Successful Concrete Pipe Solution at PT. Calvary Abadi

• 24 April 2019
• Local News
• 1733 Views

Indonesian company PT. Calvary Abadi has operated the Souveraen concrete pipe machine by BFS Betonfertigteilsysteme from Germany for almost two years. The investment was worth it, and Calvary is more than satisfied with the industrial solution.

PT. Calvary Abadi invested a lot of time and consultation by BFS Betonfertigteilsysteme GmbH and the Rieckermann Group before they took a decision. The choice fell on a Souveraen SV 1225 which has been in operation since June 2017. “With the Souveraen we are capable of handling projects with high quantity in no time.

This serves us especially in state projects,” Soerya Widjaja said. In addition, technical director of Calvary Abadi reported that labour costs were reduced by 50% in the first four months. The sales manager Rainer Straub from BFS added that “The machine is so fast that Calvary was able to expand the sales area tremendously. As a result, the high production capacity of the machine can be fully exploited.”

With the new pipe machine, Calvary can produce reinforced and non-reinforced concrete pipes, footed and jacking pipes as well as other pipes to international norms such as DIN 4032 to DIN 4035. Diameters from 300 until 1,200mm and lengths of up to 2.5 metres are possible. The Souveraen 1225 T offers high-quality product at a low employment rate. Thanks to the fully automatic and computer-controlled production, only one person is needed to operate the machine. Widjaja appreciates that “Four workers can produce more with this machine than 20 workers before with the old machine. This is a big relief for not having to find skilled labor.”

The machine’s concept is based around a power train consisting of frequency-controlled electric motors, precise rotational speed, and a big driving torque delivering exceptional compaction results. “Since the Souveraen has been in operation, the quality of the products is so good that we can neglect any post-processing”, Widjaja explained. Again, this reduces previously required work and process time while ensuring product lifetime and customer satisfaction

For the production of the reinforcement cages, Calvary invested in a cage welder by mbk Maschinenbau GmbH from Germany. The machines of BFS and mbk have been combined and worked together in many projects for a long time. The cage welding machine BSM 170 R is robust and long-lasting. The Speed Package with an optimised welding technique, an automatised winding wire cutter, and a powered uncoiler ensures high productivity, and up to 50 cages can be produced per hour. Due to the touch panel and the IPC/SPS-controls, the operation of the machine can be handled by only one worker.

BFS Betonfertigteilsysteme GmbH and mbk Maschinenbau GmbH are represented locally by the Rieckermann Group. Rieckermann links industrial process technologies, engineering operations and technical services to complete tailor-made industrial solutions. “The change to a fully automatic operation took time. Thanks to the comprehensive training received by the service personnel and on-site support from sales partner Rieckermann, we solved all problems and improved our expertise gradually,” explained the technical director of Calvary Abadi who is convinced of the benefits.

In order to have enough space for the Souveraen, the cage welding machine and other components, Calvary built a big, modern facility. This turned out to be a smart decision because after the Souveraen the company placed an order at BFS for a Jumbo to handle the rising demand for large pipes and box culverts. Calvary Abadi is set and well on track to a bright and prosperous future.