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30% less electricity, one shift fewer: How a sand-lime brick plant revolutionized its efficiency

July 22, 2026

DKXK 2600 Twin-Shaft Batch Mixer for the Production of Sand Lime Bricks

The Challenge: In 2020, a German sand-lime brick plant faced a strategic decision. The existing counter-current intensive mixer had reached its limits. The goal was clearly defined: By switching to a different mixing technology, the plant aimed to achieve a perfectly homogeneous product while reducing mixing time and increasing hourly output. In addition, the plant hoped to get the rapidly rising electricity costs under control.

The Solution: The 3-Dimensional Mixing Principle

In January 2021, the BHS DKXK 2600 twin-shaft batch mixer was installed. This technology was deliberately chosen to take advantage of the 3-dimensional mixing principle, which promises significantly higher mixing intensity with shorter processing times.

Impressive Results in Actual Operation

Regular operation began as early as March 2021—and expectations were not only met but far exceeded:

Productivity leap: Hourly output increased so significantly that the plant was able to eliminate the entire night shift. Since then, the required quantities have been produced without any problems in just two shifts
Energy efficiency: The customer’s own electricity measurements confirmed savings of over 30% compared to the previous model while maintaining the same production volume
Durability & maintenance: Today, after 5 years and nearly 10,000 operating hours, the machine is running without any significant problems. The DKXK 2600 has proven to be low-wear and cost-effective to maintain

Conclusion

The switch to BHS technology has paid off many times over for the plant: lower labor costs due to reduced shifts, significantly lower energy costs, and an absolutely reliable system in continuous operation.

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