POLYGON MACHINE
DRY TYPE CONCRETE
BATCHING PLANTS
Polygon Machine dry type concrete batching plants are emerging as a highly efficient and cost-effective choice for producing ready-mix concrete, especially in today’s fast-paced construction and infrastructure projects.
Why choose Polygon Machine?
Polygon Machine delivers certified quality (TSE & ISO 9001), global expertise, and durable solutions from 30 m³/h to 240+ m³/h. Polygonmachine is a trusted partner in both compact and large-scale projects.
What batching plant types are available?
Stationary, mobile, and compact plants—plus cement silos, feeders, and dosing units. Every system is customizable to match your space, capacity, and automation needs.
How is long-term support handled?
Polygon Machine ensures fast setup, training, and after-sales service, minimizing downtime. All plants include modern automation and safety features for easy, efficient use.
dry type concrete
batchıng plants
A dry type concrete batching plant is a system that batches dry materials—such as cement, aggregates, and admixtures—without using water at the plant. Water is added later during transit or on-site, allowing for flexible mixing, faster setup, and lower operational costs.
What is a dry type concrete batching plant?
A dry type batching plant is a concrete production system where all materials—aggregates, cement, and admixtures—are batched dry, without any water. The final mixing happens later, typically inside the transit mixer or on-site, allowing for greater flexibility and lower water dependency.
How does it differ from a wet mix plant?
Unlike wet mix plants that include an on-site central mixer, dry batching plants omit the mixer completely. This means reduced mechanical complexity, lower energy usage, and the ability to add water only when and where it’s needed, ensuring better control over mix consistency.
Why is water added later in the process?
Water is added during transport or at the construction site to achieve optimal workability and slump based on project needs. This post-batching hydration method prevents overwatering, improves mix uniformity, and allows on-the-fly adjustments in field conditions.
Is concrete quality affected without a mixer at the plant?
Not at all—modern dry plants use advanced automation to ensure precise ingredient batching. When water is added in the truck and mixed en route, the result is a homogeneous and spec-compliant concrete that meets strength and durability standards.
TECHNICAL COMPARISION
Dry type concrete batching plants offer a streamlined, energy-efficient alternative to traditional systems by eliminating the central mixer. Materials are accurately batched in dry form and mixed with water later in transit, reducing mechanical complexity, installation time, and power usage.
Equipped with advanced PLC or SCADA automation, these plants ensure precise dosing and sequencing, resulting in consistent concrete quality across all batches. The modular structure allows for quick setup on minimal foundations, making them ideal for remote sites or mobile operations.
Additionally, dry plants enable rapid truck dispatching, as batching is completed without waiting for in-plant mixing. This enhances throughput while lowering maintenance needs—making dry batching an ideal solution for efficient, high-volume concrete production.
| Characteristic | Dry Type Batching Plant (Transit Mix) | Stationary Batching Plant (Wet Mix) | Mobile Batching Plant (Wet or Dry) | Compact Batching Plant (Wet Mix) |
|---|---|---|---|---|
| Mixing Method | Dry mix – all ingredients are batched without water; water added in the transit truck later. Concrete is mixed en route or at site in the truck’s drum. | Wet mix – includes an on-site mixer (e.g. twin-shaft or pan mixer) that fully mixes concrete with water at the plant. Ready-mixed concrete is discharged into trucks “ready to use.” | Can be dry or wet, but typically includes a smaller onboard mixer for wet mixing. Designed as a portable unit where mixing can occur on-site. Some mobile units can also operate in dry mode (loading materials into truck for mixing). | Wet mix, but in a modular compact form. Has a built-in mixer like stationary plants, usually of smaller capacity. The design is optimized for a reduced footprint and easy transport in container units. |
| Mobility & Installation | Usually a stationary or semi-mobile setup. Often installed on a fixed foundation at a plant site. Some models are containerized or modular for easier relocation, but generally meant for long-term installation at one location. Quick installation due to fewer components (no mixer). | Stationary (fixed) installation. Requires a prepared concrete foundation and considerable site works. Not intended to be moved once installed; suited for dedicated long-term production at one site (e.g., a metropolitan ready-mix facility). Installation time is longer due to assembly of complex mixer unit and infrastructure. | Highly mobile. Built on a chassis (trailer or skid) with wheels or mounts, allowing it to be transported between sites. Designed for rapid assembly/disassembly – often can be erected and calibrated in a day or two. Ideal for projects that are temporary or move location (road projects, remote construction). Mobile plants often have foldable legs and pre-wired components for quick setup. | Semi-mobile (compact). These plants are smaller and modular, delivered in a few units (often container-sized modules) that can be quickly assembled on a small foundation. They can be relocated with moderate effort. Installation is faster than large stationary plants, and they are favored when space is limited. Many compact plants are also promoted as “plug-and-play,” with minimal foundations needed. |
