Basalite chooses an integrated MCT plant for high-performance bagging operations
The growing demand for high-quality dry mix products requires production systems capable of combining flexibility, precision and productivity within a single integrated process.
To address these challenges, Basalite has recently commissioned a new advanced production plant engineered and supplied by MCT Group, designed specifically for high-performance dry mix production and bagging operations.
The installation integrates raw material management, drying technology, additive dosing and packaging lines into one coordinated system, allowing Basalite to optimize production while maintaining consistent product quality.
Maximum Flexibility in Raw Material Handling
A key feature of the plant is its ability to process both wet and dry sand, a capability that provides significant flexibility in raw material sourcing and operational planning.
The installation includes dedicated storage systems for humid aggregates alongside storage for dry sand, combined with an integrated sand drying system that ensures optimal moisture levels before the mixing phase.
This configuration allows Basalite to maintain stable production conditions while adapting quickly to variations in raw material supply.
Key Project Details:
- Raw material handling: dedicated storage for both wet and dry sand
- Drying technology: integrated sand drying system for moisture control
- Bagging configuration: 2 lines fed directly by the main plant, plus a 3rd line in an adjacent building
Precision Dosing for Complex Dry Mix Formulations
Dry mix production requires precise control of additives in order to guarantee product performance and repeatability.
For this reason, the plant incorporates multiple additive dosing systems designed to manage a wide range of formulations. High-precision weighing systems ensure accurate dosing of powders and micro-components, allowing rapid switching between product types while maintaining consistent quality standards.
This level of dosing flexibility enables Basalite to produce several specialized dry mix products within the same facility.
Multi-Line Bagging Configuration for High Productivity
To maximize packaging capacity, the plant has been designed to feed multiple bagging lines simultaneously.
Two bagging lines are directly supplied by the main production plant, while a third line operates in an adjacent building. This layout improves the overall production flow, allowing packaging operations to run continuously while maintaining efficient internal logistics.
Dust Recovery and Sustainable Operation
Environmental management and material efficiency were key priorities in the plant design.
The installation features a centralized dust recovery system that collects powders from all filtration units installed throughout the plant. The recovered material is reintroduced into the production process, reducing waste and improving the sustainability of the overall production cycle.
Integrated Automation for Total Plant Control
At the core of the plant lies the fully integrated MCT control system, which manages the entire production process through a single automation platform.
All operations — from raw material handling and sand drying to additive dosing, mixing and bagging — are coordinated within one centralized system. Operators benefit from real-time monitoring, simplified plant management and full traceability of production data.
“Projects like Basalite clearly demonstrate how the dry mix industry is evolving toward highly flexible and fully integrated production systems,” says Andrea Marcantonini, CEO of MCT Group.
“Our objective is to simplify complex processes through intelligent plant design and advanced automation, allowing producers to achieve higher productivity, operational flexibility and consistent product quality.”
With this installation, Basalite has implemented a modern dry mix production system capable of meeting the increasing demand for efficiency, versatility and sustainability in the construction materials industry.
Plant Technical Specifications
The plant is composed of a double vertical tower batching plant with two sets of aggregate bins for wet and dry materials: in the first tower, an automatic aggregate loading system delivers material received by truck to wet storage with a total capacity of 6 x 135 ton. The wet material is then automatically conveyed through the dryer to eliminate moisture and, subsequently, transferred via a double bucket elevator to the dry aggregate storage, with a total capacity of 4 x 155 ton.
Two mixers with a capacity of 20 ton/h each batch the raw materials according to the specific mix design and feed the automatic bagging machines beneath the tower.
Powders are stored in 7 silos of different capacities, fed either directly by truck or through automatic bulk bag / paper bag breaker systems.
The plant is completed by the MCT-CompuNet control system, which manages the entire process, including the dust recycling system that collects material from dust collection points and recovers broken bag residues.
Technical Highlights of the Basalite Plant
- Integrated plant designed for dry mix production and bagging operations
- Raw material handling system for both wet and dry sand
- Integrated sand drying system for moisture control and process stability
- Multiple high-precision additive dosing units for flexible product formulations
- Centralized dust recovery system collecting powders from all plant filters
- Production plant supplying two bagging lines directly
- Additional third bagging line located in an adjacent building
- Fully integrated MCT automation and control system for complete plant management
- Centralized monitoring of raw materials, dosing, mixing and packaging operations
- Optimized plant layout for high productivity and efficient logistics
