Russell Roof Tiles installing new batching plant as part of £18.5m investment

Russell Roof Tiles (RRT) is installing a SKAKO Concrete ‘High Silo’ batching plant, as part of the firm’s net zero ambitions. Last year, RRT announced a milestone £18.5m investment programme and the SKAKO batching plant, complete with AM2250 planetary mixer, will significantly increase concrete roof tile production. This system replaces RRT's previous plant and with a larger volume system, will be able to handle the sand, cement, and pigment needed to feed a new mixing plant and in-turn roof tile production line. 

In addition to increased efficiencies, sustainable benefits include a water reclamation and refiltering system, that allows for recycling of all wash water, including using wash water from the factory to reduce the firm’s use of fresh water and reduce waste. It is currently working to be carbon neutral by 2040 – 10 years ahead of the Government’s timeline.

This whole project is the largest single investment since Russell Roof Tiles was acquired (from Cemex) in 2011 by Crown Global Equity, which manufactures concrete roof tiles in the US and Mexico.  Since then, the UK company has seen £17.3m invested in its three sites, continuing to increase efficiencies and capacity to meet demand.

The new SKAKO Concrete batching plant replaces RRT's old batching plant and concrete mixer that was installed in the 1990s and was designed to meet increased production demand as well as allow for further capacity increases in the future.  The much larger volume system will be able to handle the sand, cement, and pigment needed to feed a new mixing plant and in-turn roof tile production line. Utilising the latest technology, the system also provides remote operating from the factory floor, as well as remote diagnostics to minimise down time.

Bruce Laidlaw, operations director at RRT, said: “It is important that we continue to focus on efficiencies and sustainability across this major project, looking at market leading environmental options throughout the new facility. For example, this type of mixer is up to 20 per cent more energy efficient than alternatives available.

He added “Other energy efficiencies include using gravity to feed sand into the mixer below. Over time this saves a huge amount of energy moving sand.  The SKAKO Concrete solution of holding such an amount of sand above the mixer has allowed for the footprint to be compressed and thus install the full equipment within a much smaller area.”

The project installation has been managed by SKAKO Concrete and the site has remained operational during this time.

Gareth Hulcup, SKAKO Concrete sales manager for the UK and Irish markets, said: “The installation of the new batching plant has been the culmination of many months of meticulous planning by all stakeholders to ensure seamless integration of the new plant on site. We would like to thank Andrew Hayward, Bruce and all at Russell Roof Tiles for the opportunity to provide our solutions for the redevelopment of the site at Burton and contribute to their net zero pledge."

Visit SKAKO Concrete on stand 43 at The UK Concrete Show in Hall 1 at the NEC Birmingham from 9am-5pm on Wednesday 20th March, or 9am-4pm on Thursday 21st March.