Game changing precast systems: Pallet Circulation and Battery Moulds

Krishan Mohan Sharma, Head of Vollert India, extends sincere appreciation to Hon. Minister Shri Nitin Gadkari for his visionary support to the precast industry and commitment to sustainable infrastructure development in India. Vollert India is proud to contribute towards National Infrastructure Development with cutting edge precast solutions – engineered in Germany, made in India.

How has the Indian construction market adopted precast technology, and how has Vollert India contributed to this transformation?

The Indian construction sector has undergone a significant shift in recent years, with growing awareness of the speed, quality, and sustainability that precast technology offers. From metro rail systems to large-scale residential and industrial projects, precast is gaining traction as a smarter alternative to conventional construction.

We have been at the heart of this transformation. By offering German-engineered precast solutions and automation technology, we’ve enabled Infrastructure and residential developers to increase efficiency, reduce labour dependency, and maintain higher quality standards. Our solutions have helped companies transition from pilot precast setups to fully integrated and automated production lines, setting benchmarks across the industry.

Vollert is known for advanced machinery like pallet circulation systems and battery moulds. Could you elaborate on the technological differentiators that make your solutions stand out?

We continue to lead the construction industry’s transformation with our state-of-the-art machinery, particularly pallet circulation systems and battery moulds. These technologies redefine how precast elements are produced, offering unmatched efficiency, quality, and scalability.

The pallet circulation system is designed for high-volume production, where casting pallets move through various automated stations in a loop. From basic modular setups to fully automated plants with robotic shuttering, these systems produce solid, double, and sandwich walls and slabs. Though the initial investment is higher, reduced manufacturing costs and quick ROI make it a future-proof solution.

Meanwhile, battery moulds enable vertical casting of large precast wall elements with a double-sided surface finish. Their compact footprint, minimal shuttering needs, and simultaneous multi-element casting make them a productivity powerhouse. The duplex version offers flexibility with independently operable chambers and efficient vibration systems for superior concrete compaction.

Together, these systems reflect our commitment to high-performance, sustainable, and cost-efficient precast solutions—empowering clients across India and beyond to build smarter and faster.

Your production facility in Sikandrabad recently expanded. How does this support your regional and export goals, especially in Southeast Asia and the Middle East?

The expansion of our Sikandrabad facility marks a strategic milestone. It enables us to scale up production, reduce lead times, and more effectively cater to customised project needs in India, Southeast Asia, and the Middle East. This facility serves as a global manufacturing hub for the Vollert Group, producing world-class equipment “Engineered in Germany, Made in India.”

With enhanced capacity and localised production, we are better positioned to support international partners with faster delivery, lower shipping costs, and localised after-sales service. Recent exports to Saudi Arabia, Kazakhstan, and the U.S. market reflect this growing global footprint.

What procurement support, training, and maintenance services does Vollert India provide post-installation?

Supplying equipment is just the beginning of the partnership. We offer end-to-end lifecycle support, including:

• Procurement guidance: Assistance in plant layout planning, equipment selection, and integration of utilities.
• Onsite and remote training: Comprehensive operator and maintenance staff training to ensure smooth operations from day one.
• Preventive maintenance programs: Scheduled check-ups and health monitoring to reduce downtime and extend equipment life.
• Rapid spare parts availability: With local inventory and strong logistics, we minimise downtime for our clients.
• Our service model is designed to empower clients with knowledge, reduce operational risks, and ensure long-term performance.

Are you offering financing or leasing models to clients working under budget constraints but looking to adopt precast technology?

We recognise that capital expenditure can be a challenge, especially for companies transitioning to precast for the first time; we work closely with financial institutions such as SIDBI to offer customised financing models. These include:

• Subsidies through SIDBI (Small Industries Development Bank of India)
• Step-Up Financing aligned with project cash flow
• CapEx-light models for environmentally friendly precast technology

We also provide business case support, helping clients calculate ROI, cost savings, and payback periods, making it easier to justify and adopt precast technology.

How is Vollert India contributing to sustainable construction practices regarding material efficiency, energy use, and lifecycle benefits?

Sustainability is embedded in our technology design. While we don’t produce concrete, our mould systems and machinery are engineered to support low-waste, energy-efficient, and high-precision precast production. Here’s how:

• Integrated heating and embedded piping in moulds reduce curing time, saving water and power.
• High dimensional accuracy minimises rework at the site, cutting material waste.
• Durable mould systems have a longer service life, reducing resource consumption over time.
• Automation features ensure optimal material usage and consistent quality, directly supporting green construction goals.

By enabling clients to reduce their carbon footprint across the entire precast value chain, we’re helping push the industry toward a more responsible and resource-efficient future

For more information, visit: https://www.vollert.in/en/vollert-india-pvt-ltd