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Fully customized and automated cubing of concrete products

The manufacturer Basalite provides complete product lines including structural block, interlocking paving stones, wall systems, ornamental and garden products with customized shapes, sizes, colors and finishes, and are renowned for their durability, sustainability and beauty.

This focus on customization and quality led Basalite to the Equipment manufacturer Quadra. Having opened its US subsidiary in 2016, Quadra Usa Inc commited to study and understand the products and manufacturing processes for concrete products in the US. Now Quadra Usa Inc has full time dedicated technical staff and sales team as well as local spare parts inventory.

After a visit to France to see Quadra’s headquarters and several Quadra block plants in operation, the Basalite team were impressed by the technical solutions provided by Quadra un terms of block machine, handling solutions and robotic cubing systems. One of the brand leaders in France for more than 20 years, Quadra supplies fully automated production plants, typically supervised by only one operator, without any manual operations. These were exactly the kind of solutions Basalite was looking for.

For the new cubing line in Dupont, Quadra designed something completely different than any other solution available or currently being used in the US plants today. In order to create a fully automatic solution, with only one person on the line for quality control, Quadra designed a line with 3 robots avant several product conveyor and pushers.

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The manufacture of wet-ast gravel boards : high performance, state-of-the-art production plant

With a large range of colours, formats, structures and finishes, the gravel boards market is growing in the modern landscading industry. Maes Betonfabriek, based in Dessel, Belgium, is one of the main manufacturers of concrete fencing in the country. Founded in 1949 by Karel Maes, this family-owned company is currently managed by his sones, Lund and Dirk Maes, and the upcoming generation is already active in the company. With more than 50 years of experience, Maes Betonfabriek manufactures and markets a large range of concrete products.

The strong suit of the company is the sustainability, variety and contemporary design of its products. With a daily production of about 200 tons of concrete, Maes Betonfabriek is equipped with 4 wet-cast production lines supplied by Quadra, the Equipment manufacturer. The partnership between both companies began with the delivery of the first DIFAL machine in 2006. Faced with the technical and aesthetic requirements of the products and the growth of the business, Maes Betonfabriek quickly became interested in a modern, automated and efficient industrial solution, designed and manufactured by Quadra.

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Fully automatic wetcast stone

A family-owned company based in the South of France, Fabemi has been combining know-how and innovation since 1961, making it one of the most important players within the French market. With 14 plants spread throughout France, the Fabemi Group has been expanding its production thanks to innovative technology. Initially, Fabemi was known for the manufacturing of concrete blocks. Since then, the group has widened its production. Under the brand names Bradstone and Carré d’Arc, Fabemi currently produces and delivers a large range of wetcast products designed for the landscaping market: slabs, pavers, copingstones and garden products, retaining walls, and wall coverings.

In order to boost its competitiveness, enhance the quality of its products and avoid repetitive and painful tasks for its operators, Fabemi has invested in the full automation of the production line based in Donzere and exclusively dedicated to the manufacture of wetcast products. To achieve this technological leap Fabemi has established a partnership with the French equipment manufacturer Quadra. Currently, only 4 operators manage the complete production process, from the mould cleaning, oil application and concrete filling through to the curing, demoulding and palletizing of the finished product. Equipped with a modern handling system, the plant is fully automated and achieves high versatility. All the items of equipment provided have the ability to adapt their system to the multiple product formats. This is the main innovation. To do so, an RFID chip is integrated in every pallet and identifies the type of the product. Accordingly, this RFID chip controls the oiling settings, the concrete dosing, the automatic introduction of balls on the back of the products, the product reference printing, and the demoulding and palletizing conditions with high precision.

This innovative system was developed and implemented by the supplier Quadra. This is a unique process, since up to now no device has been able to adapt to successive and changing mould formats in real time. More than 4000 manufacturing recipes are recorded, handled and automatically incremented. The production line and all stations permanently and automatically switch into all recipes .

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Wet-cast production line installed in Romania: a versatile & efficient plant

The Star Stone Company was founded by Cristian Pop in 2007. Specializing in the production of wet-cast products (slabs, pavers, concrete reconstituted stone and any kind of landscaping products), Star Stone has been growing exponentially since its beginning. Cristian Pop has recently decided to reach a new level by upgrading the plant. The continuing growth of Star Stone involves a high level of performance, which its existing facilities are not able to satisfy. Rather than a supplier, Star Stone was actually looking for a fully-fledged partner for proposing a new manufacturing solution: a major change for this manufacturer, who was basically manufacturing its products manually. Following a first contact during the Batimat show in 2011, where the manufacturer Quadra is always present, Star Stone took a closer look at Quadra by visiting several plants and studying the different technologies that might be applied for automating its production.

