Feasibility Report@ZENITH 844SC PDF

With Quality & Service, We provide:
Integrated Solutions for Concrete Block Making
Feasibility Report
ZENITH 844SC Fully Automatic Stationary Multilayer Machine
(Batching and Mixing plant with Facemix Production Line)
Zenith Maschinenfabrik GmbH Telefon: (0)2735/779-0 Geschäftsführer: Xinyuan Fu

Postfachadresse: Postfach 11 60, D-57272 Neunkirchen Telefax: (0)2735/779-211 Sitz der Gesellschaft: Emden
Hausadresse: Zenith Straße 1, D-57290 Neunkirchen eMail: info@zenith.de Registergericht: Amtsgericht Aurich HR B 203050
GERMANY Homepage: http://www.zenith.de USt-IdNr.: DE 815510149
Steuernr.: 58/200/12824
Bankkonten (Bank Accounts with):
Commerzbank Siegen; Konto-Nr. 819 474 800; BLZ 460 400 33; BIC: COBA DE FF XXX; IBAN: DE41 460 400 330 819 474 800
1
Main Technical Specifications

Production per Mould: 54 pcs/mould (paver: 200x100x(50-100mm)
40 pcs/mould (paver: 225x112.5x(50-100mm)
4 pcs/mould (Curbstone: 1000x120/150x300mm)
Cycle Time: 25-45 seconds (depending on product)
Production per Shift 1,176m2, for 200x100x(50-100)mm paver（With face-mix）
(8 Working Hours): 1,248m2, for 200x100x(50-100)mm paver（Without face-mix）
(100% availability 1,120m2, for 225x112.5x(50-100)mm paver（With face-mix）
provided) 2,500 Pcs, for 1000x120/150x300mm Curbstone (With face-mix)
Largest forming area: 1240x1000mm
Height of finished
50-500mm
products:

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Gross Weight: about 24T(with face-mix)
Vibration table: 80kN
Top model vibration: 35kN
Total installed
115kN
capacity:
crushed stone, sand, cement, dust and coal fly ash, cinder, slag,
Raw Materials:
gangue, gravel, perlite, and other industrial wastes.
concrete blocks, solid/hollow/cellular masonry products, paving
stones with or without face mix, garden and landscaping products,
Applied Products:
slabs, edgers, kerbstones, grass blocks, slope blocks, interlocking
blocks, etc.
widely used in buildings, road pavings, squares, gardens,
Applied Fields:
landscaping, city constructions, etc.
Note: All the production parameters are subject to change, without prior notice.
1) Consumption report (ZENITH 844SC Automatic Mobile Multilayer Machine)
Pavers with hard facing stone: 200x100x80 mm

Stress & Strength: 30-35MPA (to increase the strength of the blocks, it needs to change the mix design)
Production per Shift (8 working hours): approx. 1,100m3 Pavers (with facemix)
Proportional Ratio:
- Main Materials: 17% Cement, 30% Sand 0-3mm, 25% Gravel 2-5mm, 28% Gravel 3-8mm
- Hard Facing (10mm) : 25% Cement, 45% Sand 0-3mm, 30% Gravel 1-3mm
Water Consumption: ~ 8% (Water consumption depends on the moisture of the aggregates)
Earth moist concrete: 0.32 –0.35 (water / cement ratio)
Consumption Consumption Consumption Consumption/year

No. Name
/hour /Shift /Day (250 days)
1 Cement 4T 32T 64T 16,000T
2 Sand 0-3mm 8.5T 68T 136T 34,100T
3 Gravel 1-3mm 1.13T 9T 18T 4,400T
4 Gravel 2-5mm 5.9T 47T 94T 23,650T
5 Gravel 3-8mm 6.9T 55T 110T 27,500T
6 Water 1,250L 10,000L 20,000L 5,000m3
Above mentioned mixing recipes are to be used as a guideline only. Optimum mixing recipes depend on
type of aggregates locally available and their natural strength. During commissioning of machine,
aggregates are tested and optimum mixing recipes are compiled by the ZENITH service engineers.

