Customer case

Bay-Lynx solidifies cutting-edge design for lighter, smarter volumetric mixer

April 06, 2022 6 min read

Case details

Product Hardox® 450

Country United Kingdom United States Canada

Company Bay-Lynx Manufacturing, Inc.

Industry Yellow goods and construction

Brand program Hardox® In My Body

Why tinker with what works? Continuous improvement delivers to mixer operators all the benefits of a more efficient, safer and longer lasting vehicle.

Bay-Lynx design engineers knew a lighter, truly modern and more efficient mixer would give their customers a cutting-edge solution. After an aggressive revamp of a proven-yet-outdated design, the Titan is born. The Canadian concrete mixer manufacturer drives innovation across key markets in the United Kingdom and North America with advanced high strength steels.

The mobile concrete mixer first introduced in 1964 operated essentially like a concrete production plant on wheels. This mixer style quickly filled a market gap for flexible short-run concrete supply. However, the original design using mild steel with multiple structural stiffeners made it tall and heavy with many welds that would tend to crack, then rust and require frequent repairs. Fifty years later, these and other efficiency factors made it a perfect time for Bay-Lynx to launch a market-leading upgrade. The improvements mean owners can enjoy a 200% stronger mixer that is 7% lighter, allowing higher payloads, less fuel consumption and lower maintenance costs.

Titan volumetric concrete mixer is 7% lighter than a mild steel version using advanced high strength steels.

Case details

Product Hardox® 450

Country United Kingdom United States Canada

Company Bay-Lynx Manufacturing, Inc.

Industry Yellow goods and construction

Brand program Hardox® In My Body

“Before launching the Titan, our market suffered with bodies that needed to be frequently repainted, required cracks be repaired to stop the rusting and be closely managed,” explains Mikkel Vlietstra, Bay-Lynx Equipment Sales. “We not only wanted to solve those problems, we needed to cut the weight, increase payloads and find a way to get more mixers through our production lines faster to meet ever-increasing demand. Manufacturing the original design created a big bottleneck in our shop output because each unit required significant time fitting and welding,” he says.
Mikkel Vlietstra, Bay-Lynx Equipment Sales

Mikkel Vlietstra, Bay-Lynx Equipment Sales shares the safety and efficiency benefits of a volumetric mixer.

Keen collaboration takes redesign from concept to market at lightning speed

SSAB’s Product Development and Engineering service team and Bay-Lynx engineers joined forces with SSAB’s Product Development and Engineering service, to move the project from concept to market at an accelerated pace. Strong collaboration between both organizations pushed the envelope. Coming to a production-capable phase meant bringing functionality and production efficiency to each of the mixer’s 35 components. Thanks to agile teamwork, design for manufacturing and weekly meetings, the project advanced from concept to a prototype model in under five weeks.

“At first, we just wanted to reduce the amount of cement sticking to the inside of the bin,” explains Kevin Koppelaar, Bay-Lynx Production Engineering Manager. “What we now call the Titan is truly the culmination of a collaborative, forward-thinking and disruptive design process tha t went from concept to product launch in just under 18 months.”

“We began our relationship with Bay-Lynx modifying the designs on a few core components,” explains Pierre Bergsten, Specialist Production efficiency, Cost improvements, End user value. “After gaining confidence in our abilities, they asked us for what they really wanted – a game changer, and that’s when the clock started ticking.”

Kevin Koppelaar, Bay-Lynx Production Engineering Manager worked closely with SSAB’s Pierre Bergsten, Specialist Production Efficiency in the Knowledge Service Center.

Advanced high strength steels combined to revolutionize mixer’s efficiency

To revamp the traditional mild steel design, engineers looked at the entire package for efficiency gains and started by reducing weight. Focus turned to using fewer parts and thinner sides for the body as a sub frame. They opted for thinner gauges of advanced high strength steels to shave off more than 272.12 kilos (600 pounds.)

“We chose a combination of Strenx^® 100 structural steel and Hardox^® 450 wear steel for thinner body walls,” says Koppelaar. “The large quenched and tempered plates allow us to bend long side walls and increase stiffness, minimizing welds and eliminated the need for multiple bulky side posts.”

Next, the project team evaluated how to improve service life. In choosing Hardox^® wear plate, they gained abrasion resistance from the steel that is both hard and tough.

“Being able to remove the most common issues that traditional volumetric mixers face like rusting, cracking and denting was a huge relief,” Koppelaar says. “This build has significantly fewer weld lines which is a key area for rust and cracking.”

