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MAKING MANY MIXES

September 02, 2021

MAKING MANY MIXES

Categories: Asphalt Plants

AMMANN ASPHALT PLANT ADJUSTS TO VARIED DEMANDS

TRAKT Co. is ready for whatever comes next – whether it’s a roadbuilding project that requires multiple mix types or increased use of recycled asphalt (RAP).

The company recently purchased an Ammann ABA 210 UniBatch Asphalt-Mixing Plant, which quickly showcased its versatility.

“We were involved in the construction of access roads to our region,” said Mr. Jerzy Szklaruk, President of TRAKT, with headquarters in Wysokie Mazowieckie, Poland. “There were lots of municipal roads, which required us to produce between three and five different types of mixes every day.”

Adjusting between the mix types was not a problem for TRAKT. “This is an advantage of the Ammann ABA UniBatch,” Mr. Szklaruk said. “We have no problem with quickly switching to the production of a different recipe.”

 

A Competitive Advantage

A key driver behind purchasing a new plant was its capacity of 210 tonnes per hour. The previous plants produced mix  with max 80 tonnes per hour, which was typically enough for TRAKT projects.

“But there are days or recipes where you need to accelerate to 210 tonnes per hour, and thanks to the ABA UniBatch we are prepared for it,” Mr. Szklaruk said. “With large contracts, the performance of the plant translates into a real margin for the entire project. In three days, we can accomplish what takes others a week.”

The plant provides the production while maintaining superior quality, which is watched more closely than ever. “Quality control by road managers in recent years is more demanding,” Mr. Szklaruk said. “For companies without experience and without good plants, some standards are impossible to meet.”

 

Green Features

TRAKT purchased its ABA 210 UniBatch with a cold recycling system and a BKS coal dust Burner. It has plans to add asphalt foaming capability as well.

“We equipped the plant with recycling components, but only with the future in mind,” Mr. Szklaruk said. “Relatively little RAP is used in our region. But whenever there is a project using RAP, we are more competitive.”

While the RAP usage may be low, that is already changing – and the percentage will continue to grow, Mr. Szklaruk said.

In the meantime, the company follows many green practices. “We are located close to forests, green areas and pastures, the so-called milky land,” Mr. Szklaruk said. “Cleanliness is a priority for us. In our opinion, Ammann offers the best filter system.”

The plant also utilises sound suppression equipment. “The plant is near a small city,” Mr. Szklaruk said. “There are other small production facilities around us, but also residential buildings. The inverters and insulation installed in the plant reduce noise.”

Ribbed sheets in the discharge channels reduce sound and improve wear resistance.

 

A Technological Advantage

TRAKT had very positive experiences with other Ammann plants, so the company naturally turned to Ammann when looking for improved productivity. “UniBatch is my second Ammann Asphalt-Mixing Plant,” Mr. Szklaruk said.

Previous Ammann plants had technological advantages over competitors, he said, and the ABA 210 UniBatch is proof that Ammann has maintained that lead.

“There has been and still is a technological gap between Ammann and other manufacturers,” Mr. Szklaruk said. “This can be seen in the aggregate sorting, filter system and control system. The Ammann plant runs smoothly, is easy to use and is economical. Operators like to work with it. All this enables the production of bituminous mixes of the highest quality – at the lowest possible cost.”

Mr. Szklaruk likes that the ABA 210 UniBatch can easily be upgraded in the future. “Not everything must be bought at the start,” he said. “The construction of the ABA UniBatch is modular and allows frequent adjustments. The borrowed solutions and components from top Ammann plants such as the ABP Universal make it a solid plant with high capacities.”

In addition to being efficient, the ABA 210 UniBatch is also precise, Mr. Szklaruk said. “There are double-stroke actuators for dosing aggregate and inverters, especially on the main fan,” he said. “There is precise dosing of material with the mixer screw and the latest control system.”

  

The Operator’s Point of View

Mr. Szklaruk praised the proprietary as1 Control System, the brains of the plant. “On the one hand, the control is very extensive and gives practically unlimited possibilities,” he said. “At the same time, it is intuitive and modern. In addition, Ammann is the only asphalt-mixing plant manufacturer that provides the control itself, which ensures ongoing service.”

Plant operator Mr. Marcin also praised the as1 Control System.

“The as1 allows you to transfer data to the manager on a memory stick, so you do not have to manually rewrite or print it,” he said. “It’s easy to contact the Ammann service team, and when we connect remotely, I can see what they are doing on the computer screen.”

He described operating the plant as “simple and intuitive, like a smartphone. When an error occurs, I immediately know what happened and on which component.”

Mr. Marcin said the plant is economical, mainly due to the brown coal dust Burner – but also because of electrically heated bitumen tanks.

The operator station is comfortable, too. “We produce about 100,000 tonnes of mix per year,” he said. “Production is a pleasure. The cabin is clean, heated and air conditioned.”

There is easy access to components when it’s time for maintenance, and Mr. Szklaruk believes the Ammann service team adds value during visits. “Our operator assists the Ammann service department during each visit,” he said. “Each meeting is a kind of technical training.”

 

A Reputable Company

TRAKT was established in 1991. Since then, it has built a solid reputation among road companies in the country’s northeast region. It specialises in the construction and modernisation of roads, streets, bridges, sewage systems and engineering structures – and above all in the production of varied bituminous mixes.

“We try to be the best at every stage of the work,” Mr. Szklaruk said.

 

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