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2) Production output
ZENITH 844SC Automatic Mobile Multilayer Machine - Production Output
L H W Quantity Quantity in 8
BLOCK TYPE
mm. mm. mm. per Mould Hours
225 50-100 112.5 40 1,120m2
163 50-100 198 36 1,120m2
200 50-100 100 54 1,176m2
210 50-100 105 40 1,003m2
1000 300 120/150 4 2,500
The capacity data are theoretical and are dependent on machine settings, mix design, aggregates used
and other environmental conditions, are for reference only.
3) Time Schedule:
1. Production of Machine: 12-18 weeks after receipt of the advance payment (30% of the total value).
2. Shipment: about 30 days from Belgium Port to Xiamen Port, China.
3. Custom Clearance: about 10 days depending on customer efficiency.
4. Preparation: about 4 weeks. (can be done during machine production and shipment)
5. Installation/Commissioning/Training of your workers: about 10 working days.
Total: about 150 days to 190 days. If the customer clears custom very soon and prepare everything on
time, the production line can be expected to be ready for producing blocks in about 5 months.
4) Workers suggested: Total about 4-5 workers in the whole factory.

1 driver for loader 1 workers for operator for the complete line
1 driver for forklift block clamp 1-2 workers for delivery
We suggest for at least one electrical engineer and one mechanical engineer are needed for
repair and maintenance.
5) Land area suggested: 4000-5000m2, including factory hanger about 60mx20m, materials storage
area (aggregates), stocking area, office and parking.
6) Power: Total 163kW (215KVA) (including 97KW for QGM Batching and Mixing Plant, 66KW for
ZENITH 844SC.)

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Annex-1: Photo of Machinery
QGM Batching and Planetary Mixing System

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ZENITH 844SC Fully Automatic Mobile Multilayer Machine

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ZENITH 844SC Fully Automatic Control System 控制系统

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Annex-2: Technical Specifications and Descriptions

Technical Specification
A. Production Range, Cycle Time, Power, Machine Weight & Dimensions
1) Pavers & high block: 500mm;
Max.Production area: 1240x10000mm;
Block height: 50-500mm;
Max. stacking height (pavers): 640mm;
2) Cycle Time: without facing concrete for 60 mm pavers approx. 25 sec. with facing concrete for 60
mm pavers
3) Max. Power: 66KW;
4) Machine Dimension: 6200mm×3000mm×2470mm;
5) Pallet Size: 1270mm×1050mm×125-140mm;
6) Machine Weight: 24T (machine with accessories);
7) Nominal Voltage: 400V;
8) Line Frequency: 50HZ;
9) Connecting Cable: 4×70 mm2
B. Mechanics:
1)．Frame
1.1) Sturdy machine frame of rectangular steel sections;
1.2) four columns system, mould frame and tamper head guided in four columns diameter of columns 80
mm, large dimensioned guide bearings with dust protection (cleaning rings), diameter of guide
bearing 80 mm;
1.3) guide columns and piston rods chrome-plate;
2). Mould Frame Lift

2.1) mechanical synchronization of mould and tamper head by means of lever shaft. Driven by two
cylinders bearing joints in the mould frame;
2.2) Parallelism can be achieved by adjusting the connecting rod and bearing joints;

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2.3) hydraulic locking device for tamper head during demoulding;
2.4) hydraulic pressure device for pressing mould frame during vibration
upon vibrating table;
2.5) Drive means on the frame built-mold clamping device, through the
effect of a pressure spring and can be adjusted with a separate
clamping and damping pressure release function. (Recommendation:
rebound stroke25mm, equivalent to about 9,000N acting force.
2.6) Reduce the vibration effect on mould frame fixture by rapid change
device
3）．Tamper Head Lift
3.1）The tamper head is lifted by two hydraulic cylinders, which are

synchronized by a lever shaft and adjustable driving rods.
3.2 ） The demoulding parallelism can be achieved by adjusting the

