Application of the Fully Automated PC Precast Wall Panel Production Line and the CO-NELE Planetary Concrete Batching Plant

Prefabricated construction has become an inevitable trend. However, traditional precast component production has long faced pain points such as high labor costs, fluctuating production efficiency, poor mixing homogeneity, and low waste utilization. In 2025, a PC precast concrete manufacturer in the UAE introduced a fully automated PC precast wall panel production line and built a dedicated PC vertical shaft planetary concrete batching plant from CO-NELE. Since its full operation in the fourth quarter of 2025, this combined solution has not only achieved the implementation of an "unmanned" production line but also made significant breakthroughs in the resource utilization of industrial waste.

Fully Automated PC Wall Panel Production Line – From "Manufacturing" to "Intelligent Manufacturing"

At the production site of the UAE PC precast concrete manufacturer, there is no bustling scene reminiscent of traditional building materials factories. On the 100-meter-long production line, only three technicians monitor the process in the central control room. This is the core of the project – the fully automated PC lightweight wall panel production line.

1. Highly Integrated Automated System

This production line is seamlessly integrated into eight subsystems: molding machine system, cutting machine system, conveyor system, hoisting system, electrical control system, pneumatic system, and material conveying system. The central control system acts as the "brain," controlling each process in real time through signal sampling switches distributed throughout the line.
Intelligent Control Mode: Utilizing a dual-mode design of "central computer automatic control + manual backup," the system automatically completes the entire process of batching, molding, cutting, and palletizing according to preset parameters during normal production. During debugging or under special conditions, engineers can make fine adjustments via manual operation boxes to ensure the production line's flexibility and adaptability.

Data-Driven Production Management: Through integration with the MES system, each wall panel leaving the factory is assigned a unique "ID card," recording production time, operating team, and raw material batch, achieving full lifecycle quality traceability.

2. Breakthrough in Core Molding Technology

The core of the production line lies in the molding machine system. The equipment used in this project is based on the principle of vibration extrusion molding and is specifically optimized for PC precast wall panels.

 PC-Dedicated Planetary Concrete batching Plant – The "Heart" of Precise Energy Supply

If the molding machine is the torso, then the PC-dedicated concrete batching plant built adjacent to it is the one that continuously supplies the "blood" to the PC production line. To meet the high standards required for concrete in PC precast components, the UAE PC precast concrete manufacturer selected the CO-NELE CMP1000 vertical shaft planetary concrete mixer.

1. Why Choose a Planetary Concrete Mixer?

PC precast wall panels, especially lightweight wall panels produced using solid waste, have extremely high requirements for the workability, homogeneity, and fiber dispersion of concrete. Traditional twin-shaft mixers often fall short.
Complex Convection Motion: During operation, the vertical shaft planetary mixer's mixing arms revolve around the center of the mixing drum while the mixing blades themselves rotate at high speed. This unique counter-current planetary motion trajectory creates a vigorous multi-dimensional convection cycle within the mixing drum.
1. Comprehensive Shear Force: The complex motion trajectory ensures that materials undergo intense shearing, convection, and diffusion within the drum, eliminating blind spots. Even with the addition of short-cut fibers or minimal amounts of admixtures, they are uniformly dispersed in the mixture within a very short time (typically within 60 seconds). This is crucial for ensuring consistent strength in lightweight wall panels and preventing cracking.
2. Structural Innovation Designed Specifically for PC Production Lines: This precast concrete batching plant was designed with the specific needs of downstream PC production lines in mind from the outset:
The CO-NELE planetary concrete mixer features a multi-outlet discharge design: Considering the potential expansion to a second or even third PC production line, the mixing plant is equipped with two independent discharge ports. Through hydraulic control, one main unit can alternately feed materials to two different production lines, achieving "one machine, two lines," significantly reducing equipment investment costs.

Furthermore, addressing the strict proportioning requirements of PC components, a double-door discharge structure and a dual-speed metering system are incorporated. Combined with automatic drop compensation via computer, this ensures that the metering accuracy of cement, water, and admixtures reaches a dynamic 0.1% level. Chapter 3: Case Study Benefit Analysis

After nearly a quarter of actual operation, this combined equipment from the UAE PC precast concrete manufacturer has delivered impressive results:

Soaring Production Efficiency: The PC production line is designed to produce 150,000 square meters per year per shift. In actual operation, by optimizing the feeding rhythm of the mixing plant, continuous and stable extrusion by the molding machine was achieved, with actual production capacity approaching the design peak, fully meeting the needs of three-shift continuous operation.
Leap in Product Quality: The slurry provided by the planetary mixer results in a uniform internal structure and high surface flatness of the wall panels. Testing showed that the product's compressive strength and shrinkage value both exceeded national standards, and the occurrence of hollow areas and cracks in the walls after construction was significantly reduced.