Rocktec designed, built, and commissioned a 45 TPH twin shaft mixer for use in the production of concrete roof tiles in New Zealand. This high-efficiency mixer was developed to combine sand, cement, and water in a precise 3:1 ratio to form a consistent dry pug suitable for tile forming.
Project Overview: 45 TPH Twin Shaft Mixing System
- Client: Undisclosed (Concrete Roofing Materials Manufacturer)
- Location: New Zealand
- Industry: Building Materials / Concrete Products
- Scope: Design, build, and install a twin shaft mixer with integrated maintenance access and wear-resistant paddles
The Challenge: Consistent Dry Pug Mixing at Scale
The client required a twin shaft mixer capable of reliably producing 45 tonnes per hour of consistent dry pug. The mixture needed to maintain exact sand-to-cement proportions while allowing easy cleaning and inspection. As this mixer would operate continuously in a manufacturing environment, durability and access were critical.
Rocktec’s Solution: Accessible, High-Throughput Mixing Technology
Rocktec engineered a compact, rugged system tailored to the demands of roof tile manufacturing. The mixer includes:
- 45 tph nominal production capacity
- 15 kW drive motor for powerful, continuous operation
- 2.9m long mixing chamber with a 460mm paddle diameter
- Hinged top and bottom doors for unobstructed access during maintenance and inspection
- Removable shaft assemblies for quick cleaning and servicing
- Bolt-on paddles arranged in an advancing helix, made from high-grade wear-resistant plate
These features allow the system to operate efficiently while remaining easy to maintain and clean—helping minimise downtime during regular servicing.
Implementation and Performance
- Design Phase: Rocktec worked closely with the client to size the mixer and define chamber dimensions, paddle specs, and discharge timing.
- Fabrication: All components were built and assembled in Rocktec’s Matamata facility.
- Installation: The twin shaft mixer was installed on-site and integrated into the client’s concrete batching line.
- Commissioning: System testing confirmed throughput and mixture consistency targets from day one.
Results and Benefits
- Consistent Mixing: The twin shaft action ensures uniform blending of sand, cement, and water every cycle.
- High Wear Resistance: Bolt-on paddles made from tough steel reduce wear and extend service life.
- Fast Cleaning: Hinged doors and removable shafts speed up washdowns and maintenance.
- Compact Layout: The design fits easily into tight manufacturing spaces without sacrificing capacity.
Conclusion: Efficient Mixing with Built-In Access and Durability
This twin shaft mixer demonstrates Rocktec’s ability to deliver high-output, low-maintenance systems for continuous concrete production. With smart access features and durable construction, this unit supports consistent pug quality and long-term operational reliability.
Want to Learn More?
To explore more about dry pug mixing systems and twin shaft designs, visit the QuarryNZ website.
If you’re planning a twin shaft mixer or looking to upgrade your mixing process, contact Rocktec today.