Asphalt Batch Mix Plants' Manufacturers doing Modifications & Upgradations for Better Output

    Apollo

    Asphalt batch mix plants with technically advanced features are delivering the rated output for faster completion of road projects. NBM&CW reports.

    With road contractors looking for Asphalt batch mix plants that enable faster set-up and lower operational cost, manufacturers are making improvisations in their plants to grow and sustain their business, with some even launching newly-developed plants

    Sunil Sapru
    Ammann’s new Apollo ValueTec asphalt bacth mixing plants are designed for business owners who want straightforward processes and the option for customization and range from the basic to the advanced. Avers Sunil Sapru, Ammann’s Region Director for India, “ValueTec offers the lowest product life cycle cost of all plants in this segment, and the batch plants can also be recycled.”

    “Customized options include components that enable utilization of 25 to 40 per cent RAP. There is a foam mix option for the production of energy-saving warm mix, and capabilities for liquid and solid additives that help the customer to adjust mixes to a specific design,” informs Martinho Fernandes, Commercial Manager for Ammann India.

    Martinho Fernandes
    Martinho Fernandes
    Key to the plants is the intuitive CS100 Control System, tried and tested in the world’s toughest environments. The system provides efficiency during production and delivers built-in statistical reports to uncover cost-saving opportunities. Many of the plants’ features are also built around providing efficiency and ultimately reducing costs and improving profits.

    A compact, modular four- or five-bin feeder ensures quick transport and assembly. The plants’ small footprint allows ValueTec to fit into tight spaces. The quality of mix is consistent from the feed stage due to a large storage capacity. Frequency controlled conveyers extending to the drum inlet chute ensure hassle-free material delivery. A simple, effective calibration system provides essential support. “Value is added throughout the production process,” says Sapru. “For example, the low tipping heights for feeder bins eliminate the need for construction of expensive ramps. Instead, a loader can be used with a small ramp.”

    The fully modulating burner features a simple, easy-to-adjust mechanism to set the air/fuel ratio for precise combustion and emissions control. The burner combines with the baghouse to ensure suspended particulate matter (SPM) levels are within limits and the carbon footprint is minimal. Direct-coupled gear motors also add value by reducing fuel and maintenance costs. The counterflow dryer drum is compact, efficient and reliable. Quality is boosted through a screen that uses vibratory motors, providing uniform distribution of aggregate on the screen mesh surface. Circular material movement and transverse transport between the two shafts ensure thorough mixing. The plants feature safety measures to protect plant personnel.

    Ammann & Apollo range of equipment will cater to expressways, national highways, state, city and village roads. The products will be manufactured to global standards with technology from Europe, and with components made in India, they will be competitively priced.

    Kranthi Kumar Ravuri
    Vibrant Construction Equipments Pvt Ltd. has made two improvisations in its asphalt bacth mixing plants: one in the mixer design such that the mixing efficiency is increased and cycle time for each batch is reduced, leading to increase in output. The other change is in the bag house, which has been upgraded to pulse jet bag house system to minimize pollution, making the plant eco-friendly too.

    Says Kranthi Kumar, MD Vibrant Engineering, “We have a tie-up with B/R Automation System and with Siemens for their control panels. Our improvised design has reduced pollution and increased mixer efficiency, which thereby increases plant output. Moreover, the compact design of our plants enables quick and easy transportation, and thereby faster installation. At least 9 trailers of 40-ft each are required for transportation of the heavy machinery to the sites.”

    Eco Tower

    TIL’s range of hot mix asphalt plants comes with a host of technical features that improve efficiency, enhance productivity, help in conserving the environment, and provide a significant advantage on total cost of ownership. Features include counter flow continuous technology for optimizing fuel efficiency, option for multi-fuel burner; screw conveyors for returning fines collected in the bag house to the drum; and 100% portable plants for quick set-up and dismantling.

