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Singapore-based concrete producer Pan-United Corp adopts a holistic, tech-driven approach to sustainable concrete production. At its new batching plants, the company reduces embodied carbon by using greener building materials, installing solar panels and battery energy storage systems, and optimising operations through its AI-powered solution for the end-to-end concrete and logistics ecosystem.

The ready-mix concrete (RMC) industry in Singapore operates under a unique set of constraints shaped by the city-state’s urban density and limited land. Undeterred, Pan-United Corporation (Pan-United), a global leader in concrete innovation, has proven that operational excellence and sustainability are not mutually exclusive, even in a capital-intensive industry.

Pan-United stands out as an early adopter of digital solutions and a strong advocate for concrete innovation. It takes a holistic, technology-driven approach to sustainable concrete production. The Singapore-listed company has digitalised operations management to levels unrivalled in the industry, creating low-carbon concrete using recycled materials and incorporating renewable energy sources − such as solar panels and battery energy storage systems − at its batching plants. These forward-looking efforts optimise resource use across the organisation, as a model for future-proofing the built environment against climate change and resource constraints.

Challenges in Singapore’s RMC industry

Setting up an RMC batching plant in Singapore is complex. Mainly, the delicate navigation of various requirements such as land acquisition, compliance with regulations, and the securing of relevant certifications. A critical issue is the limitation on land tenure. Sites designated for ready-mix operations often come with leases as short as three years, which is a challenge for operators to justify heavy capital expenditure on new technology or site upgrades. Even within that short window, the average site area available for such plants is only about 5,000 square metres − a physical challenge for rooming sizeable components such as aggregate storage bins, cement silos, conveyor systems and concrete mixers.

The just-in-time nature of RMC, where the concrete starts to harden within two hours, means batching plants should be located close to project sites. Proximity matters not just for efficiency, but also to meet customer expectations for timely delivery and concrete performance. Delays could adversely result in rejected concrete loads and material waste − with cascading effects that can be amplified in round-the-clock continuous mass pours.

Confronted by a myriad of operational factors and stiff competition, digitalisation and decarbonisation can take a back seat amongst strategic priorities, even though these investments offer better returns − financially, operationally and environmentally − over the longer term.

Pan-United’s sustainable approach to batching plants

A compelling solution to current constraints is the new Jurong Port Integrated Construction Park at Jurong Port in Singapore. Pan-United will have new batching facilities as part of a total RMC Ecosystem being built within the Park, which presents a unique port-centric facility drawing critical parts of the construction supply chain into one central location. The Park will assemble RMC batching plants, cement and aggregates terminals with handling and storage facilities all in. The co-location aims to improve efficiency, while enhancing safety and sustainability.

Within this tight envelope, Pan-United will have high-volume batching output from three independent production lines with a combined capacity of 480 cubic metres of RMC per hour − a remarkable achievement given the spatial limitations.

A key enabler is the automated material feeding and storage system, comprising three conveyor belts serving large-capacity hoppers. This achieves continuous, high-speed batching with minimal manual intervention. The plant’s modular storage system will also handle multiple types of aggregates and raw materials simultaneously, ensuring flexibility for different mix designs and project requirements.

A hoisting system allows for equipment maintenance and parts replacement across multiple levels, reducing downtime and easing the burden on maintenance teams. Additionally, an auto-flushing system keeps the internal drainage clear without the need for manual cleaning, saving time and reducing labour exposure to potentially hazardous environments

Figure 1: Leveraging AiR Digital to meet the growing demand for smarter, more sustainable operations (Credit: AiR Digital)

Digitalisation plays a pivotal role in maximising resource efficiency for Pan-United. Its proprietary AiR Digital solution − an end-to-end operations management system for concrete and logistics businesses – powers AI-enabled features at its operations in Singapore, Malaysia and Vietnam.

Sensor technologies embedded at its stockpiles and cement silos enable real-time monitoring and automated replenishment. An AI-powered concrete discharge control system optimises the consistent loading of concrete into the mixer trucks and prevents spillage.

Crucially, AiR Digital consolidates all weighing operations into a single centralised system, eliminating the need for multiple batching panels. This reduces system complexity and enhances real-time visibility into batching accuracy. Operations are streamlined and controlled, improving communication across teams.

The true value of AiR Digital goes beyond revolutionising operations. It reduces manual errors, enables predictive maintenance and enhances overall plant resilience − all critical factors for operational excellence in the competitive Singapore market, where production delays can have financial and reputational risks. 

AiR Digital is being sold as a solution for data-driven, automated decision-making of businesses with complex delivery demands.

Sustainability and safety by design

Pan-United’s upcoming batching facilities at Jurong Port reflect its broader commitment to safety, environmental stewardship and sustainable growth.

For example, its concrete sampling system will eliminate a common safety risk by allowing samples to be taken directly from the discharge hopper. This removes the need for staff to manually collect samples from the mixer trucks. Meanwhile, its drive-through design will streamline vehicle movement and reduce the risk of traffic congestion or accidents on-site.

To reduce resource wear-and-tear and maintenance costs, the new plant will feature a high-pressure automated mixer washing system. Trucks moving in conventional plants typically require daily manual cleaning and can lead to excessive water usage. The plant will be fully enclosed to minimise dust pollution, contributing to cleaner air quality in the surrounding area. 

In line with the Singapore Green Plan 2030 – a whole-of-nation movement to advance Singapore’s national agenda on sustainable development – Pan-United embeds sustainability into every level of its operations. Green energy features such as solar panels and battery energy storage reduce reliance on the national grid and lower carbon footprint. An electronic delivery ticketing system and smart truck queue management also significantly reduce paper waste and idling time for delivery vehicles, contributing to a leaner, more eco-conscious workplace. These initiatives complement Pan-United’s sustainability targets to offer only low-carbon concrete by 2030, offer carbon-neutral concrete by 2040, and to become a carbon-neutral company by 2050.

The use of smart design and a commitment to digitalisation and decarbonisation have redefined what Pan-United can achieve with RMC batching. As cities around the world seek ways to balance rapid urban development with environmental responsibility, Pan-United’s approach offers a unique strategy to future-ready the RMC industry and beyond.

Figure 3: Aggregates unloaded at Jurong Port