connecting rod bearings and joints;
3.3）Main tamper head plate was hanging by a bridge to the guide damping, thereby effectively utilizing
centrifugal force;
3.4）The process of compacting the tamper head's pressure to the end is stepless control, (recommended:
9600N force, the pressure is set to 14MPa);
3.5）There are two outside vibrators installed on the main tamper head plate, vibrators can produce 35KN
centrifugal force.
4). Blocking / Locking Device:
4.1) Hydraulic clamp controls the tamper head locking device;
4.2) The blocking device of mould & tamper head is used for demoulding & control by hydraulic clamp.
5). Feeding System
5.1) The feeding system consists of hopper, guid table, feed drawer & shaft. As a complete one on the
main machine & additional device, height adjustable;
5.2) Feeding system for backing and facing concrete consisting of lift frames, guide rails for the feed
drawer and feed drawer table, which are height-adjustable using rack winches (adjustment to the
respective mold height);
5.3) Collar rolls and height-adjustable double rails guide the feed drawer precisely along the entire path.
The sheet plates are made of wear-resistant steel and are easily replaceable.
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5.4) Through the built-in swing grating to ensure that the mould is properly feeded, convenient
disassemble & easy clean.
5.5) The mould scraper is divied into three parts & make sure the cleanliness of mould surface. The
scraper that mounted on the front wall of the feed drawer of backing concrete can make sure the
cleanliness of tamper head.
5.6) The feed drawer of backing concrete has pneumatic

scraper;
5.7) Two hydraulic cylinders supported in the lift frame move

the feed drawer back and forth using synchronizing
shafts with adjustable driving rods in the guide rails.
5.8) The volume of hoppers for backing concrete & facing

concrete are 2100L, which are designed to match the
feeding convey system;
5.9) The diameter of feed drawer roller is 110mm.
6). Vibration
6.1) Moveable vibrating table in the machine frame.
Vibrating table in two-part execution for
optimum transmission of vibrating force with
easy exchangeable wear plate;
6.2) vibrating table with two twin high frequency
eccentric vibrators HFZ 16.015 synchronised by
toothed wheels for directional vibration with four three-phase motors, 3 kW each;
6.3) vibration force max. 4 x 20 kN;
6.4) can change the wear-resistant steel plate to protect the top of vibration table & both sides are
available;
6.5) separate control of table vibrators via two frequency control units for adjustment of vibrator motors
up to max. 50 HZ separated;
6.6) 2 blowers for cooling of vibrator motors;
6.7) tamper head with two motor vibrators ZE 35-2 K, motor capacity 2 x 2,12 Kw, braking via electronic
braking device
6.8) The flexibility of the machine is provided by the height adjustable vibrating table. (first layer=product
height 50-300mm, second layer=product height 325-400mm, third layer=product height is only
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500mm).
6.9) Realize fast start-up and braking through tiny mass acceleration;
6.10) single connection and fuse for all vibrator motors.
7). Sand Scattering Device

7.1) The sand scattering device with mechanical
cover for sand intake and with hydraulic
gate for sand runout is attached to the
vibrating table. The molding frame can also
be attached laterally to the machine frame
on one or both sides;
7.2) The sand scattering device is best filled by a
separate valve control for both filling pipes.
8). Quick Change Unit for Mould.
8.1) tamper head Quick change device;
8.2) mould installation carriage and waste collecting bin;
8.3) main tamper head plate equipped with hydraulic tamper head quick change
device;
8.4) self-supporting machine construction.
9). Lift Table

9.1) The lift table is designed as a scissor lift
table and is actuated by one hydraulic
cylinder;
9.2) Lowering the lift table is regulated by a
load-independent throttle valve. The
speed set can be changed by turning
the screw.;
9.3) The touch panel is used to set the
number of layers to be deposited on the
lift table. The display shows the number
of layers set.
10). Slide conveyor

The ratchet conveyor transports the empty pallets from the pallet retainer to the lift table and the
stone cubes from the lift table to the roller conveyor.
11). Powered Roller Conveyor

Divided in two sections for 3 pallets each, pallets can be transported by section separately, control
of roller conveyor drives via frequency converter.

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12). Pallet Retainer
The pallet retainer can receive approx. 15 wooden pallets or

12 steel pallet. It is equipped with a lifting device to pull the
bottom pallet free of the retainer (with the slide conveyor).
Side feeding from the left or right, as well as from the back is
also possible.
13). Hydraulics
13.1) multi-circuit medium pressure hydraulic system, fed by three pumps: capacity max 2 x 47 l/min +
9,8 l/min + 13, 2 l/min = 117 l/min. with working pressure of max. 180 bar; reversing valve control
the movement (Rexroth)
13.2) The pushrod of main material & face feed drawer is equipped with buffer;
13.3) thermostatically controlled oil cooler with a cooling capacity of 16 kW, with separate motor for
filtering;
13.4) The speed is adjustable;
13.5) Check valve, overpressure valves, relief valves can be
embedded installation;
13.6) Oil Temperature indicator and cooling system;
13.7) hydraulics with proportional technology allow individual
production speeds depending on product;
13.8) cylinder suspensions on both sides with spherical rocker
bearings;