    Aramid fiber baghouse filters in the plants prevent dust emissions and protect the environment. PLC-based controls ensure better plant operations. There is a bigger surge bin for storage and discharge of mixed material with minimum segregation. Latest generation of warm mix systems simplify production of warm mix asphalt, achieving better foaming with less maintenance, while the unique design of the double barrel technology eliminates blue smoke from the plants.

    Astec Asphalt Plant

    Raj Shrivastava
    The controls in its 200 TPH plants are fully automated, and semi-automated in its new 120 TPH plants, which makes them very user-friendly.

    Informs Raj Shrivastava, Executive In-charge, Crushing & Screening & HMAP-TIL Limited, “TIL, under strategic alliance with Astec Inc. USA, offers a range of world-class Hot mix asphalt plants in India. Apart from being energy efficient, our plants can utilize up to 50% Recycled Asphalt Pavement (RAP). Faster setup by virtue of their modular design, ensures higher uptime and availability of the plants. Our continuous-type asphalt plants can be towed away and installed at ease. In fact, they can be dismantled and reassembled in 24 to 72 hours depending on the technology and size, as compared to the 6 to 12 weeks taken for a batch plant.”

    Kaushik Cesan is ramping up manufacturing capacity for producing higher capacity Asphalt batch mix plants of up to 300 TPH. The modular design of the plants (built on European standards and engineering specification) makes them easier to install and dismantle within two to three days, and easy to transport. Critical components are sourced from reputed manufacturers, especially the gears, which are of Turkish origin. PLC system is from Phoenix, Motors are Siemens or Crompton. The fabricated grilled material is made at Kaushik’s factory as per Cesan’s standard for durability and safety.

    Saumil Shah
    Says Saumil Shah, Director, Kaushik Engineering Works, “Our plants are known for the best fuel efficiency in the industry as the burner and the bag house are synchronized so the fuel-efficiency is at least 4.5 liter/ton as compared to 5.5 liters/ton in other plants. This also minimizes energy wastage and makes them very cost-effective, besides which the SCADA system in the plants gives online support to plants working in the most remote locations, which helps solve problems and minimize downtime.”

    Adds Shah, “We have multiple options to use RAP, with more than three machines in India using RAP currently. Our plants can take 15-20% of RAP materials, but we are not making fully RAP-enabled plants due to the high cost. However, we plan to make a greater number of plants to take on RAP materials.”

    Kaushik Cesan

    Kiran Pandya
    Capious Roadtech has developed a system for incorporating RAP in its Asphalt batch mix plants. To lower the operating and maintenance cost, it has developed a unique system for preventing free dust from entering the plant’s process system. Absence of free dust in aggregates increases heat transfer, which, in turn, reduces fuel consumption; it also reduces load on the dust collector and bag house, thereby extending the life of the filter bags.

    Says Kiran Pandya, MD, Capious Roadtech, “Our plants have a customer-friendly software for ease of operation and fault finding. Our plant towers are constructed in modules for ease of erection and dismantling. All units are manufactured as per the road transportation norms; their dimensions are within specified limits, and they are prewired for fast erection.”

    Capious and Alltech

    The technology in Alltech Asphalt Batch Mix plants enables ease of maintenance, minimal fuel consumption and heat transfer. The company’s broad spectrum of products includes plants for hot asphalt mix processing. Recycling components are also used to retrofit existing plants that can be adapted and integrated as per customer demand.

    Paresh Patel
    Says Paresh Patel, MD, Alltech Industries India Pvt Ltd, “Targeting upcoming road and expressway projects, we launched small (80tph) to high (240tph) asphalt batch mix plants. We proved maximum fuel efficient, less maintenance, cost effective and high production plants for both the domestic as well as international markets.”

    According to him, the highest possible addition of RAP depends mainly on its grading curve, which should (as far as possible) be approximated to the desired grading curve of the finished product. “This cannot be achieved with normal crushing plants which produce too many fines and sand for proper granulation, but at Alltech, we have the technology for utilization of RAP materials to the highest extent.”

