At the end of 2017, Al-Hareth commissioned the renowned consulting firm HWP Consulting with the task of constructing a plant with all modern details for the production of concrete block products of very high quality. The products were to meet the quality demands of Al-Hareth and its customers. The company supplies high-quality products, which are produced by a high-performance concrete block manufacturer from Germany. The company Zenith Maschinenfabrik GmbH was chosen because it has been supplying machines and circulation systems to the region for over 60 years and Zenith is known for its quality and customer service.

 

 

It was not long before an agreement was reached with Zenith so that the foundation work and construction of the plant could begin in mid-2018. The installation and commissioning were carried out by the well-rehearsed specialist staff of the three companies Zenith, QGM and HWP Consulting.

 

The newly designed high-performance single pallet machine Zenith 1500 forms the centrepiece of a state-of-the-art and ef- ficiently working concrete block production. The wide range of production possibilities meets customer requirements. The Zenith 1500 comprises the production of niche products, gardening and landscaping products as well as pavers, kerb- stones and bricks. In addition to high quality and productivity, the engineers put special focus on guaranteeing a low- maintenance and trouble-free production process. The use of screw fittings allows easy exchange of all worn parts within a short time. Due to the screwable design of the vibration table, the motor cross beam and the frame side bars, this machine adapts to the customer’s production conditions. An automatic quick-change system for moulds, various Colormix equipment and other special equipment as well as tamper head cleaning devices complete our delivery program.

 

The single pallet machine Zenith 1500 is working with an in- innovative servo compaction system named Ultra-Dynamic. This high-quality vibration system stands for very high compaction and extreme dynamics and therefore guarantees a quick and efficient production of high-quality products. Especially for products with a large volume and also for high-quality products, which are produced with pre- and intermediate vibration, this vibration system provides many advantages.

 

Moreover, the plant is equipped with a control and diagnostic system which supports the machine operator during his work and therefore always guarantees an efficient production.

Zenith is using Siemens Control and Circuitry Technology for all applications. Siemens is a global player and guarantees a quick spare parts supply worldwide. You can be sure that we are always using the latest and fastest technology. Thanks to the continuous use of Profinet and Ethernet, all information is available anywhere at any time. All controlled axes are monitored via absolute value encoder technology. This eliminates a time-consuming calibration of the plant in case of a black-out. Our service engineers, which are based worldwide, can offer support at any time by using the already installed internet remote maintenance.

 

The cabling as well as the air and water supply for the entire circulation system were laid overhead. Thus the space for the plant was optimally used. The wet side was equipped with an intermediate station for quality control. In addition, a product emptying station for removal after machine cleaning, etc., was installed.

The dry storage has been installed with a height of 14 levels so that temperature control can be guaranteed from top to bottom. The complete double board vehicle group is operated by laser distance control and data transmission devices by motorized cable drums on both sides.

On the dry side, a specially developed cuber was developed for the various products of the Zenith 1500, such as concrete blocks of various sizes, kerbstones or paving stones. For the safe transport of the products to the end user, Zenith and Al- Hareth have opted for a horizontal strapping machine from Signode and a compact stretch packaging machine from Octopus. Here the customer is not only assured of safety but also protection of the products.

 

An installed stone brush and a spraying device, which sprays oil onto the pallet surface, ensure that the pallets are returned clean to the production cycle. An additional board turner ensures that the pallets are used evenly on both sides.

The entire machine and the control room were then each equipped with a soundproof booth. This also ensures the protection of the operators.