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C. Electric
1) as a standard equipped with a fully electronic PLC (programmable logic controller) system, Siemens
S 7 – 317;
2) operator access via touch panel with 15” color display;
3) Easy Operation:
-Menu Navigation: Operating authority is strictly limited &
Managed by several passwords. Only the operators have the
permission;
- Recipe Management: Process data classification based on the
content clear, easy call; the lower limit can be set on the recipe,
thereby optimizing the production; Prevent misuse and errors
production; all information generated along with the date and
time information can be recalled in the log；
- Display and control manipulation possibilities: all production
process parameters, such as time, counter, options, working
path, hydraulic speed and pressure, etc., can be set by touch
panel; the whole production line operation or fault information
can be called up by the respective picture shows; display language can be changed; operating data
includes production time, hours of operation, maintenance and downtime; product thickness
measurements.
4) additional control elements arranged below touch panel for following hardware functions: operation
mode selector switch, control voltage On/Off, automatic mode On/Off, activation of safety guard
system, vibrators On/Off, machine lighting On/Off, emergency stop；
5) vibration control according to time or stone height；
6) variable adjustment of pre-, intermediate and main vibration；
7) linear path measuring system for movements of mould, tamper head, feed drawer and vibration
table allow easier adjustment of paths during product change；
8) parameters such as times, counters, selection possibilities, cycle- and trouble shooting indication as
well as recipes administration and ODA are adjustable or can be recalled via touch panel；
9) working hour meter；
10) air conditioning unit for control cabinet；
11) Electricity Parameter: 400 V AC / 50 Hz
Electric variable Effective installed load

Nominal voltage 400 V AC
Line frequency 50 Hz
Power input Cross section at least 4 x 70 mm2

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Electric drives (400 V / 50 Hz), Modell 844 Standard
Quantity Nominal Total current
Supply Drive Power
Motors current consumption
Pump motor P1 / standard

1 9.0 KW 19.80 19.80
design
Pump motor P2 / standard
1 9.00 kW 19.80 19.80
design
Pump motor P3 1 5.50 kW 11.80 11.80
Oil cooler
1 0.75 kW 1.86 1.86
(FGSL-30-EGO)
Tamper head vibrator 2.20 kW
2 3.35 6.70
(EVIRO ZE 35-2 K) (4.40 kW)
3,00 kW
Table vibrator
4 (12.00 kW 6.90 27.60
(HFZ 16015)
)
0.12 kW
Table vibrator fan 2 0.32 0.64
(0.24 kW)
Adjustment 0.70 kW
2+2 2.60 5.20 + 5.20
Filling unit K + V 1) (2.80 kW)
Travel gear 0,55 kW

2 1.75 3.50
Hardfacing unit 2) (1.10 kW)
Vibrator –
1 0.15 kW 0.30 0.30
Sand scattering device
0.55 kW
Roller conveyor 2 1.45 2.90
(1.10 kW)
Control system - general - 1.00 kW 3.00 3.00
Total value: 47.04 kW 108.30
D. Hard Face Unit

1) face concrete hopper geom. volume 2.100 litres;
2) feeding system and hopper adjustable by means of electric rack
jacks fast and easy;
3) concrete hopper with hydraulic discharge;
4) level indicator with optical signal lamp;
5) linear path measuring for movement of feed drawer.
E. Safety System:
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Safety guard system on the various safety grates via code lock for accident prevention of supervising
personnel during production;
F. “Speed & Confort” Package

1) upgrade of programmable controls to Siemens S/-300, CPU 317；
2) hydraulics with improved pump capacity,
pump 1 with 47 l/min and motor 15 KW
pump 2 with 47 l/min and motor 15 KW
pump 3 with 13,2 / 9,8 l/min with motor 5,5 KW
3) large sized oil cooler with separate circular filtering, 16 KW cooling capacity;
4) feed drawer for back concrete with hydraulically driven grate;
5) linear path measuring for feed drawer-, vibrating table- and slide conveyor movements;
6) frequency control of table vibrators: two frequency control units for separate control of each part of
the vibrating table, for control of vibrator motors of 25 Hz up to max. 50 Hz; pre- and main Vibration
in different frequency ranges possible;
7) Powered Roller Conveyor： divided in two sections for 3 pallets each, pallets can be transported by
section separately, control of roller conveyor drives via frequency converter；
8) Operating Platform：with hot dip galvanised walking grates, stairs and handrail；
9) Oil Cooler;
10) Air Conditioning Unit for PLC;
11) Telecommunication System / Modem;
12) Mould Table Extension with safety grates
G. Special Four-side Forklift Clamp

