout the mix. Furthermore, traditional drum mixers or concrete mixing trucks producing UHPC can be very difficult to clean, making it an undesirable product to supply.

Planetary mixers, horizontal shaft and twin shaft mixers are the most common mixers used to mix UHPC. Planetary mixers from Mixer Systems, Inc. produce a unique counter current mixing action, resulting in fast, homogenous mixes. Horizontal mixers from Mixer Systems, Inc. are typically used on smaller applications, including on-site UHPC production.

Mixer Systems, Inc., Twin Shaft mixers are high volume, high shear with mixing times from 60-90 seconds. Intermeshing paddles to rapidly blend materials while maintaining consistent flow and distribution and have been successfully used on major UHPC projects such as the Delaware Memorial Bridge resurfacing project.

High-shear energy is especially important during the addition of water and superplasticizers. The extremely low water content of UHPC means that even slight inconsistencies can lead to clumping, reduced workability, or strength losses.

Advanced mixers often incorporate variable speed controls and multiple mixing phases – dry blending, liquid introduction and high-energy homogenization – to achieve the required paste fluidity and particle dispersion. All of these systems can be equipped with automatic washout systems making maintenance significantly easier.

Batch Plant Automation and Accuracy

Beyond the mixer itself, the batch plant plays a vital role in successful UHPC production. Precision is paramount at every step, from weighing powders to testing aggregate moisture. UHPC mix designs have small tolerances compared to conventional concrete, and errors in batching can have serious impacts on performance and can be very costly.

UHPC producers should look for batch plants that provide:

• Automated powder handling systems for cement, silica fume and quartz powder.
• High accuracy weighing systems capable of handling fine powders and micro-additions.
• Specialized liquid dosing equipment for superplasticizers and other admixtures that must be delivered within tight tolerances.
• Fiber feeders that meter and introduce steel or polymer fibers without clumping.
• Temperature control to manage heat generated from mixing, including a cooling system or chilled water dosing.

The BatchMaster plant from Mixer Systems, Inc., is a top-of-the-line plant capable of producing up to 250 yards per hour. Mixer Systems load cells feature an aggregate weighing accuracy within +/-2% and cement/water weighing accuracy within +/-1% of the batch size. Proprietary automated controls run a high-volume batch plant from start to finish-batching, mixing, moisture control, even automated concrete delivery of different mix designs to multiple locations.

The Path to Scalable UHPC Production

As demand for UHPC grows in infrastructure, precast, and architectural applications, the importance of advanced mixing and batching systems will only increase. High-shear mixers and precisely engineered batch plants are essential to unlocking the full potential of this specialty mix.

Mixer Systems, Inc., pours more than 45 years of experience into the design, manufacturing and construction of every mixer system we produce. We build every mixer, batch plant and batch control system from the ground up to meet customer specifications.

For producers, investment in the right equipment enables not only superior material quality but also improved efficiency and repeatability, ensuring UHPC can be scaled to meet the needs of tomorrow’s most ambitious projects.

When you’re landlocked on just 3.5 acres in the middle of a residential neighborhood, expanding your concrete operation to increase output isn’t an option. For Zeiser Precast, a long-standing precast concrete producer in Elmira, New York, the challenge was clear: how to significantly increase daily concrete yield without adding a single square foot. 

Their solution? Upgrade to a larger mixer within the same footprint. 

Ready for an Upgrade 

Zeiser has been producing precast concrete since its establishment in 1946 as Zeiser Wilbert Vault, Inc. From burial vaults to retaining wall blocks, manholes, and septic tanks, their product line and customer base have expanded, while their production space remained fixed.  

Since the 1980s, Zeiser’s concrete was mixed with a Mixer Systems, Inc., Model 30 Horizontal Shaft. In 2008, Zeiser replaced the Mixer Systems E-100 batch control system that was over 20 years old with a touchscreen automation system from a different manufacturer that provided the features they needed. By 2024, the third party control system, which was running on outdated Windows 98 software, was failing and prone to glitches.  

“We’d been struggling with the failing operating system for the last couple of years,” said Stephanie Risley, president and second-generation owner. “We could no longer operate as we were, it was costing us a lot of time and money.” 

At the same time, demand for Zeiser’s precast and specialty products was outpacing their production capabilities. That’s when they turned back to a trusted partner: Mixer Systems, Inc. 

