Mixer Systems to Host Emerging Leaders

Mixer Systems, Inc. will be hosting the Concrete Masonry and Hardscape Association’s Emerging Professionals Group (EPG) Fall Workshop, September 10-12, at their headquarters in Pewaukee, WI.

The EPG workshop is an opportunity for the next generation of leaders in the concrete masonry, hardscape, and manufactured stone veneer industries to convene and explore market expansion. Over the course of 1.5 days, participants will engage in team-building exercises, off-site tours, networking sessions, insightful guest speaker presentations, and much more!

Learn more and register here.

Mixer Systems Celebrates 45 Years of Excellence

Mixer Systems, Inc. proudly announces its 45th anniversary in 2024. Established in 1979, Mixer Systems continues to be a leader in providing whole-plant solutions for concrete products in the industry and environmental markets worldwide.

“Since its inception, Mixer Systems has been committed to delivery exceptional products and customer service. Our highly skilled engineering staff works closely with our customers to develop tailored solutions to meet their specific needs. This commitment to customizations sets us apart,“ says Nicholas Passint, President of Mixer Systems, Inc. “Furthermore, all our products are designed and manufactured in America. We are grateful to all the customers who have supported us over the last 45 years and look forward to building new partnerships.”

Spanning an impressive 86,000 square feet, the Mixer System facility houses advanced product planning, state-of-the-art manufacturing, and the capability to design and construct concrete batch plants from the ground up. While the Turbin Mixer laid the foundation for the business in 1979, today Mixer Systems boasts four mixers – Planetary, Horizontal Shaft and Twin Shaft, and a comprehensive line of related components and accessories to design a batch plant precisely to customers’ specifications.

Mixer Systems’ product line represents the largest family of equipment in the industry, renowned for its American reliability and durability, standing up to the to the challenges of the concrete world. Visit www.mixersystems.com to see the complete line of products.

New Equipment and New Product Revive an Aging Batch Plant

An old, rusted hulk of a batch plant turning out a nearly obsolete product. That was the situation confronting Har-ford Venture Group when it purchased Suscon Products (previously known as Suscon Stacks) near Baltimore. The new owners saw potential, but could the dilapidated plant that once supplied concrete smoke stacks up and down the East Coast rise from the rust?

“The company was pouring high heat stacks, but they weren’t environmentally acceptable, and the power industry was turning away from them,” said Alan Trebes, chief operating officer of Suscon. “When we first acquired the property, we just wanted to keep the store open.”

The broken-down batching and mixing equipment was long past its prime, however.

“We completely mothballed it,” said Miguel Lambert, Harford principal. “It was over 30 years old and in the center of the building, an unsuitable location for rebuilding.”

To stay productive Suscon devised a workaround, bypassing the ancient mixer and silos with ready-mix trucks driven into the plant to pour concrete in the product forms. Coordinating just-in-time arrival of the trucks was a constant challenge, though, and Suscon needed a better long-term solution. It was especially urgent as the company had set its sights on expanding production of concrete block for the profitable retaining wall market.

Suscon contacted Mixer Systems, Inc. (MSI), in Pewaukee, Wis., to renovate the plant. “We started by determining if the old equipment could be made operational again, but it was completely worn out,” said Jonathan Jaruseski, eastern US and Canada regional manager. “Instead, we proposed sev-eral different concepts for supplying new batching and mix-ing equipment to be installed where the existing equipment was.”

The costs for removing the old equipment and then doing an upgrade were prohibitive, however, sending MSI back to the drawing board.

“We quoted a completely new batch plant at the far end of the existing building that would not require demolition of the old equipment,” Jaruseski said.

The proposal included a plant in two modular sections: a mixer section and an aggregate section. Both were substan-tially wired and plumbed at the factory prior to shipment to reduce assembly time and start operation sooner.

“What I was most impressed with Mixer Systems was their ini-tial engineering to help us design the flow of the plant,” Lam-bert said. “They looked at the products we wanted to manu-facture and said, ‘Here’s a way for you to maximize production and minimize construction,’ and that was really helpful.”

Suscon had two stipulations: that the plan not make extensive modifications to the existing building and that Mixer Systems partner with a company to complete a turnkey erection.

MSI chose Concrete Plants, Inc., a contractor with which it had collaborated on other projects.

“Very, very few batch plants are identical and the Suscon site was unique,” said Denny Holmes, Concrete Plants area man-ager. “The mixer section was designed so it could be lowered into the building with no modifications. The customer was concerned about cutting the roof open and the clearance was tight—about a foot around. But we had no problem at all, and it went together perfectly.”

The entire installation was completed in about two weeks. The plant was built around Mixer System’s legendary Turbin mixer, with a capacity of 72 cu. ft. or 7,200 lbs. Other com-ponents included three aggregate storage bins, each with a 40-ton capacity, and two cement silos. Additionally, Concrete Plants, Inc. fabricated stairs and walkways for the facility.

Currently, Suscon operates one shift at the plant producing blocks for the Redi-Rock system of engineered retaining walls, shipped to Amazon warehouses, large contractors, and commercial developers. The smallest weighs about 700 lbs. and the largest just under 5,000 lbs.

“We’ve heard these called rather large, adult-size Lego blocks,” said Joshua Edwards, production manager at Sus-con. “They’re able to be stacked into retaining walls as high as 15 feet without tiebacks using the system Redi-Rock has developed.”

From pouring the concrete mix to pulling the finished blocks from the forms takes about 16 hours. Crews begin the day breaking apart forms from the previous day’s production, then pour about 40 new blocks to be dried overnight.

“The mixer is at the back end of the plant on an elevated plat-form about 15-feet high,” said Edwards. “When the material is ready and the gates open, it flows into large ladles, or hop-pers, and then is carried over the forms by a 10-ton crane.”

