Fabryka Maszyn Leżajsk Sp. z o.o. is the only manufacturer of hydraulic concrete mixers in Poland and the largest in this part of Europe. It also leads in the production of trucks and battery-powered tractors. With over 50 years of experience, the company produces 300 pieces of equipment of this type each year.
What challenges did FML face?
FML reached out to Ennovation Technology in response to the rising demand for fully electrified heavy equipment, including concrete mixers.
There is a limited number of manufacturers producing these types of vehicles, while interest from construction industry entrepreneurs continues to grow.
Additionally, FML wanted to ensure that users could operate the vehicle in a familiar way, maintaining their previous habits without needing to relearn control panel functions.
What was the scope of the collaboration, and how was the intended goal achieved?
The project scope included a comprehensive conversion of a combustion engine vehicle to electric power while maintaining its previous functionalities. Key solutions applied in the project included:
- Drive System – Due to the high load the vehicle would endure, a 680 HP electric motor was installed, paired with a 4-speed automatic transmission. Additionally, the drive system includes a mechanical power take-off (PTO).
- Battery Pack – To accommodate the vehicle’s weight, six LFP-type batteries were installed, providing a total battery capacity of 387 kWh, with potential scalability up to 512 kWh.
- High-Power Charging – The vehicle is equipped with two CCS ports that support continuous charging at 700 kW and peak power up to 1 MW. Given the limitations of standard CCS chargers, dual ports allow simultaneous connection to two charging stations. The setup complies with market standards and enables public station charging. While MCS (Megawatt Charging Solution) compatibility is possible, CCS ports were maintained due to the limited availability of MCS stations.
- Customized Controllers and AC Charging – Proprietary charging controllers tailored to the vehicle and its technical requirements were developed and implemented. Additionally, the vehicle supports AC charging at 2x 22 kW, with V2G capabilities, allowing it to serve as a mobile energy storage unit.
- Vehicle Control Unit (VCU) – The vehicle features a proprietary VCU that manages the entire drive system, serving as the operational center of the vehicle, fully configured for specific usage conditions.
- Electric Mixer Drive – Replacing the hydraulic mixer drive with an electric one yields significant energy savings. The mixer is powered by the vehicle’s traction batteries.
- User-Friendly Operation – After consultations with FML, our engineers ensured that operating the mixer is as close as possible to operating its combustion-engine counterpart.
- Calibration – We calibrated the mixer on-site to ensure it met performance requirements and client specifications.
- Supporting Systems – Given the truck’s unique requirements, solutions such as an air compressor for pneumatic brakes and an electro-hydraulic pump for the power steering system, both powered by the batteries, were implemented. Previously, these components relied on the combustion engine.
- Cost-Saving Mixer Drive – Replacing the hydraulic mixer drive with an electric system, even on existing combustion mixer trucks, can lead to substantial financial savings. Ennovation also offers a mixer drive solution with a power pack.
„While working on the conversion project, we used a number of innovative solutions that increase the utility of the vehicle, while positively influencing the competitiveness of our solution over other vehicles of this type. We are talking here about two fast charging sockets that allow us to charge the vehicle with a maximum power of 1MW, or the use of two types of power take-offs: electric, the so-called E-PTO, and traditional, mechanical.”
Piotr Lange
Chief Technical Officer,
Ennovation Technology
Final Parameters of the Mixer
• Power: 680 HP
• Gross Vehicle Weight: 44,000 kg
• Battery Capacity: 387 kWh, NMC
• Range: Approx. 350 km
Final parameters of the concrete mixer
Power of the drive unit: 680 HP
- Permissible total weight: 32,000 kg
- Battery energy: 387 kWh, NMC
- Range: approximately 350 km