Same Space, Bigger Capacity 

Zeiser had relied on Mixer Systems for more than 40 years, so when the opportunity came to upgrade both the control system and the mixer, the decision was easy. The existing mixer was a Model 30 Horizontal Shaft Mixer with a 1-yard input capacity.  

“We decided it would be a good idea to increase our capacity and upgrade our operating system at the same time,” Risley said. “We are planning for our future and wanted to be ready for our next phase.” 

The upgrade to a Model 54 Horizontal Shaft Mixer, which has a 2-yard capacity, doubled the potential production for Zeiser. With their current production schedule, the increased capacity allowed the Zeiser team to immediately boost their yield by 50% per batch. 

What made this project stand out was that Mixer Systems helped fit the entire upgrade within the same production footprint. No structural expansion, no additional land needed. Just smarter, more efficient equipment designed to work harder in the same space. 

“Our plant is surrounded by homes, churches, schools. We can’t expand,” said Jeremy Sherman, general manager for Zeiser Precast. “So, we had to get creative. The Mixer team worked closely with us to design a system that would maximize every square foot.” 

Operational Payoff 

The new mixer, powered by Mixer Systems E-150 Batch Control system, transformed operations. Batching is now faster, more consistent, and less labor-intensive. 

“The decision to replace the operating system alone was a lifesaver,” Sherman said. “We struggled to produce a well-designed batch on a daily basis because the software was so old.” 

The E-150 Batch Control System was designed with growth in mind. Based around a 22” high-definition, industrial touchscreen display, the E-150 is powered by a PLC/PC hybrid computer system housed in a NEMA 4 wall mountable enclosure that is adaptable to most concrete batch plants currently in operation.  

“It was amazing how quickly things improved,” said Sherman. “After just three trial batches, we saw a difference. We’re producing more yards at a faster rate and more consistently, and our team is going home earlier. That’s a big deal for us.” 

Additional features include full simulation mode, printable plant schematics and electronic drawings, highly accurate slump and yield control, automatic and manual batching modes, online access for remote diagnostics of mechanical and electrical plant issues, a dedicated Mixer Systems service staff, and more.  

“Zeiser was excellent to work with, very accommodating and open to discussing their long-term growth plans so we could ensure they had the right solution now and into the future,” said Jonathan Jaruseski, National Sales Manager for Mixer Systems, Inc. 

A Future-Proof Investment 

From improved batching speed to reduced software headaches, Zeiser’s new Mixer Systems mixer proved to be a sound investment with immediate returns. 

“We were shut down for about a month for the install,” Risley said. “When Mixer Systems got our new system online it was so exciting, it’s been about 6 months and the new mixer and operating system have been flawless.”  

Whether producing burial vaults, catch basins, septic tanks, or custom solutions, Zeiser now operates with the confidence that their plant is designed to handle the demands of modern precast production, without needing more space to do it. 

The Model 54 Horizontal Shaft is the same footprint as the Model 30 Zeiser was already using, the installation team just needed to accommodate for additional height.  

“We’ve never had a quality issue with anything from Mixer Systems and this upgrade was no exception,” Sherman said. “It exceeded expectations.” 

Zeiser employs a team of 35 employees, with 30 on the production and dry side. Yet they produce a wide variety of precast products, many made to order, some kept in inventory. Increasing output without increasing hours has not only improved productivity but also strengthened employee satisfaction. 

“We’re a family-oriented company,” Sherman said. “If our team can work efficiently and still have time with their families, that’s a win. This upgrade gave us that and more.” 

In foundry operations, the quality of green sand means the difference between producing reliable, defect-free castings and facing costly rework or scrap. Every mold’s performance and every casting’s integrity depends on the consistency, strength, and permeability of its sand.

First, each grain of sand needs to be evenly coated with clay binder and moisture. Well-prepared sand packs uniformly, giving the mold enough strength to hold its shape during pouring. This also controls permeability, allowing gases to escape without letting metal steep through.

A dialed-in preparation process creates predictable results from mold to mold, which is essential for meeting tolerances and surface finish requirements.

Mulling machines are an ideal piece of foundry equipment for the initial preparation of sand and to condition it for reuse in making molds.