1) Opening range W 550 - 1.230 mm;
2) Opening range W 900 - 1.400 mm
3) Inside height E 850 mm
4) Carrying capacity 2.600 kg
5) Dead weight 740 kg
6) Manual adjustable pressure valve;
7) To operate this clamp two independent hydraulic
circuits are necessary.
ZENITH Maschinenfabrik GmbH

Steuernr.: 58/200/12824
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With Quality & Service, We provide:

Integrated Solutions for Concrete Block Making

Zenith Maschinenfabrik GmbH Telefon: (0)2735/779-0 Geschäftsführer: Xinyuan Fu

Main Technical Specifications

Zenith Maschinenfabrik GmbH Telefon: (0)2735/779-0 Geschäftsführer: Xinyuan Fu

1) Consumption report (ZENITH 844SC Automatic Mobile Multilayer Machine)

Pavers with hard facing stone: 200x100x80 mm

Consumption Consumption Consumption Consumption/year

Zenith Maschinenfabrik GmbH Telefon: (0)2735/779-0 Geschäftsführer: Xinyuan Fu

1000 300 120/150 4 2,500

4) Workers suggested: Total about 4-5 workers in the whole factory.

Zenith Maschinenfabrik GmbH Telefon: (0)2735/779-0 Geschäftsführer: Xinyuan Fu

Zenith Maschinenfabrik GmbH Telefon: (0)2735/779-0 Geschäftsführer: Xinyuan Fu

Zenith Maschinenfabrik GmbH Telefon: (0)2735/779-0 Geschäftsführer: Xinyuan Fu

Zenith Maschinenfabrik GmbH Telefon: (0)2735/779-0 Geschäftsführer: Xinyuan Fu

ZENITH 844SC Fully Automatic Stationary Multilayer Machine

Max.Production area: 1240x10000mm;

Block height: 50-500mm;

Max. stacking height (pavers): 640mm;

3) Max. Power: 66KW;

4) Machine Dimension: 6200mm×3000mm×2470mm;

5) Pallet Size: 1270mm×1050mm×125-140mm;

6) Machine Weight: 24T (machine with accessories);

7) Nominal Voltage: 400V;

8) Line Frequency: 50HZ;

9) Connecting Cable: 4×70 mm2

1.1) Sturdy machine frame of rectangular steel sections;

1.3) guide columns and piston rods chrome-plate;

2). Mould Frame Lift

Zenith Maschinenfabrik GmbH Telefon: (0)2735/779-0 Geschäftsführer: Xinyuan Fu

3）．Tamper Head Lift

3.1）The tamper head is lifted by two hydraulic cylinders, which are

3.2 ） The demoulding parallelism can be achieved by adjusting the

4). Blocking / Locking Device:

4.1) Hydraulic clamp controls the tamper head locking device;

5). Feeding System

main machine & additional device, height adjustable;

respective mold height);

5.6) The feed drawer of backing concrete has pneumatic

5.7) Two hydraulic cylinders supported in the lift frame move

5.8) The volume of hoppers for backing concrete & facing

5.9) The diameter of feed drawer roller is 110mm.

6.1) Moveable vibrating table in the machine frame.

Vibrating table in two-part execution for

optimum transmission of vibrating force with

easy exchangeable wear plate;

6.2) vibrating table with two twin high frequency

eccentric vibrators HFZ 16.015 synchronised by

6.3) vibration force max. 4 x 20 kN;

6.6) 2 blowers for cooling of vibrator motors;

6.10) single connection and fuse for all vibrator motors.

7). Sand Scattering Device

8). Quick Change Unit for Mould.

8.1) tamper head Quick change device;

8.2) mould installation carriage and waste collecting bin;

8.4) self-supporting machine construction.

9). Lift Table