TBA 4000 mixing plant opened in Belgium

The first TBA from Benninghoven’s new factory

The new TBA 4000 is a truly special plant for its manufacturer Benninghoven. This is because it is the first asphalt mixing plant launched by its new Wittlich factory, where the Wirtgen Group company produces asphalt mixing plants that meet the requirements of customers and users all over the world. Its new headquarters are not far from the River Moselle on the German side, near the plant site, and represent the largest single investment in the Wirtgen Group’s history. With the construction of its new building, Benninghoven is becoming even more competitive on the global stage. “When we deliver new plants and are privileged enough to see such proud faces, it’s very pleasing,” says Jean-Luc Didier, Head of Sales at Benninghoven. “Since we’ve moved into our new factory, it’s been even easier for us to see why. Because we’re immensely proud of the site too.”

This pride shown by the asphalt-making specialist is due not only to the company’s impeccable infrastructure but also to a new product philosophy. This is characterized by unbeatable quality and production standards. This includes a highly interconnected production setup that has resulted in an unprecedented degree of variety and diversity in the options available to it. The company is thus ideally positioned for the future – just like its Belgian customer.

First-class asphalts for Belgium and the region

The company’s move to its new factory and its new product philosophy also played a role in decision-making. “We deliberately went for the first plant from the new factory, simply because we were persuaded by the benefits.” With good reason, too: The Benninghoven factory is equipped with numerous pieces of advanced technology and sets new standards for manufacturing systems. One of its many highlights is its state-of-the-art surface treatment using solvent-free powder coatings. As long-winded as this may sound, it actually increases the plant’s service life as it makes the surfaces scratch- and shock-resistant and the anti-corrosion protection long-lasting. And, as far as Bodarwé is concerned, that counts because, as Michel Bodarwé says, “We’ve got some big plans for our TBA 4000 in the long term.”

And nothing is standing in their way: With the help of the plant, his construction firm can produce and supply large quantities at up to 320 metric tons per hour, thanks to numerous optional technologies offering a wide range of alternatives and, of course, proven Benninghoven quality. A mixed material loading silo with a volume of 341 metric tons ensures an adequate buffer in day-to-day operations. Some of the asphaltic mixture will be sold in the future, and some will be further processed by the company itself, as Bodarwé also has a fleet of Wirtgen Group construction machines – the paving teams work their asphalt mixture using Vögele finishers and Hamm rollers.

Green technology holds the key to cost-effective, future-proof design

What makes Benninghoven’s technology particularly efficient and fit for the future is the fact that it complies with the most stringent emission regulations all over the world and leads the way in the matter of recycling. For example, Bodarwé’s plant can achieve RAP material rates of up to 70% thanks to two technologies – a multivariable feed system and a parallel drum. With regard to its recycling technologies, Benninghoven distinguishes between cold and hot feed systems. The multivariable feed system is a cold feed system that gently adds up to

40% reclaimed asphalt straight into the mixer. The parallel drum hot feed system heats the preconditioned reclaimed asphalt and transfers it hot into the mixer. This method enables the maximum RAP material rate possible for the TBA to be achieved. The technology behind the world’s highest RAP material rate of 90 + X% is also a Benninghoven invention. Again with good reason: The recycling technology turns the reclaimed asphalt from a problem into a valuable raw material that stays within the cycle instead of being disposed of at significant cost. And, should the feed rates stipulated in law ever increase, the TBA 4000 in Baugnez will remain in business. “The new Benninghoven will be the engine that powers our future,” says Mr. Bodarwé.

The same could also be said of the foam bitumen module that is also integrated into the TBA 4000. One important reason is that the use of this binder attracts state subsidies in Belgium. This innovative technology enables low-temperature asphalts to be produced at a temperature of 110°C, which is around 40°C lower than the 160°C required for conventional asphalts. This reduces the energy required to produce the asphalt by around 9 kWh per metric ton, which equates to 0.9 liters of heating oil per metric ton of finished asphalt. CO2 and other harmful emissions are also reduced. “Although we haven’t commissioned the foam bitumen module yet, it’s precisely this flexibility that prompted us to pick it,” says Managing Director Michel Bodarwé. “The technology will play a key role for us in the future, no doubt about it.”

Active partnership with the Wirtgen Group

Besides technical characteristics and benefits, it also goes without saying that the quality of after-sales service is another key factor for operators. “In the Wirtgen Group and Benninghoven’s Customer Support, we have a partner that we can rely on to be by our side – from large-scale winter maintenance and spare parts supply through to everyday questions about process technology. When we need the lads, they’re there,” Michel Bodarwé underlines.

Head of Service Alain Heukemes adds: “We’re delighted that our first TBA enjoyed such an opening and are looking forward to production getting under way. Of course, we’ll retain very close links to our first TBA 4000 through service work. Getting a degree of customer satisfaction like Bodarwé’s doesn’t happen by itself. Rather, it’s the constant aim of the entire Customer Support team.”

“We’ll be making a start with our new TBA imminently,” says Bodarwé’s Managing Director Michel Bodarwé. “W have a lot of orders on hand and are very much looking forward to tackling them with the new plant. That’s because, as well as being able to produce large quantities, it’ll let us take a leap forward in quality terms.”