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Fully automatic dosing and filling system set up in South Korea

Founded in 1971, the Ino block company, currently headed by Mr Han and based in Hwaseong in South Korea, is now acknowledged as a leading manufacturer of landscaping materials in this area. Specialized in the manufacturing of pavers and all other kinds of landscaping products such as slabs, retaining walls, kerbstones, etc., Ino block supports the development and the reconfiguration of the urban design in Korea by continuously manufacturing new products. As a licensee of products such as Nikko from Japan, Godelmann from Germany and Anchor and Rosetta from the United States, Ino block takes advantages of strong partnerships which enable it to manufacture products that are designed worldwide. This manufacturer aims at sustaining its leading position through the quality, advanced design and large diversity of its products. Thanks to the implementation of the INO CAD program, Ino block is able to design customized products and offers more than 2000 different products in 300 different colours. Last but not least, this manufacturer is an avid user of equipment of the latest generation, including state-of-the-art manufacturing solutions. Ino block placed an order with the equipment manufacturer Quadra, which is well known for supplying tailor-made automation solutions. Ino block’s investment was based on a fully automatic filling system, designed for manufacturing the Rosetta product range and similar products with a view to improving productivity while maintaining and enhancing high product quality.

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Highly versatile wet-cast machine: more than 100 different product references daily manufactured

Founded in 1949, the company Daulouede has progressively achieved a strong position as a leading manufacturer of concrete products in the South-West of France. Currently comprising 6 plants, Daulouede is specialized in manufacturing concrete fences, window sills and other concrete products designed for landscaping (slabs, pool coping stones etc…). As the key customer of the company Ateliers du Loir, Daulouede has naturally solicited the manufacturer of equipment Quadra that acquired the company Ateliers du Loir in 2010. This range of equipment is designed for perfectly performing the automated precast production of concrete products by means of semi-dry demoulding, wet-cast demoulding, and mixed wet and semi-dry production. Quadra applies its renowned expertise in automated processes and its longstanding know-how of manufacturing special machines in view of offering the most suitable manufacturing solutions for the concrete industry.

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High-class concrete fence manufactured on fully automatic wet cast production line

Concrete fences have become outdoor decoration component increasingly valuable and popular in the field of landscaping realisation. Nowadays smoked and sophisticated, concrete fences benefit from great texture, and keep improving their appearance through regular innovation. This growing market led the manufacturer Rousseau Clôture to replace one of its production lines. Headed by Mr Le Strat, this French company, leading player in the precast industry for more than 20 years, owns 8 production lines. Its whole range of products, recognised as high-end concrete fences on the market, is manufactured in its plant based in Domloup (Bretagne).

 

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Fully automatic wet cast plant for a versatile production in the United States

As a market leader offering a complete line of interlocking concrete paving stones, architectural paving slabs, precast concrete products, and segmental retaining wall systems, Nicolock Paving Stones and Retaining Walls, based in New York, has steadily increased its output and product offerings to further secure its dominant position in the concrete industry. To address these concerns, the company has invested in a fully automatic factory from Quadra for the production of wet cast products. Quadra’s challenge was to design a versatile production plant to produce a board range of products with a sensible layout.

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Wet-cast production with a fully automatic plant

Creative concrete has always been at the heart of the development and diversification strategy of the company Hermet. The company is accentuating further its efforts in this direction by putting up a new Quadra plant. This plant is fully automatic for the production of wet-cast ,products. This is the 10th wet-cast unit installed by the French manufacturer. Quadra is continuing to develop this activity on the basis of these achievements. The construction of these materials from the study to the full manufacturing is made in Quadra’s facilities. The company Hermet wanted to manufacture a wide range of products such as tiles, slabs, pool edging, wall coating, fences plates, window sills, natural stone aspect, etc … in industrial rate. The facility had also to offer pleasant working conditions in a quiet atmosphere. The challenge was to build a highly technical plant in an existing environment while having a functional and rational implementation. The company Hermet was born in the middle of the vineyards of Gaillac. Its activity is spread over four sites covering the region of Midi Pyrenees and Languedoc-Roussillon in France.