    He adds, “Fuel quality and availability is a big challenge in India, hence, we have designed multi fuel systems in our plants such that customers can use waste, heavy or recycled oil, diesel, Ldo or gas, supported by our various burners. We also ensure faster and cheaper transportation and quick set up of our plants because all parts have standardized transport dimensions that allow use of standard trucks or 20 and 40-ft trailers.”


    At Atlas Technologies Pvt. Ltd., improvisations are being made to make the Asphalt batch mix plants better adapted to higher aggregate moisture content. The bag filters have three rotors on top for efficient cleaning. The mixing unit comes with planetary gear boxes on each shaft, which is better for torque absorption. Superior quality materials for liners, arms and tips ensure longer lifespan of the plant. The thermal oil heaters with three pass systems, specially designed by the vendor for Atlas, enables heat transfer efficiency with use of minimum fuel.

    “We have supplied plant burners in the past that work on PNG gas both for drying drum as well as thermic heater, which give true value to customers. We have supplied 5 asphalt batch mix plants with RAP system. We have designs that can add up to 30% RAP material, and we are one of the front runners in providing solutions for addition of reclaimed asphalt,” informs Bhavesh Patel, MD, Atlas Technologies Pvt. Ltd.

    He informs that their stationary plants’ modular structure enables faster installation: each unit can be picked and placed in a truck for transport, while the major units have skid plates for quick installation. The company has also introduced Mobile Asphalt Batch Mix plant that can be installed and commissioned in less than 48 hours using a single hydra crane. All the units are fully mobile, and each chassis can be attached to the kingpin of a trailer. The machine is the best option for customers, who shift sites frequently. The machine’s hot bins and mixing unit are also of adequate capacity for the require production.

    Atlas Technologies

    According to him, the precisely manufactured drying drum burners enable fuel efficiency with a saving of 0.5 to 0.9 liter of diesel per ton compared to other brands. All the control panels have in-built SCADA, enabling remote troubleshooting. “Smaller problems can be solved within minutes and we do not require a technician to visit the site. This feature, though it comes with a higher initial cost, has proved to be immensely beneficial to customers. The gear, motors, electronic components, sensors, etc. are of the highest quality that ensure higher performance of our plants - easy to operate and maintain by the customers. Even our higher capacity plants of 200 and 260 tph are designed on the principle of simplicity and efficiency. Particularly their software, which enhances ease of use and maintenance, and there is minimum requirement for spare parts.”

    Vatsal Patel
    Ashitech Equipments has been carrying out technical improvisations in its Asphalt batch mix plants and has developed and installed a plant with state-of-the-art RAP system. “Use of RAP has been our primary concern for environmental protection. For maximum heat transfer, we have upgraded the plants’ design and insulation material, says Vatsal Patel, Director, Ashitech Equipments.

    He adds that they have developed a software for easy functioning of plant with HMI and PLC from a renowned global manufacturer. “The hardware and software are user-friendly and enables higher performance, while the plants’ compact design makes their transport and installation faster.”

    Ashitech

    Speedcrafts has been collaborating with its principals to provide their Asphalt batch mix plants with a circular motion vibrating screen for better screening efficiency, and a reverse air bag house filter for longer bag life and to achieve minimum emission. Generous insulation of bitumen tank and dryer drum to minimize heat loss, modulating burners for higher fuel efficiency, and infrared and thermal sensors for maximizing their plant’s thermal efficiency.

    Shashank Agarwal

    Says Shashank Agarwala, Director - International Sales, Speedcrafts, “Our plants can use RAP up to 20% on ‘as is basis’ with addition of RAP feeding system. We can also offer plants with up to 50% RAP usage. Presently, we are providing up to 200 tph capacity plants with electronic, PLC as well as SCADA based controls. Our endeavour is to select components of globally recognized companies but made locally in India so that we can provide timely product support. Our plants have modular cold feed bins, mixing tower, bag filter, bucket elevators, filler silos etc, for ease of transportation and installation.”


