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 By 2024, the third party control system, which was running on outdated Windows 98 software, was failing and prone to glitches.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.”