When it comes to concrete production, the efficiency, scalability, and customization of your batching system can significantly impact your bottom line.
Mixer Systems, Inc., has been a leader in designing and manufacturing mixers and batch plants for more than 45 years. In this guide, we’ll walk you through the key differences between Mixer Systems batch plant products so you can find the perfect fit for your operation.
First, let’s cover the basics of what a concrete batch plant is and how it works.
A concrete batch plant, also known as a concrete mixing plant or batching plant, is a facility where the ingredients of concrete—such as cement, water, sand, aggregates, and admixtures—are precisely combined to produce concrete. These plants are designed for efficiency, accuracy, and consistency to ensure high-quality concrete for construction projects.
How a Concrete Batch Plant Works
Concrete batching involves a series of carefully controlled steps. Here’s a breakdown of the process:
1. Material Storage
The raw materials—cement, sand, gravel (aggregates), water, and additives—are stored in separate containers:
- Cement silos store cement and fly ash.
- Aggregate bins hold sand and various sizes of gravel.
- Water tanks supply clean water.
- Admixture tanks store chemical additives used to modify the properties of the concrete.
2. Weighing and Measuring
Accuracy in proportions is crucial for quality control. Each component is measured by weight using load cells and scales:
- Aggregates are weighed on conveyor belts or in hoppers.
- Cement is weighed using screw conveyors or gravity-fed hoppers.
- Water and admixtures are measured with flow meters or scales.
3. Mixing Process
The measured materials are transferred to the mixing unit. Mixers can be of various types, including horizontal shaft, turbin, planetary, and twin shaft, each offering different mixing speeds and qualities.
4. Loading and Delivery
Once mixed, the concrete is discharged directly to a production line or construction site with a skip hoist, a conveyor, a monorail transport bucket, or an overhead crane bucket.
A concrete batch plant provides consistency through automated systems that ensure uniform quality. They are also efficient, producing large volumes of concrete quickly. Batch plant and mixer designs can be adjusted to meet specific project needs and controlled batching minimizes material waste.
Every batch plant from Mixer Systems is custom designed, manufactured and installed to meet a customer’s exact specifications for capacity and performance. Concrete producers choose a batch plant and one of four different mixers to handle production requirements for consistently high quality wet or dry mixes. Mixer also provides silos, hoppers and other components from a single source.
Choosing the right batch plant depends on your production needs, jobsite flexibility, and growth plans. The following are the different ways Mixer Systems batch plants can work for you:
EconoBatch: Smart, Scalable, & Budget Friendly
Best for: Small to mid-sized plants, precast operations, or businesses just starting out.
If you’re looking for an affordable, reliable entry point into automated batching, the EconoBatch is a great starting option. It’s designed with flexibility in mind — modular, customizable, and easy to upgrade down the road.
Top Features:
- Handles up to 6 aggregate compartments
- Produces up to 48 yards per hour
- Modular design makes future expansion easy
- Lower initial investment without compromising performance
This is your go-to if you’re launching a plant and want a smart foundation that can grow with you.
Skid Mount: When Portability Matters
Best for: Temporary jobsites, remote locations, or operations that need flexibility and mobility. Need a batching system that can move with your project? The Skid Mount plant is essentially a mobile version of the EconoBatch, mounted on a heavy-duty steel skid for easy transport and fast setup.
Top Features:
- Portable design for rapid deployment
- Pre-wired and pre-plumbed — saves installation time
- Same high-quality components as EconoBatch
- Ideal for tight spaces or jobsite moves
If your operations are always on the go or you need a fast-setup solution, this is the plant for you.
BatchMaster: Built for High-Volume, High-Speed Production
Best for: Ready-mix plants, high-output producers, and facilities needing full automation.
The BatchMaster is Mixer Systems’ top-tier batch plant — designed for companies that need speed, volume, and total control over the process. If you’re producing large volumes daily, this system delivers serious horsepower.
Top Features:
- Output of up to 250 yards per hour
- Fully automated controls and batching software
- Customizable for multiple mix designs and configurations
- Best choice for long-term, high-performance concrete production
This is the batch plant that keeps your production moving — no matter how demanding your schedule.
Quick Comparison Chart
Building Your Mixer System
Mixer Systems works with producers every step of the way when building and maintaining a mixer system for productivity, reliability and safety. We assemble a total, unified system to provide you with smooth, dependable material flow throughout your entire plant.
Once the specifications are confirmed and a batch plant is selected, we customize a solution that includes one of four high-performance mixers, plus material handling components, and accessories. All from a single source.
Batch plants are powered by E-150, our proprietary computerized batch plant control system. The PLC/PC hybrid computer features an operator-friendly high-definition industrial touch-screen display for automatic and manual batching.
E-150 offers:
- Full simulation to batch mix designs without actually using cement and aggregate materials.
- Highly accurate slump and yield control.
- Remote diagnostics of mechanical and electrical plant troubleshooting.
- Accessible and printable plant schematics and electrical drawings.
- Fully accepted by the PCI, DOTs and numerous other associations.
- Serviced and supported by Mixer Systems engineering staff.
Ready to Take the Next Step?
Mixer Systems prides itself on being a one-stop resource. Our 86,000-square-foot Wisconsin facility houses advanced product planning, state-of-the-art manufacturing, and the capability of designing and constructing concrete batch plants from the ground up. Our product line is the largest family of equipment in the industry, built with American reliability to stand up to the challenges of the world of concrete. Internationally, Mixer Systems’ equipment is at work in over 60 countries.
Contact Mixer Systems today to ask questions or request a quote.