The Challenge
In 2023, a precast concrete manufacturer — known in the US market as a masonry producer — approached Rometa to set up a brand-new, high-output plant in the Miami area (USA), on a 1,500 m² site. The reason was strong demand for concrete blocks and pavers in the area, with material supply falling short: the client needed a high-capacity installation built from scratch, not a replacement for previous equipment.
The technical target was to manufacture solid blocks measuring 19 x 39 x 19 cm, with a 1,400 x 1,200 mm tray capable of producing 15 blocks per cycle, reaching a rate of 2,700 blocks per hour.
The Rometa Solution
To meet these high-output requirements, Rometa chose the 4050 Installation:
Concrete batching plant. Fitted with an M2250/1500 mixer and 3 aggregate hoppers, to guarantee a high-density mix at all times.
Compaction. A 4-axis vibration system, allowing precise adjustment of frequency and force to maximise piece quality and strength.
Handling and curing circuit. A circuit made up of a 13-level lift and lowerator, with an automatic multi-fork carriage that moves pieces to the curing area and back to palletizing. The dual curing zone design minimises the carriage's travel distance, allowing 2 shifts or even 3 shifts a day. Total capacity is 4,000 trays, equivalent to 60,000 blocks inside the curing area.
Palletizing. The palletizer is fitted with servo motors to keep the cycle time perfectly in sync with the machine, with a configuration that adapts to stack 4, 5 or 6 layers high depending on customer demand, plus a downstream strapping system for the final pack.
The Result
The result is a brand-new, automated, high-performance plant adapted to the North American market, capable of sustaining continuous output of up to 2,700 blocks per hour with excellent density and finish, directly solving the material shortage the area was facing.