| Production Capacity | Small to Medium output. Typically ranges from ~20 up to 100 m³/hour for standard Polygonmach dry models (e.g., 30, 60, 100 m³/h). High-output dry plants are possible, but extremely large capacities (above 120–150 m³/h) are less common in dry configuration. Suited for medium-scale projects or multiple small projects served from one plant. | Wide range, Medium to High output. Can be designed for 60, 120, 180 m³/h or even more. Large stationary plants (e.g., 200+ m³/h) are common for supplying concrete in bulk, such as for dam construction or big urban projects. They can run continuously with multiple mixer trucks cycling through. | Medium output. Mobile plants typically range around 30 to 100 m³/h. The capacity is somewhat limited by their size and portability constraints, but high-end mobiles can approach 100+ m³/h. They cater to projects that need a decent volume but also require mobility – e.g., paving a highway section by section. | Medium output. Compact plants fill the niche of 30 to 100 m³/h as well, similar to mobile units. They pack the capability of a stationary plant into a smaller form factor. While not aimed at the ultra-high production segment, they are sufficient for most urban construction sites or as satellite plants for larger operations. |
| Concrete Quality | High quality with proper controls. Achieves good uniformity by thorough dry mixing and careful water addition. Modern dry plants (like Polygonmach’s) use automated systems to ensure consistent batching; the truck mixing can yield concrete meeting strength specs reliably. However, quality can be influenced by truck mixing efficiency and travel time. Best suited for standard strength ranges and where a small variability is acceptable. (For very high-spec concrete or very low slump requirements, wet mix may have an edge in initial uniformity.) | Excellent homogeneity and consistency. Wet stationary plants provide very uniform mixes since water and all components are blended in a controlled mixer at the plant. This results in minimal batch-to-batch variation and is ideal for high-strength or specialty concretes where precision is critical. The controlled mixing environment often yields concrete with slightly higher initial strength consistency compared to dry mix. | Good quality concrete. Mobile wet plants can produce quality comparable to stationary wet plants, especially if they use modern mixer designs. Some very compact mobile units might have smaller mixers which limit aggregate size or mixing intensity, but generally they can meet typical commercial concrete standards. If operated in dry mode (without using the onboard mixer), quality will depend on the transit mixing similarly to standard dry plants. | High quality (comparable to stationary). Despite their size, compact plants usually incorporate the same mixer types as larger plants (e.g., planetary or twin-shaft mixers) and thus can produce homogeneous concrete. They are often used in urban areas for ready-mix supply, where they reliably meet quality requirements. The mix consistency is on par with conventional stationary plants of similar capacity. |
| Water Usage & Environmental | Water-Saving: Does not use water in batching; water added at site in controlled amounts. Great for water-scarce regions or urban areas with water use restrictions. Also tends to produce less waste and sludge, since there’s no mixer washout after each batch and unused dry mix can be recycled. Dust control measures (silo filters, covered conveyors) are implemented to minimize emissions; noise levels at plant are lower (no mixer engine running). Overall, often considered more environmentally friendly in terms of resource consumption and site impact. | Significant water usage at plant for mixing and cleaning. Requires a steady water supply and generates wash water after each batch (mixer washout) that must be treated or disposed of. Dust can be an issue around the mixer and aggregate transfer points if not properly contained. Noise is generated by mixer motors and loading operations. Environmental controls (recycling systems, noise dampers) are typically needed to meet regulations. Wet plants in general have a larger environmental footprint on-site due to these factors. | Water usage and environmental impact depend on mode: in wet operation, similar concerns as stationary wet plants (water needed for mixing and washouts). In dry operation, water usage is offloaded to the trucks, similar to standard dry plants. Mobile plants often have an advantage in that they are used on-site, so any concrete leftover can sometimes be used directly in the work (less waste from returns). Many mobiles come with enclosures or retractable covers to reduce dust during transport and erection. Noise is moderate – they have smaller mixers and often operate intermittently. | As wet mix plants, compacts do use water for mixing and cleaning, but their smaller size usually means lower absolute water consumption per batch compared to very large plants. Many compact plants are designed with recycling in mind – e.g., reclaiming wash water or slurry – to fit in environmentally sensitive urban locales. Dust is managed with built-in filtering systems due to the close proximity of equipment. Noise is also generally lower than huge plants, but still present around the mixer and pumps. |