Titan operator, Gary West of TruMix in the United Kingdom takes advantage of this design improvement having experience with his last mixer often in the shop for repeated repairs and repainting.

“We use our Titan to pour concrete of all types of mix designs,” West says. “Our mixer’s body is very strong and shows no signs of cracking.”

Titan operator, Gary West of TruMix enjoys safe operations, a lighter weight vehicle and long service life with Hardox® and Strenx® aboard.

Titan operator, Gary West of TruMix enjoys safe operations, a lighter weight vehicle and long service life with Hardox^® steels and Strenx^® steels aboard.

Sam Overduin, Bay-Lynx Operations Manager cites a 26% reduction in fabrication time with the new design. Consistent properties of Hardox^® and Strenx^® steels allow predictable performance in the workshop.

Making friends in the workshop

Both Hardox^® wear plate and Strenx^® performance steel offer workshop efficiencies. According to Bay-Lynx Operations Manager, Sam Overduin, accelerated takt time improvements came from fewer hours required for fitting and welding. For example, because of the formability and bendability of the Hardox^® and Strenx^®steels, the Titan’s body now features a sleeker design where the aggregate bin and cement bin are now combined with one long side panel as opposed to the traditional method of separate components welded together.

“With all the changes, we saw a 26% reduction in fabrication time. There are 70.10 fewer meters (230 fewer feet) of weldments, and the new design features 7% fewer parts,” Overduin explains. “Our fabricators were trained by SSAB technical experts to handle the Hardox^® and Strenx^®steels. Now, we have more mixers going through the shop than ever.”

Using SSAB’s suite of apps for improved performance

SSAB offers multiple calculators, tools and mobile apps to give customers insights on potential benefits of upgrading to high strength steels. For example, the EcoUpgraded app shows potential savings in terms of fuel consumption and payload increases.

For Bay-Lynx, not only did an upgrade improve service life, but the report shows a 5.62 metric ton (5.1 ton) CO2 reduction, fuel reduction by 107.25 liters (406 gallons) and an increased payload of 265.35 kilos (585 pounds).

“Upgrading to an advanced high-strength steels offers environmental impacts,” says Maurice Picard, SSAB Technical Development Manager.

EcoUpgraded app report shows environmental improvements possible with the upgraded mixer design using advanced high strength steels.

Hardox^® In My Body member Bay-Lynx certified the Titan mixer to ensure the highest quality.

Standing behind the signs of quality

SSAB’s brand program Hardox^® In My Body features a sign that represents equipment manufactured to the highest standards by qualified members. All members are thoroughly assessed and earn the right to display the program’s logo as signs of their commitment. Certified equipment offer long-term cost efficiency, increased payloads, fuel savings, low maintenance, long service life and higher resale values. Each company’s sign is traceable for authenticity and can be validated. Bay-Lynx is among these elite manufactures with products certified in each of the programs.

Titan mixer with advanced strength steels for safer, more efficient operations.

Efficiency reigns supreme for mobile concrete deliveries

For example, because the entire mixer is mounted on a truck or trailer that contains separate compartments for sand, stone, cement and water, it can produce the exact amount of concrete needed upon arrival at the job site.

“Both a concrete plant with ready-mix drum trucks and volumetric concrete mixer produce quality concrete however, there are some distinct advantages to choosing a volumetric mixer,” Explains Mikkel Vlietstra, Bay-Lynx Equipment Sales. “With a Titan, the customer only pays for exactly what they need. The concrete is always fresh. Small quantities are not a problem, and time is not a factor, which opens up delivery options for evenings and on weekends. Plus, operators can perform a variety of mixes at one stop.”

Mixing it up for continued change

According to Vlietstra, orders for Titan mixers increased 40% from its launch in 2020. With 30 years under their belts, Bay-Lynx and its nearly 100 employees will continue to up the game turning out efficient vehicles from their respective facilities in Ancaster, Ontario and Runcorn, UK. The future for new product innovation is bright. Introductions like the company’s Atlas Live Bottom will undoubtedly continue rolling out of rapid research and development projects.

“SSAB was the key factor in bringing the Titan to life. Our now most-popular product is the Titan, and we plan to continue this growth with SSAB on our side,” Koppelaar says. “We are constantly developing our technology to be the most advanced in the industry. Every year, we make improvements to our builds, components and technology. We have never and will never stop improving.”