    Speedcraft

    Fab India has launched a new 80-100 TPH mobile plant, which can be installed and operated in less than a week. For installation, a single pick and carry crane is sufficient as the parts are mobile. “This plant is highly recommended for customers who shift plants frequently from site to sire. Though the machine has been made compact and mobile, the output has not been compromised in any way, and it will deliver the same output as a stationary plant,” avers Ritesh Prajapati, CEO, Fab India.

    Ritesh Prajapati
    Ritesh Prajapati
    He informs that their plant is divided into five major parts and 9-11 trailers are required for the stationary asphalt batch mix plants. Their skid plate structure reduces time of installing the plant at site. The size of the hot bins has been increased to get maximum rated output. The other improvisations include, enhanced size of the bag house so that more filter bags can be fitted inside which results in increase in recycled air to prevents pollution in the plant’s surrounding.

    The company has also modified the size of the burner; altered the flight design of the drying drum for faster and uniform drying of material with less use of fuel in the burner; is using specially manufactured thermic oil heater of advanced technology for maximum heating; and is using only superior quality material for the liners, arms and tips for more durability of the plant; with SCADA remote-controlled machine parts and operations.

    Says Ritesh Prajapati, “We have designed our plant in such a way that it can add 30-40% RAP material for highway construction and decrease environmental pollution. Though our high capacity plants (of 160/200/240/260TPH), feature advanced technologies, their hardware and software can be easily understood by the operator.”

    Fab India
    Competition Driving Business

    The market for asphalt batch mix plants in India is becoming highly competitive with multinational manufacturers claiming several technical and competitive attributes in their plants, and driving other manufacturers also to incorporate advanced features in their plants.

    “Capious has adopted proven global technology, and as an exporter is competing internationally with multinational brands in global markets. It offers the same technology to the Indian market, which makes our plants competitive. Apart from our standard features, we incorporate customer’s specific requirements in our plants,” says Pandya.

    “The market is thronging with indigenously developed plants with foreign technological collaboration. However, to be competitive, one has to understand and provide solutions as per customer requirements, and with the right pricing. At Atlas, we design and alter our products as per the harsh Indian conditions,” says Bhavesh Patel.

    “Through rigorous R&D over two years we have developed our genuine Ashitech designed plant that gives high performance and output, and hassle-free operation,” informs Vatsal Patel.

    Kaushik Cesan’s new factory at Sanand, Gujarat, has an increased production capacity of 5 to 6 times. It is using state of the art manufacturing methods for faster and precision manufacturing such as the CNC Plasma Cutting machine for cutting steel sheets and plates with high precision and speed, and the latest welding and quality analysis equipment.

    “We, at VIBRANT, always remain technologically advanced in designing our batching plants. Our in-house R&D team keeps working on improving the plant performance. As local manufacturers, we have the price advantage,” avers Kranthi Kumar.

    “Fab India plants are competitively strong due to their customization and ability to perform easily in tough conditions with minimum maintenance. This is because we use only superior quality components,” says Ritesh Prajapati.

    “Speedcrafts has two manufacturing units where the plants are manufactured with a design and technical collaboration with a European company. The local content and improvisation done in our plants make them compatible with Indian conditions,” says Shashank Agarwala.

    “Efficiency and productivity are the primary parameters when it comes to the choice of asphalt plants. The technical features in our plants offer benefits of high quality of asphalt, competitive pricing, lower energy requirement, lower operating costs, acceptable emission values, quick setup & dismantling time, portability and last but not the least, higher equipment uptime. It is our constant endeavor to incorporate in our products the latest cutting-edge technology to offer long-term solutions and add value to customers’ operations,” says Raj Shrivastava at TIL.

    Alltech is aligning its quality processes with global standards to position its plants more competitively in the marketplace. Its plants deliver the rated capacity under continuous working such that the user can decide their operating hours. The company’s manufacturing facility has modern machines for plasma and laser cutting and for bending, and an efficient raw materials procurement plan in place to meet timely delivery of plants. “Our plants can utilize high percentages of recycled asphalt as well. This saves our customers the aggregate costs making our plants more cost effective. Improvisations are being made to minimize waste for lower emission,” informs Paresh Patel.