The forms have rubber molds on the bottom to create a nat-ural, stone-line appearance. Once poured, the top of the blocks is troweled to a smooth finish. In all, Suscon mixes 30-35 batches a day, with some of the larger blocks requiring two-and-one-half batches and the smaller ones one-quarter batch. Each batch takes about five minutes, and the Turbin mixer typically runs two-and-one-half to three hours a day.

Suscon is unique in using recycled aggregate and sand in the mix from Repurpose Aggregates, an allied company lo-cated on the same site. Though the material is repurposed, the finished product must meet the same standards as virgin material. Suscon has an in-house test lab to check quality.

“Redi-Rock requires a target strength of 4,000 psi after 28 days, and we are actually at 4,500 psi,” said Edwards. “Overall, they’re looking for quality.”

With a dependable batch plant now thriving, Suscon is think-ing ahead. “What we’d like to do is continue to increase production at our current facility and learn from this design-and-build,” Lambert said. “If we expand to another facility, we think Mixer Systems would be a great partner, even helping us evaluate an existing plant.”

New Owners Take the Controls at Mixer Systems, Inc.

New Owners Take the Controls at Mixer Systems, Inc. for the First Time in a Generation.

Pewaukee, Wis., July 25, 2023 — Mixer Systems, Inc., North America’s premier manufacturer of mixing and batching equipment for the concrete, glass, and environmental industries, today announced new ownership and promotions of the management team.

Family owners Lesley Hill and David Boles, who shared leadership of the company, sold a majority stake to a group comprised of a Milwaukee-based growth partner and Mixer executives. This is the first change of ownership outside the family since Mixer was founded by William Boles, father of Hill and David Boles, in 1979. The siblings retain minority ownership in the company.

As part of the ownership transition, Doug Duley, president of Mixer, has been promoted to CEO, and Nicholas Passint, general manager, has become president. In addition, Scott Adams, general manager of the DustMaster division, will be expanding his role with Mixer and taking on the GlassMaster product line.

“We’re extremely grateful to Lesley and David for their steady leadership in guiding Mixer forward after the death of William Boles in 2014,” said Duley. “While we’ll miss their energy and spirit, we congratulate them on their retirement and wish them well in spending more time with family and pursuing their passions outside of Mixer.”

The ownership and management changes are expected to bring new capital to Mixer and help position the company for significant growth in the years to come, while also maintain its innovative tradition. Mixer presently makes the largest line-up of mixers and related equipment in its industry.

“This is a truly exciting time for the company as we look to a new chapter of being an industry leader and continuing to provide the best possible solutions for our customers,” said Passint. “Our products will still proudly wear the ‘Made in America’ label to reflect the engineering, craftsmanship, and reliability for which Mixer is known worldwide.”

Contact: Nicholas Passint, 608-213-6429 mobile, nickp@mixersystems.com

2023 Trade Shows

Mixer Systems, Inc. will be exhibiting at the following trade shows this year. Stop by and see us at our booths to get an up close look at our mixers and/or batch plants.

The Precast Show – Booth #1225
February 23 – 25, 2023
Columbus, Ohio
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NCBVA Annual Convention
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Enterprise Precast, Corsicana Texas

A diversified economy and population growth are tempering the effect depressed energy prices would traditionally have had on the Texas construction market, where commercial building work held strong this year on the heels of surging 2013–14 activity. One of the most recent arrivals in architectural precast production, Enterprise Precast Concrete of Texas, LLC, is set to close out a year when historic rainfall totals—40 inches or more in some central and eastern parts of the state, or four times their normal annual precipitation levels—were as disruptive as oil dropping to $40/barrel. Read More

Coating is Key to Reducing Heat Transfer

A leading independent in one of the more specialized areas of manufactured concrete, Rialto, Calif.-based Eagle Roofing Products continues regional rollout of Platinum Tile, whose patented, penetrating coating acts as a thermal insulator to reduce heat transfer into and out of a structure. Applied to freshly extruded concrete tile, the coating is a product of nanotechnology, where measurements tend to billionths of a meter. Read More

Could Ash be the solution?

Is fly ash an essential part of your operation? Use of fly ash in concrete has been on the rise, and for good reasons. Fly ash can produce concrete with higher strength, lower permeability, and a lower carbon footprint. Read More

Mixer Systems Part of New Solution

A contractor upgrading a Whiting, Ind., petroleum refinery recently tapped a distant precast producer for a mostly rectangular vault , one side with a slight, coffin-like angle to accommodate site infrastructure. While customized recast concrete might economically “travel” farther than a standard product, it takes unusual circumstances to justify
shipping a mundane, 75-ton under ground structure from near the Gulf of Mexico to the southern tip of Lake Michigan.Mixer-Systems-Planetary-Mixer

Houston-based Locke Solutions recognized site, labor and safety circumstances surrounding the refinery structure, and delivered a precast solution for a customer mindful of cast-in-place methods’ quality control and schedule variables. The upstart producer thrives on oddball requirements and one-of-a-kind jobsite conditions calling for product fabricated beyond ASTM or related parameters.

Locke Solutions capped its second year in production with a batch plant installation. Mixer Systems furnished a 1.5-yd. planetary mixer, whose twin discharge doors feed buckets transferred by tandem overhead cranes. The batch plant has a 2- to 2.5-minute cycle time, depending on mix design, and affords plant crews the option of
a single 1.5-yd. load or a double batch in a 3-yd. bucket. Mixer Systems also equipped the operation with two 30-ton sand & gravel bins, plus 350-bbl cement silo. The plant runs on E-150 touch screen controls, for which up to 50 mix designs can be programmed.

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