Recipes and processes
Production setup tailored to product variety, batch size, and changeover frequency.
CONSTRUCTION CHEMICALSFrom recipe to pallet.
From recipe to pallet.
Consistent production target.
We design dosing, mixing, and end-of-line operations together to ensure product quality and production continuity.
Discover our approach
Mixing + Palletizing
Recipe managementHomogeneous mixtureEnd-of-line integration
ENGINEERING THAT CONSIDERS THE WHOLE
The right equipment. The right process.
Success in dry mix production comes from accurate dosing, homogeneous mixing, and repeatable recipes. Metkan designs the entire system—from raw material feeding to the end of the line—with a focus on quality standards, dust management, and production continuity. The goal is to produce the same product with consistent quality every time and to minimize downtime.
OUR PROCESS APPROACH
Consider the steps together.
Examine the input, function, and impact on the next step for each stage.
FEEDING
A system starting from raw materials.
We evaluate raw material properties and the transition from stock to production, planning feeding and conveying steps in conjunction with the facility layout.
- WHAT WE EVALUATE
- Raw materials and stock organization
- WHAT WE PLAN
- Feeding and conveying setup
DOSING
Every component in its designated place within the recipe.
We configure the weighing and dosing system according to the recipe. Assembly, calibration, and mechanical factors are considered as integral parts of the process.
- WHAT WE EVALUATE
- Recipe and component quantities
- WHAT WE PLAN
- Batch-based dosing setup
MIXING
Batch-to-batch consistency.
We evaluate mixer volume, fill level, mixing time, and product changeover frequency together. We incorporate access for discharge and cleaning into the design.
- WHAT WE EVALUATE
- Batch volume and product properties
- WHAT WE PLAN
- Mixing and discharge cycle
PACKAGING
Extend the production rhythm to the end of the line.
We address packaging, bag flow, and the separation of non-conforming packages in conjunction with subsequent conveying and palletizing steps.
- WHAT WE EVALUATE
- Package and line speed requirements
- WHAT WE PLAN
- Consistent bag flow
PALLETIZING
A final stage ready for shipment.
We design end-of-line solutions that take into account bag characteristics, pallet patterns, and robot operating layouts.
- WHAT WE EVALUATE
- Bag specifications and pallet layout
- WHAT WE PLAN
- Palletizing and shipping configuration
SOLUTION SCOPEFor a system
For a system
that works as one.
Dry mix plants, new production lines, and capacity expansions.
Production lines for C1/C2 ceramic adhesives, tile grout, interior/exterior plaster, repair mortars, self-leveling screed, waterproofing, and thermal insulation adhesives/plasters; new plant installations and capacity expansions.
Dosing and mixing
Integrated selection of weighing, raw material transfer, mixing, and discharge steps.
Packaging and palletizing
Coordination of bag conveying, straightening, weighing, sorting, and robotic palletizing steps.
Dust and product changeovers
Dust management, cleaning access, and assessment of cross-recipe residue.
PROCESS MACHINERY
All products Get to know the equipment.
Your products
Product family, recipe variety, and raw material characteristics.
Your production plan
Batch size, target capacity, and product changeover frequency.
Your packaging
Bag type, weight, pallet pattern, and shipping layout.
FREQUENTLY ASKED QUESTIONSClear answers
Clear answers
for your project.
Based on the recipe, fill level, target mixing time, and frequency of product transitions.
Dust leakage increases maintenance needs and compromises occupational safety; proper filtration and enclosed design details enhance operational continuity.
Vibration, mechanical stress, incorrect calibration, and improper installation affect weighing accuracy.
Cross-contamination and residue. Cleaning access and the process plan are important.
Typically occurs when the synchronization between packaging and palletizing, the bag flow, and the rejection scenarios are not properly configured.
A proper shape and balanced distribution enhance pallet stability and elevate shipping standards.
The bottleneck could be in dosing, the mixing cycle, packaging, or palletizing; the specific point requiring reinforcement is determined based on data.
Dry mix mortar and construction chemicals plants
A dry mortar plant can be configured for tile adhesive, dry render, grout, repair mortar, self-levelling screed and insulation mortars. Raw material feeding, weighing, additive dosing, mixing, bagging and palletizing must operate as a coordinated line. Formulations and target output define the scope.
Several dry mortar families can share a suitably configured storage, dosing, mixing and cleaning system. Coloured grouts, low-dose additives and different particle-size distributions require specific changeover and residue-control planning.
Define raw material reception and storage, sand preparation or drying where required, batching, mixer, bagging, palletizing, dust extraction and automation in the proposal. Civil works, utilities, installation and commissioning responsibilities must also be agreed.
RELATED ARTICLES
Technical guides for the right choice.
How Is Dry-Mix Homogeneity Measured with CV?
A dry blend that looks uniform does not prove that every bag has the same composition. Homogeneity verification requires a measurable marker, a representative sampling plan and one consistent analytical method. The coefficient of variation (CV) expresses the spread among samples relative to their mean. The number alone is not mixer performance, because sampling and laboratory error also affect it.
Read the technical article
Why Does a Dry Blend Segregate After Mixing?
A dry-mortar sample taken at the mixer may be satisfactory while the first and last bags differ in composition. Increasing mixing time at this point is an intervention made before locating the problem. Dry-blend segregation, meaning the separation of previously mixed components, can develop during downstream handling. This guide offers a diagnostic approach from mixer discharge to bagging to identify where the blend changes.
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How Is Dosing Accuracy Checked in a Dry-Mix Plant?
In a dry-mix plant, the actual amount of an ingredient in the mixer can differ even when the recipe display looks correct. A weigh hopper may appear to have reached its target while mechanical stress, vibration, suspended material or product that continues to flow from the feeder changes the result. A sound check considers the target, net weight, discharge and batch repeatability together, not only the kilograms on the screen. This allows mechanical and process causes to be tested separately before the problem is attributed to calibration.
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How is Construction Chemicals Plant Capacity Calculated? Hourly and Daily Production Planning
The capacity of a construction chemicals plant directly influences many critical decisions, ranging from investment planning to production costs. This is because the plant's hourly and daily production output is calculated based on a combination of factors: mixer volume, feeding system, raw material flow, weighing precision, filling time, bagging speed, operator scheduling, and automation level. Therefore, simply asking "how many tons does it produce?" ...question does not yield an accurate result. The enterprise must evaluate the product recipe, shift duration, production variety, and in-line waiting times collectively. Metkan Makine approaches capacity calculation for construction chemicals production lines based on the entire process flow, rather than solely on machine power.
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How Should Dry Mix Recipe Changeovers and Cleaning Be Planned?
Recipe changeovers and cleaning in a dry mix plant should be planned by considering product quality, production continuity and the risk of cross-contamination together. The best approach is to sequence recipes according to ingredient similarity and cleaning requirements, control material remaining in the line during changeover, and establish a practical cleaning plan for each product group.
Read the technical articleWhy Is Building a Construction Chemicals Plant a Critical Investment? Effective Line Design and Efficient Production
Constructing a construction chemicals plant requires not just the installation of the production line, but the proper structuring of the entire process. This is because raw material flow, mixing homogeneity, conveying arrangements, and bagging performance all contribute to the same quality standard in construction chemicals production. If feeding systems do not advance raw materials at the right pace, the mixer cannot achieve the desired efficiency. If the mixer fails to create a homogeneous mixture, product consistency suffers. If the bagging and palletizing line is not synchronized with the process, shipment quality declines. For this reason, the construction of a facility requires far more extensive technical planning than the mere installation of individual machines.
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