Mulling machines help achieve ideal green sand quality by doing three critical things at once:

1. Kneading and coating the sand grains – Heavy muller wheels press and shear the sand, forcing the clay binder and moisture to wrap evenly around every grain. This creates uniform bonding strength so the mold can hold its shape without weak spots.
2. Breaking up clumps and blending additives – Any lumps of sand, dried clay, or leftover additives are crushed and dispersed. New sand, reclaimed sand, bentonite, sea coal, and other additives are blended into a perfectly consistent mix, preventing areas of the mold from behaving differently during pouring.
3. Controlling moisture and plasticity – The mulling process evenly distributes water through the sand, preventing soggy spots and dry patches. This ensures consistent compaction, so the mold surface is smooth, strong, and has the right permeability for gases to escape.

Mulling isn’t just mixing, it’s conditioning the sand, so it behaves the same way every time, which is exactly what a foundry needs for consistent casting quality.

Following are the differences between poorly prepared sand and properly mulled sand:

While mulling machines are critical to operations, historically, foundries have had limited equipment options. The SandMASTER Muller Mixer from Mixer Systems, Inc., leverages a simplified compaction technology that was designed specifically for foundry sand preparation.

Five mixing paddles are fixed on a counter-rotating start for fast, thorough blending that is consistent across all batches.

Top-mounted drive and access doors provide easy maintenance without the need to dissemble the mixer.

An innovative Sand Wedge compaction technology replaces rollers for cleaner, more efficient mulling.

And a liner wall scraper follow the Sand Wedge to gather compacted sand and push it toward the mixer bottom.

The quality of a casting is directly tied to the quality of mold it was poured in. Mulling machines condition green sand to ensure uniform binder coating, consistent moisture, and proper compaction. The simplified and innovative SandMASTER mulling mixer helps foundries produce molds that perform reliably under the extreme demands of metal casting. The payoff is clear: reduced scrap rates, improved surface finishes, and repeatable quality with every pour.

For more information on SandMASTER download our brochure.

Unlocking Better Concrete with Sequencing and Automation

In the world of concrete production, consistency is everything. Whether you are pouring a few yards a day or hundreds, the performance of the final product hinges on the precise sequencing of ingredients during batching. Stone, sand, admixtures, cement and water must be introduced into the mixer in a specific order, and that sequence is far from arbitrary. Done incorrectly, it can drastically impact the strength, finish and performance of the final product.

At Mixer Systems, Inc., we understand the complexity and science behind batching. That’s why we’ve designed our equipment and automation systems to bring precision and repeatability to every batch at any scale. As a one-stop shop, we supply everything, from mixers and complete batch plants to mixer and batch controls, material handling systems and wash down systems. There’s no need to coordinate multiple vendors because we streamline the entire operation for our customers.

Mix Order Matters

The sequence of introducing materialslike stone, sand, admixtures, cement and water affects not just how the mix performs, but also how efficiently the equipment runs. Variables like mixer style, speed, accuracy of the amount being batched, yardage, and admixture types (including superplasticizers, densifiers, or self-consolidating concrete mixes) all influence the required order of operations.

For example, stone is typically added first to allow the voids to fill with the finer materials and help prevent buildup. Sand follows, often making up 60–80% of the aggregate if a customer is following industry standards with their mix design. A small amount of pre-wet may be introduced next, precisely timed to avoid premature cement hydration or pooling in the aggregate. Cement and admixtures are added afterward, using timers for accuracy. This controlled, sequenced approach ensures that materials blend properly and the admixtures perform as designed.

Common Issues

When materials are added out of sequence or in incorrect proportions, issues like spalling, balling, or inconsistent setting can occur. For example, adding admixtures too early or too late in the main water sequence can prevent them from dispersing properly which can weaken the mix or alter its intended characteristics.

Timing errors also impact the functionality of chemical additives. Superplasticizers, for instance, are meant to enhance flowability over time, but if added incorrectly, they can cause the mix to separate or remain too fluid. Accelerators added too early can create a lumpy or granola-like texture.

Tail water, which is leftover water from the mix, can further complicate matters, preventing the formation of a smooth, homogeneous blend. These small missteps, if left uncorrected, can significantly degrade the strength, workability and finish of the final product.

Environmental conditions also play a critical role in batch control. Pre-wetting aggregates is key to achieving consistent moisture content, especially in environments that are overly humid or dry. Without the right moisture level, cementitious binders may not hydrate properly, leading to performance issues.

Accurate batch control is essential in concrete mixing to ensure consistent performance and durability.

