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One of the most automated factories in western Poland

Betonmischanlagen für Fertigteile
Polen

Formee Sp. z o.o. is a manufacturer and contractor of structures made of prefabricated concrete. The factory is located in Międzyrzecz and the core business is to offer comprehensive solutions for the design, production and installation of precast elements.

Formee brings together a team of expertise with extensive experience in turnkey projects in the fields of housing, agricultural, industrial and the most complex public buildings

During Covid, in mid-2021, due to the significant increase in demand and in line with the requests of our customers, the company decided to invest 20 million euros to increase production.

This once again underlines the commitment and confidence in the country’s development, thanks to the extraordinary ability of the modern plant to produce elements of any geometric shape based on Tekla BIM systems, delivering high quality products to construction sites.

Application and advantages of prefabricated buildings

The main advantages of prefabricated elements Fomee Sp. z o.o. are:

  • Dimensional precision and consequent integration with auxiliary elements (e.g. windows, kitchens) already present in the workshop;
  • Surface quality;
  • Speed of assembly and reduction of construction time by 30%;
  • Realization of projects even at temperatures below zero;
  • High fire resistance;
  • greater resistance to aggressive biological and chemical environments;
  • Exceptionally short outdoor construction times (a medium-sized single-family house can be completed within three weeks from the date of signing the contract);
  • The flexibility of the system allows you to carry out any project, even the most complex.

New concrete plant

The key component of this new factory, the new complete concrete batching plant capable of feeding the entire production, was thoroughly studied during the development process within Formee Sp. z o.o., selecting MCT Italy as the best partner for this important step for the group, also aimed at strengthening its presence in the Polish construction sector by starting a proprietary business for the production of prefabricated elements.

The plant itself consists of a receiving hopper, into which trucks unload the materials which are then transported, via a wagon elevator, to the aggregate storage hoppers. The materials are then distributed into the correct compartment via a reversible moving belt; All these functions are also controlled by the MCT aggregate power system, which works independently of the main control system.

A number of 5 aggregate hoppers, with a capacity of 40 m3 each, 240 m3 in total, then receive the materials, monitored via laser probes to ensure control of the accuracy of the volumes, both for the materials used and for the materials discharged correctly when they are filled by the aggregate supply system.

When a mix is ​​requested, the materials are collected by the MCT mobile aggregate batcher, with a capacity of 2 m3; the „moving scale“ passes under each compartment and receives the correct volumes of material, also allowing the materials to be unloaded in any order, allowing a „premixing“ of the material before arriving at the mixer. There are several reasons why this solution was used over a conventional dosing/weighing belt arrangement. The main reasons were greater accuracy of the weighed materials, lower investment costs and the elimination of material spills.

The „dumb lift“ then takes the materials to the 3000/2000 planetary mixer, which supplies the concrete to the factory. On the mixer platform there are the components for the usual functions, including cement weighing, water distribution, admixture, dust extraction.

The mixer is equipped with 2 doors which allows for further expansion to the second line of mobile wagons if necessary in the future. The cement is fed from 3 Silos 3x 100T (80m3) to the mixer.

The concrete is unloaded into MCT’s mobile bucket to be supplied to area 1, with a total distance of 200 m, all controlled by MCT’s control system, which guarantees optimal delivery to the entire construction site in automatic mode.

The tipping bucket has a capacity of 3,000 liters and can travel at a speed of up to 240 m per minute and deliver the concrete directly to the distributor for pouring.

The mixers and mobile wagons are washed using washing heads designed by MCT. All water and washed materials are collected under the plant where they are separated and the water is completely recycled in the plant; even waste material can be recycled.

All batching, mixing and dispensing of concrete is controlled via MCT’s easy-to-use CompuNet system.

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Plant capacity
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Cement storage
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Aggregates storage

Partners with added value and long-lasting collaboration

Eng. Falchetti Gabriele, Area Manager for MCI, comments: „The whole plant supporting structures, the aggregates stor­ age and all the conveyors are hot dip galvanized, ensuring a long lifespan of the plant, which be­ ing the heart of the main factory meant to develop this Polish re­ gion, will need to operate at full load and efficiency for a very long time, fulfilling its impor­ tant role for our partner and for this important market of ours. We at MCT fully understand the importance of our supplies in the assets of private companies as well as in the social fabric of the regions hosting them, so we do not compromise with anything concerning quality, efficiency and support. For this latter in particular,the expertise of our local partner Ciepela Technology is a real added value,and it was a pleasure to engage this project development with them and with the whole Formee Sp. z.o.o. team. The teamwork and the creation of such partnerships is always paramount for the succesfull outcome of our projects”.

The Eng. Rafał Kubrycht comments: “We actively collaborate with our suppliers, including MTC and EBAWE. Together we had fun like children playing with each other, making mistakes and learning from them and drawing the right conclusions according to the principle that a person who has never made a mistake has never tried anything new.

We created a company from scratch, full of energy and passion, building individual departments and creating a modern factory, based on innovative management, design and production systems.

Together with our partners MCT Italy and Ebawe Anlgentechnik, we have created one of the most modern precast concrete plants in Poland.

We thank our customers for the trust they have shown in us.“

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