| Operational Complexity | Simple operation. Fewer moving parts and simpler workflow (batch and load) mean these plants are straightforward to run. They typically feature a high level of automation for batching; the operator mainly supervises and manages mix recipes. Maintenance is easier (no mixer gearbox or liners to service). Training operators on a dry plant is relatively quick. However, coordination with truck drivers is important to ensure water is added correctly and mixing is adequate. | Complex operation. More equipment (mixer, possibly dual batch lines, multiple motors) requires careful synchronization. Operators need to manage mixer timing, discharge gates, mixer cleaning, etc. The control systems are advanced, often managing multiple simultaneous batches (one mixing, one loading). Maintenance requires skilled technicians, as mixers need regular inspection and part replacement. The payoff is high throughput and tight quality control, but at the cost of more intensive operation. | Moderate complexity. Mobile plants, though compact, still have all essential systems and often automated controls. Setting up a mobile plant requires leveling and perhaps some calibration, but after that, running it is similar to a stationary plant just on a smaller scale. The operator might have to manage extra tasks like folding/unfolding equipment and ensuring stability at each new site. With smaller crew and limited storage, logistics (supply of cement, aggregates) must be well-planned. | Moderate complexity. Compact plants operate like traditional wet plants, but generally come as pre-configured modules, which reduces on-site wiring and configuration complexity. They often have simplified controls optimized for ease of use, since they target projects that may not have highly specialized batching personnel. Maintenance is manageable – parts are smaller, and many compacts are designed for quick cleaning and upkeep given their role in urban settings with limited downtime windows. |
| Ideal Applications | Remote and infrastructure projects; Precast factories; Cost-sensitive operations. Dry plants shine in projects where transporting ready-mix from a central plant is impractical or water access is limited – e.g., remote highway construction, rural developments, or desert projects. They are also ideal for precast concrete production where multiple mix designs may be needed and water can be precisely controlled at the point of use. Ready-mix suppliers looking to minimize investment yet meet local demand also benefit from dry plants. |
COST & EFFICIENCY
POLYGON MACHINE
Lower Initial Investment
Dry type concrete batching plants require fewer components than wet mix systems. With no central mixer or mixing motor, the upfront equipment cost is significantly lower.
This makes the initial investment far more accessible for small to mid-size contractors or businesses entering the ready-mix market. Less structural work is also needed during installation.
Polygon Machine offers dry plants starting from approximately $30,000, depending on capacity and configuration—making advanced concrete batching technology available at a lower entry point.
Reduced Operating Costs
Operating costs are greatly reduced since no mixer motor means lower energy consumption. The plant focuses only on batching and loading dry materials, which uses much less power.
With fewer moving parts, maintenance needs are minimal. There’s no need for mixer liner replacements, blade servicing, or gearbox repairs typical of wet systems.
Staffing requirements are also lower. One operator can manage the batching process using Polygon Machine’s automated control panel, helping reduce labor expenses.
Simple and Affordable Maintenance
Dry plants are mechanically simple, which means fewer parts to wear out or service. This leads to lower downtime and reduced maintenance budgets over time.
Components like aggregate bins, dosing systems, and silos are designed for easy access and servicing, even on job sites with limited resources.
Thanks to standardized components, replacement parts for Polygon Machine plants are easy to source globally—keeping service quick, affordable, and hassle-free.
Faster ROI for Every Project
Lower setup costs and quicker deployment lead to a faster return on investment. Many dry plants can be fully operational within just a few days of delivery.
Since they’re easy to relocate, one dry plant can serve multiple job sites, reducing idle time and extending equipment utility across projects.
Polygon Machine’s energy efficiency and low operating expenses help contractors break even sooner, making every cubic meter of concrete more profitable.
QUALITY & SUSTAINABILITY
Consistent Concrete Quality
Dry batching may sound simple, but with accurate dosing and automated controls, it delivers impressive consistency. Each ingredient is measured with precision before being loaded into the mixer truck.
Because materials are blended dry before water is added, cement and aggregates are evenly distributed, reducing the risk of weak spots in the mix. The result: uniform strength and workability.
Polygon Machine plants use advanced automation to fine-tune every batch, ensuring reliable concrete output, even in high-volume or demanding applications.
Flexible Water Control
One major benefit of dry systems is precise water-cement ratio control. Since water is added in the truck or on-site, the mix can be adjusted based on weather, slump requirements, or pour location.
This helps avoid common quality issues like overwatering, which can reduce strength or durability. Instead, contractors get the flexibility to respond to on-site needs in real time.
This approach also supports specialty mixes and customized slumps, making dry batching ideal for projects where every pour needs to meet unique specifications.
Sustainable Water Use
Because water isn’t used at the batching stage, dry plants consume significantly less water overall. Only what’s needed at the final mix point is used—nothing more.
This makes dry batching a smart choice for arid regions or locations with limited water access. It also eliminates wash water and reduces sludge from mixer cleaning.
Polygon Machine’s dry plants help contractors meet environmental targets more easily by minimizing water waste and simplifying compliance with local regulations.