Automation systems are designed to precisely control when and how much of each material is introduced, preventing errors that may not be visible until the final product fails in the field.

Automated Batching for Repeatable Results

Batching is as much about order and timing as it is about consistency. Mixer Systems, Inc. is one of the few manufacturers that builds its own batch plant controls in-house. This gives us the unique ability to tailor the entire system to each customer’s mixer, production needs and preferred mix designs. Other manufacturers often outsource these controls, which runs the risk of inefficiencies and miscommunication.

Our batch plant automation is designed to repeat the exact same sequence throughout the production day, allowing customers to replicate performance across dozens or even hundreds of batches. Full simulation mode allows batch operators to gain experience by batching their mix designs in real-time without actually using cement and aggregate materials.

Each system includes:

• Pre-programmed timers for sequencing ingredient drops
• Weight-based batching for cement and aggregate
• Moisture compensation using bin probes and water meters
• Adjustable mix times based on current draw and mix type

Precision matters even more for specialized mixes like self-consolidating concrete, where delayed chemical introduction is critical. With automated batching, customers can program secondary timers to ensure the admixture is only released after the main water is added.

The Water Quotient

A precise water-to-cement ratio is a must, which requires an understanding not only of how much water to add to a mix, but how much is already contained within the aggregate. The correct water-to-cement ratio will also help indicate when a mix is complete.

Aggregate moisture levels can vary significantly depending on where material is sourced from within the stockpile and how long materials are sitting in bins. Different moisture levels arise due to the natural settling of water. Environmental conditions such as rain and humidity also play a part. Bin probes and water meters from Mixer Systems, Inc., provide real-time readings of moisture levels so that water and material are both considered when adding an ingredient to a mix. This ensures proper sequencing and yield.

Once in the mixer, Mixer Systems, Inc., relies on a wattmeter to monitor a mix and understand when it is complete. The wattmeter measures how hard the mixer motor is working. When there is less water, it requires more power to mix. As water and admixtures are added during the order of mixing, the motor will require less power. Once the wattmeter shows the motor is working at the target power percentage, as an example, 40%, the operator will receive a mix complete signal.

Testing Makes Perfect

While we do not create mix designs for customers, we strongly emphasize the importance of thorough testing when developing a concrete mix. Admixtures play a critical role in achieving durability, sustainability, and workability, but their performance can vary depending on many factors. That’s why product testing is essential—to confirm that each component interacts as expected within the desired performance parameters. Partnering with admixture suppliers who understand both product chemistry and environmental considerations can help identify opportunities for improving the mix through trial, testing and adjustment.

One of the key factors in mix behavior is the nature of the aggregates. Our aggregate supply is based on the Fineness Modulus (FM), which measures how fine or coarse the material is. Depending on the customer’s original mix, adapting it to our FM values can require careful adjustment. For example, we’ve seen issues such as slurry balling when using quartz aggregates that couldn’t absorb enough moisture to properly disperse. In contrast, our usual materials, including sand, stone, and fly ash, have established performance characteristics that support a predictable batching and mixing process. But even with familiar ingredients, testing is still necessary to ensure consistency and repeatability.

Geographic and environmental conditions also affect concrete performance, which is why localized testing is so important. For example, mixes must be tailored to withstand challenges like freeze-thaw cycles in regions such as the Midwest, where frost balls can affect mix integrity. Working with admixture partners who understand these regional variables allows for better planning and performance. Regular testing such as strength breaks and monitoring for issues like inconsistent test strengths can reveal problems early, such as equipment malfunctions like a leaking gate. Ultimately, dialing in a reliable mix is a process of trial, testing and refinement.

Selecting the Best Mixer for the Job

Selecting the right concrete mixer is critical to achieving consistent quality, efficiency, and performance, especially when production volume and mix design requirements vary. Different mixes, such as those with high-flow admixtures, low-slump materials, or specialty aggregates, demand specific levels of agitation and batch control.

High-production environments often benefit from twin-shaft mixers, which offer intense shear and fast mixing cycles, while smaller batches or intricate mix designs may be better suited for planetary or pan mixers. Choosing the wrong mixer can lead to inconsistent blending, longer cycle times, and even material waste, especially when dealing with complex or sensitive formulas.

Additionally, pooling is more likely in horizontal or turbine-style mixers, which offer less agitation compared to planetary or twin-shaft mixers. This makes precise control over material addition even more important in those systems to avoid uneven distribution and ensure a reliable mix every time.