    Focus on Customer Support

    In a bid to expand and sustain business, manufacturers are providing end-to-end service to their clients. Service extends from delivery of plant till its commissioning and includes operator training and maintenance to ensure smooth running of the plants, with a ready supply of spare parts. All of them have a dedicated team to address or analyze any problems at site and take corrective action immediately.

    “Optimum support has given Atlas a strong brand recall, despite our products being priced15 to 30% higher. We have one of the biggest manufacturing units in India with all the components ready for dispatch within 1-3 business days,” informs Bhavesh Patel.

    Vatsal Patel says, “Ashitech has an experienced team of technicians and engineers for addressing the flaw on an immediate level. This is done either through a telephone call or a site visit, making a detailed assessment on the cause and suggesting measures to curtail its future occurrences.”

    “Vibrant has a dedicated service team for 24x7 customer support. If the issue remains unsolved our service engineer will visit the site within 24 hours. Our warehouse is stocked with a full range of components for quick supply of spare parts,” says Kumar.

    “Kaushik has pan India offices with trained service personnel and adequate stock of parts. Our engineers undertake projects in the most efficient and affordable manner even in the most adverse conditions. Intensive training to the operators is also being rendered by our engineering team,” says Shah.

    “At Fab India, we are prepared to tackle any problem with a provision for parts supply across all regions. We train operators not only to run the plant as per given guideline which minimizes downtime but also to repair and find solution to minor problems,” says Prajapati.

    Mr. Agarwala informs, “We have a dedicated team of product support engineers and technicians. They work very closely with customers from the time of installation and commissioning of the Speedcrafts plants across its lifecycle. It is our standard practice to provide onsite and offsite training at our factory to the operation and maintenance team of customers. This is to get them acquainted with the equipment for hassle free operation.”

    TIL has been consistently providing its customers innovative solutions to ensure higher returns on their investments and enhance overall profitability. “Customer support, aftersales service, and aftermarket operations – these are critical levers in the growth engine of every organization. Providing right partnership and aligning business practices with the business goals of customers has always been integral to TIL’s corporate philosophy. Our integrated product support is aimed at reducing equipment downtime and cost of operations,” says Raj Shrivastava.

    Informs Paresh Patel, “Higher plant reliability and continues performance is how we benchmark product support at Alltech. We have in-house testing of critical components; we give demos of the installation and erection of plant before dispatch to ensure its quick and safe operation at customer’s site; and we also enable quick dismantling by our service engineers who undergo regular training at our factory. Our plants require minimum maintenance and we give some spare parts on FOC to our customers, having possibilities of higher breakage.”

    Ammann India supports its plants after their sale with quality, reliable parts. Service packages are available to ensure all maintenance is up to date. A future-ready design ensures the seamless addition of upgrades. To contribute to the government’s Skill India mission, Ammann India has identified a skill gap in operation and maintenance of road construction equipment, which has a huge potential for employment given the equipment population and the thrust on roads, and the high demand for certified operators. Ammann India Academy, fully equipped with training kits, simulators, equipment and latest tools, will offer real-life skill enhancing training to the youth on asphalt plants, paver finishers and compactors, in collaboration with Infrastructure Equipment Skill Council (IESC). With this training, the youth will become certified operators, besides which, the Academy will provide advanced training for existing operators to improve the quality and productivity for laying world-class roads.

    Customer service is crucial for all the manufacturers as any unprecedented delay in supply of spares or in troubleshooting will be detrimental to their business. To keep competition at bay, they plan and develop the best service plans since a lot depends on the uninterrupted working of their plants.

    NBM&CW September 2018

    CURRENTLY ONLINE
    We have 193 guests and no members online

    NBM&CW

    New Building Material & Construction World

    New Building Material & Construction World
    MGS Architecture

    Modern Green Structures & Architecture

    Modern Green Structures & Architecture
    L&ST

    Lifting & Specialized Transport

    Lifting & Specialized Transport
    II&TW

    Indian Infrastructure & Tenders Week

    Indian Infrastructure & Tenders Week