Ultra-modern Kalkman plant for ‚Modern Mondrian‘ in Kampen

MBI De Steenmeesters celebrated an extraordinary milestone with the inauguration of their production hall – the ‚Modern Mondrian‘. After eight months of intensive work, the former heap of sand had been turned into an impressive production hall, that proudly bears the name of the Dutch master Mondrian. The brand-new factory hall is not only state-of-the-art, but also part of one of the most sustainable concrete plants in Europe. The plant was supplied by the Dutch family-run business Kalkman Machinebouw.

Sustainable future

Using cutting-edge technology, the plant is one the most sustainable concrete plants throughout Europe. „The plant is highly energy efficient and completely free of gas. This factory also ensures a much lower carbon footprint, what makes the product manufactured even more sustainable, too,“ states Ton Pasnagel, director for production and technology at MBI.

The New Mondrian integrates advanced technologies in order to ensure energy efficiency, with implementing clean production processes. The products, for example, are stored in the climate chamber for 24 hours a day under perfect conditions, without the consumption of gas. This innovative approach, making use of released heat, results in a remarkably energy-efficient process and a substantially lower cement consumption and energy demand. The use of purified water from the Ijssel river, a complete LED lighting in the factory hall and electrically powered belt conveyors contribute to a sustainable production environment. The integral use of electric systems – even for the dust extraction (that is returned to the base concrete too) – creates a hybrid system, not only saving energy, but also generating energy and makes MBI De Steenmeesters a pioneer in environmentally-friendly concrete production.

Exceptional products

The modern machines provide opportunity for the development of natural nuances and large sizes by which MBI intends to further strengthen their position in the market of decorative paving. In this regard, the commercial director, Patrick van den Tillaart, states: „Owing to our innovative products, manufactured by means of advanced technologies, MBI helps to make the world every day more beautiful. The Inuancia Technology developed by MBI allows processing our products in any direction without impairing the beautiful, nuanced pattern. In this way, we can manufacture slabs, not only being denser and more stable, but also affirming the position of MBI as a leading brand in the paving sector.“

The supplier: Kalkman Machinebouw

Kalkman Machinebouw is part of the Kalkman Group based in Krimpen aan den Ijssel in the Netherlands. The family-run business is celebrating its 100-year anniversary this year. For 75 years, Kalkman Machinebouw has been involved in the development and production of machinery and other equipment for manufacturing concrete products and is specialized in the field of concrete slabs in all types and sizes. With Kalkman machines, slabs in sizes of up to 100 x 100 cm can be made in thicknesses ranging from 3 to 8 cm. The slabs manufactured with Kalkman machines can be used both in the public market and in the private (garden) market.

Further development of concrete compaction

The method for compacting the slabs developed and used by Kalkman is an advanced version of hammer compaction and can be described as targeted vertical high-frequency hammering. A major advantage of this Kalkman hammer compaction is the fact that a very good compaction of the concrete is achieved in a very short time with a relatively low cement content. This advantage is particularly notable compared to slabs that are hydraulically pressed. The carbon footprint is consequently lower as against machines that require more cement.

In Kalkman machines, the slabs are made with the top side (visible side) facing down in the mold. During compaction, the loose steel bottom plate of the mold (the mirror plate or matrix) rests on the anvil, resulting in a very closed surface layer. This allows for relatively quick post-processing. Another advantage of producing slabs upside down with a loose bottom plate is that no mold change is needed for different slab thickness. The slab thickness is determined during the filling process of the base mix concrete by raising or lowering the bottom plate in the mold. Nowadays, the freshly produced slabs are immediately turned over so that the visible side faces up. This allows for direct inspection of the slabs, enabling any necessary adjustments to the machine to be made immediately.

Kalkman pallet circulation systems

For more than 70 years, Kalkman has also been supplying automatic circulation systems with support pallets on which the slabs can harden in a curing chamber. For curing chambers, one can choose between natural curing or faster conditioned curing. For the latter, the supplier collaborates with partners. After hardening of the slabs, they can be post-processed to create a higher quality product. This post-processing includes shot blasting, curling, coating, washing, printing, and more.

A special order: The high-performance machine for MBI

The machine supplied to MBI Beton located in Kampen allows the production of slabs of up to 100 x 100 cm, with the appearance of the slabs resembling a painting – a groundbreaking revolution in the field of decorative paving.

The machine has a capacity to produce two slabs of 60 x 60 cm with face layer in eight seconds. For 100 x 100 cm it is 15 seconds. The speed of the machine and the pallet circulation system are coordinated. The storage capacity in the curing area amounts to 2960 pallets. More than enough for 24 hours of production of 60x60 or 100x100cm slabs.

The demand for slabs made by this machine is growing so rapidly that they had to start working in multiple shifts sooner than expected. We, as the supplier, see this as a great compliment and reward from a market, where consumers are becoming increasingly discerning,“ states general manager Wim Kalkman.