Built for Today and Tomorrow

Understanding customer business goals and plant operations is the first step in delivering the right systems and services to them, not only for current needs but with future growth in mind. Whether it’s an 8-cubic-foot mixer or a 9-cubic-yard twin shaft behemoth, our systems scale with your operation. From a customer pouring 7 yards a day to a wall panel plant needing 400 yards, we deliver purpose-built solutions.

When you choose Mixer Systems, Inc., you’re not just getting a batch plant, you’re getting a partner in performance. From equipment to automation to field support, we make sure your mixes are done right, every time.

Ready-Mix Concrete vs. Batch Plant Investment: Which is Right for Your Business? 

When it comes to sourcing concrete for construction or manufacturing, contractors and business owners typically face two options: ordering ready-mix from a local production facility or investing in their own batch plant. Each choice carries distinct advantages, costs, and risks. Understanding the key differences can help you make the best decision for your operation. 

Ready-Mix Delivery: Third-Party Dependence 

Ready-mix concrete is produced off-site at a central batching facility and delivered to job sites or facility locations via mixer trucks. Ready-mix providers handle raw material procurement, quality control, environmental compliance, and delivery logistics. With no need for upfront capital investment or dedicated staffing, ready-mix can be the go-to choice for short-term projects, variable production demand, or lower annual volume demand. 

The cost of using a third party for concrete delivery is two-fold. First, is unpredictable delivery scheduling. Most of the time, ready-mix plants are producing concrete for a variety of customers at the same time. Sometimes a pre-caster who relies on ready-mix has to wait longer than expected for a delivery, which in turn impacts their own production schedule and goals. Second, the per yard cost can total more than $200/yard especially when delivery fees and waiting charges are included.  

For manufacturers who produce concrete-based products such as underground utilities, culverts, septic tanks, structural elements, and infrastructure products, a ready-mix order could easily equal 100 yards per day or more, costing $20,000 per day. Owning a batch plant may be a more cost-effective option and it eliminates access to concrete as a constraint. 

Batch Plant Ownership: Control and Cost Efficiency 

For operations requiring large volumes of concrete—such as pre-casters serving the burial, infrastructure, and waste management industries —investing in a batch plant can lead to significant long-term savings. By producing concrete on-site, companies reduce transportation costs, gain full control over production schedules, and can adjust mix designs in real time. 

Owning a batch plant comes with an increase in responsibility compared to a ready-mix delivery service. Start-up costs can exceed $200,000, not including land, utilities, and permitting. Ongoing expenses include staffing, maintenance, material sourcing, and regulatory compliance. But once it is up and running, a batch plant will reduce the cost per yard for concrete from an estimated $200/yard to $90/yard. 

Mixer Systems Inc. prides itself on being a one-stop resource. We provide advanced product planning, offer state-of-the-art manufacturing, and design and construct concrete batch plants from the ground up. Our product line is the largest family of equipment in the industry, built with American reliability to tackle the challenges of the world of concrete.  

A Skid-Mounted Batch Plant, for example, is an economical and flexible option featuring a wide variety of mixers and controls. It can pour concrete volumes anywhere from a few yards to 25 yards per hour. It’s also pre-plumbed, pre-wired and shop-tested for a quick and easy installation. Set-up time from delivery to installation is as little as three days.  

One hesitation manufacturers may encounter when considering owning a batch plant is how to operate it. Mixer Systems developed its E-150 batch control system with this in mind. The system features fully automated sequence batching of materials, scales for cements and aggregates, a recordation program for materials use, and remote access for trouble shooting.  

Mixer Systems experts are available for any batch system support your team needs, including training, troubleshooting, servicing, and shipping parts within 24 hours. Explore all of our batch system products in our Buyers Guide. 

Choosing the Right Option 

The break-even volume—the point where a batch plant becomes more cost-effective than ready-mix deliveries—varies by region and costs, but generally falls around 25 cubic yards per day. Business owners expecting lower annual volume and can establish a reliable relationship with a ready mix company could find ready mix a reasonable option. Those with limited scheduling flexibility, higher-volume needs, the capacity to manage production, and the need to control costs may benefit from batch plant ownership. 

By carefully evaluating costs, logistics, and operational demands, you can choose the most efficient and profitable concrete sourcing strategy. 

Contact Mixer Systems today to calculate your break-even cost.