Turning Waste Into Profit

Ammann Asphalt-Mixing Plant Utilises Recycled Asphalt

Does an Ammann ABA UniBatch Asphalt-Mixing Plant help businesses profit?

Yes – and the numbers prove it, according to Siddharth Shah, director at RKC Infrabuilt Pvt. Ltd., Ahmedabad, India.

“It’s very economical compared to all other plants,” Shah said. “We have been saving great amounts.”

An ability to utilise recycled asphalt (RAP) in place of fresh aggregate is the key cost saver. In addition, ABA UniBatch is able to maintain high mix quality while repurposing the RAP.
 

 
“The plant provides excellent asphalt mix,” Shah said. “The baghouse is amazing. The drum is good for recycled asphalt as well. These are the things that attracted us to buying this plant.”

A specific and significant factor in RKC choosing the ABA UniBatch was the plant’s ability to add hot and cold recycling material. There is a growing demand for the use of RAP in India, so the plant is a good fit for the Indian market. It’s an example of a plant that is built in India, for that particular market, but also utilises European technology.

The plant can also access a foam generator that produces asphalt at a reduced temperature. This low-temperature asphalt (called “warm asphalt” in India) has the same quality as a traditional mix but requires less fuel to produce. Emissions are lower, too, and the paving crew is more comfortable working with the lower temperature mix.

Shah said the intuitive nature of Ammann’s proprietary as1 Control System makes production of all the mixes possible.

“The as1 is amazing software,” Shah said. “I’ve never seen such a software before. It gives you a total description of the entire plant.”

Shah also was pleased that the ABA UniBatch meets the expected production levels. “Ammann is the only provider that keeps its promised plant capacities,” Shah said. “Others brag about large capacities and then only reach 70 per cent to 80 per cent. Ammann always reaches the promised capacities.”

RKC has needed high production on some recent large-scale roadbuilding projects. “The plant has produced 130 000 tons in fewer than 100 days,” Shah said.

Martinho Fernandes, the commercial manager for Ammann and Apollo plants in India, has reviewed many plants in that country and locations around the world. He is often able to put hard numbers to the efficiencies and ultimately the cost savings ABA UniBatch plant provides.

• The ABA UniBatch can develop mix that utilises up to 40 per cent hot RAP and 25 per cent cold RAP. It also offers a foam mix option and solid additives.
• Uptime of the RKC plant is close to 100 per cent.
• Parts life is extended by 25 per cent because of the ABA UniBatch’s advanced metallurgy.
• The direct-drive system of gear motors reduces power consumption by 10 per cent and maintenance by 20 per cent.
• Research and development has led to green technology efforts, including an efficient burner and baghouse that ensure less than 20 mg/Nm³. This also provides customers with additional carbon credits.

Fernandes says the plant is ready for the next round of challenges, too. “The ABA UniBatch is also ‘future ready,’ meaning customers can easily incorporate new technology as it becomes available,” he said.