MALCON4/4E

The Hofmann MALCON4/4E is a multifunction road marking control unit integrating three distinct systems into a single device: a line-spacing electronics unit for manual, semi-automatic, and fully automatic marking; a paint quantity regulation unit for dosing pump control across multiple material types; and a documentation unit for marking output recording, layer thickness verification, and data export. The unit controls up to 4 sequentially arranged marking units — including paint guns, bead guns, and extruder flaps — and executes country-specific line marking patterns for up to three parallel lines simultaneously in fully automatic mode. Data export is available via PDA, USB stick, or GPS/GSM module (GPS location tracking with GSM data transmission), enabling marking quantity and layer thickness documentation to be generated per ZTV-M regulatory requirements. The software interface is available in 13 languages switchable from the display. An optional printer connection allows documentation printouts during or after the marking run.

The paint quantity regulation function registers and controls the current output of dosing pumps across four material categories: 1K cold paint and spray 2K cold plastic via plunger pumps in both low-pressure airspray and high-pressure Airless configurations; 2K cold plastic via bellows pump; and spray thermoplastic via bellows pump with integrated temperature display. A layer thickness analysis function generates a statistical profile of marking film thickness across a user-defined number of measurement points within a distance — for example, within every 250 meters — meeting ZTV-M quality assurance requirements. Ambient temperature, road surface temperature, relative humidity, and bead application rate can be entered to meet regional self-monitoring requirements. Optional accessories include a feedback system, rear-view camera, and MultiDotLine® control for profiled marking production.

The Hofmann MALCON4/4E is installed on self-propelled road marking machines for motorway, highway, and urban road marking programs where ZTV-M documentation compliance, multi-line simultaneous marking, pump output regulation, and layer thickness quality assurance are all operational requirements in the same marking campaign — particularly on public road contracts requiring certified marking output records as part of project handover documentation.

Leader Infra supplies this integrated multifunction marking control unit for road marking contractors on public and regulated infrastructure projects — combining line-spacing automation, pump output regulation, layer thickness documentation, GPS/GSM data export, and 13-language interface capability in a single control unit meeting ZTV-M quality assurance standards.

FAQ — What does the ZTV-M layer thickness analysis function in the MALCON4/4E produce, and why is it required on public road contracts? The ZTV-M (German Technical Contract Conditions for Road Markings) standard requires contractors to document marking film thickness at defined intervals along the marked route as proof that the correct material application rate was maintained throughout the job. The MALCON4/4E generates this statistical layer thickness profile automatically from its pump output data across user-defined measurement intervals, producing the contractually required documentation record without requiring separate manual thickness measurement during or after the marking run.