The bagging centre and its packing system are the most recent innovations at the new facility, the second-largest cement plant in North America and one of the most technologically advanced and sustainable ever built.
Like other aspects of the new plant, the bag packer—a Ventomatic GIROMAT EVO V12 Rotary Packer, pre-assembled in Italy—represents the latest technology. The 12-spout, automated rotating packaging system can fill a bag per second. It can fill 3,600 bags per hour, resulting in greatly expedited service. Another technological advancement is the bagging centre's automated kiosk system, which will facilitate product loading, increase the number of trucks served and improve safety.
The new Mitchell plant has enhanced the support of Heidelberg Materials' existing customer base in the Midwest while also expanding the company's reach in the growing cement market. It is helping ease construction supply chain issues by producing four times the amount of cement produced at the old facility.
The new plant's primary product is EcoCemPLC, a branded portland limestone cement available in bulk and bags. The company's popular Brixment Masonry Types N, S and M cements are also made at the facility, as well as Stone-Hold, which is used for the installation of manufactured and natural stone and thin brick. While the first clinker was produced at the Mitchell plant in April of 2023, the bagging centre was soft-opened in the fall, with startup and commissioning occurring in stages for various bag styles.
"Compared to earlier operations, when bags had to be put on spouts by hand, the increase in efficiency provides more opportunity," said Toby M. Knott, vice president of cement sales for Heidelberg Materials North America's Midwest Region. "Operations at Mitchell, including the bagging centre, ensure that the same quality products we've always offered are available on an expanded scale.
"Plant-wide, the new Mitchell facility uses the latest technology and environmental controls, and the bagging centre is no exception. As the rotary packer was not yet operational at the grand opening event in 2023, today's open house offered the first chance for our customers and partners to see the packing system and observe its efficiency improvement," said Carl Applebaum, sales manager for Heidelberg Materials North America's Midwest Region.
Heidelberg Materials North America has also introduced new bag styles. The new bag designs reflect the company's recent rebranding from Lehigh Cement to Heidelberg Materials. A new company logo was introduced at the time of the name change. The logo features two organically connected elements that represent the "h" in Heidelberg. The stem of the "h" was designed to evoke a construction element, symbolising the technical strengths of Heidelberg Materials. In contrast, the curved shoulder of the "h" resembles a leaf and symbolises the company's future growth. These elements are echoed in the new bag designs for EcoCemPLC, Brixment, Stone-Hold, and Flamingo Custom Color Masonry Cement. They will reflect Heidelberg Materials' commitment to nature positivity, its future growth and its products' technical and structural strengths.
Visit heidelbergmaterials.us to learn more about the Mitchell, Indiana, cement plant.
