In order to adapt to Thailand’s green infrastructure policy and road recycling construction standards, and at the same time to solve the industry problems of rising raw material costs and high investment in new equipment, the upgrading of old asphalt mixing plants has become the preferred solution for local engineering enterprises to reduce costs, increase efficiency and operate in compliance with the law. ZOOMLINE has successfully completed the upgrade project of the Thai customer’s plant. For the ZAP-S120 primary asphalt mixing plant, ZOOMLINE adopts the non-destructive function superimposed retrofit program, and on the basis of completely retaining the capacity and performance of the original plant, ZOOMLINE adds an independent 60t/h RAP thermal regeneration system, and successfully upgrades it into a dual-mode primary+recycled asphalt plant.
This transformation can stably realize 30%-40% adjustable recycled material mixing ratio, and all the finished products with high proportion of recycled asphalt mixture have successfully passed all the performance tests and official completion acceptance by the local government of Thailand. As a professional asphalt mixing plant manufacturer, ZOOMLINE can provide customized regeneration and upgrading solutions for all kinds of old asphalt mixing plants, helping overseas customers to revitalize their old equipment assets and realize green and compliant production.
As a professional asphalt mixing plant manufacturer, ZOOMLINE not only provides new complete sets of RAP recycling asphalt mixing plant equipment, but also has mature intelligent regeneration transformation of old plants, customized functional upgrades, capacity expansion and optimization of technical capacity, according to the customer’s existing equipment conditions, production needs and local compliance standards, tailored to the high adaptability, cost-effective, high-throughput regeneration transformation solutions.
The customer is a veteran engineering enterprise that has been deeply engaged in road construction in Thailand for many years, mainly engaged in the core business of municipal roads, highway reconstruction and expansion, maintenance and repair, with stable project resources and sufficient construction volume. The customer maintains long-term strategic cooperation with ZOOMLINE, and the ZAP-S120 virgin asphalt mixing plant in use at the site is in stable working condition, with mature operation and maintenance, which can guarantee the supply of brand new asphalt for all kinds of new road projects all year round.
In recent years, Thailand’s green infrastructure policy continues to tighten, all kinds of road project bidding documents clearly require asphalt mixture mixed with a certain amount of waste recycled material, the industry compliance threshold has increased significantly. At the same time, the price of virgin asphalt aggregate continues to rise, the new recycled asphalt mixing plant procurement costs are high, the production cycle is long, blind replacement of equipment will also cause the original asphalt plant equipment assets idle and wasteful, to the local engineering enterprises to bring great pressure on the operation and production costs. Based on the development trend of the industry and the current situation of their own production, the customer has made clear the precise requirements of equipment upgrading.
Adhere to the reuse of stock assets, do not replace, do not eliminate the original excellent condition of the ZAP-S120 asphalt plant, low-cost incremental upgrades instead of heavy assets equipment procurement, to avoid the waste of idle assets;
The upgraded asphalt plant needs to break through the production limitations of the traditional virgin asphalt plant, with 30%-40% stable and adjustable high-ratio RAP production capacity, fully matching the construction specifications of local high-end municipal, highway and road projects;
Strictly control the quality of finished products to ensure the stable performance of high-ratio recycled mix, which can successfully pass the government sampling test and official compliance acceptance, guarantee the normal delivery of the project, and solidify the enterprise’s local bidding qualification and market reputation.
Original equipment shortcomings, no recycled production capacity: the customer’s original ZAP-S120 asphalt mixing plant only has a new aggregate asphalt mixing function, lack of waste asphalt crushing, screening, heating, accurate mixing of a full set of regeneration processing module, unable to meet the current Thai project more than 30% of the mandatory use of high proportion of recycled material standards, the equipment production capacity can not be adapted to the new policy. The production capacity of the asphalt plant equipment is no longer able to meet the construction demand of the new policy.
Outstanding technical defects of conventional retrofitting solutions in the market: Most of the simple old station retrofitting solutions in the Thai market have obvious technical shortcomings, and they are generally crude and simple modifications, which can only realize very low and unstable RAP blending and cannot maintain 30%-40% high proportion of recycled material production in a sustainable and stable manner. At the same time, under the high mixing production condition, it is very easy to have quality problems such as mix gradation imbalance, void ratio exceeding the standard, and stability insufficiency, which leads to the finished product failing to pass the official inspection and acceptance, and probability of triggering the project bidding cancellation, schedule delay, economic loss and other major business risks, and completely unable to meet the high standard construction requirements of the formal municipal and high-grade highway.
After several rounds of program comparison and technical research, the customer finally discarded the heavy asset program of “brand new equipment procurement” and the low-quality program of “low-end simple modification”, and chose ZOOMLINE non-destructive regeneration function expansion and upgrading program for the old station. The customer highly recognizes our differentiated technical advantages: the transformation does not destroy the original host performance, does not reduce the original production capacity; can accurately and controllably achieve 30%-40% high proportion of regeneration blending; the quality of the finished product is stable, the official acceptance rate of 100%, and it can fundamentally solve the problem of regeneration production compliance.
Difficulty in controlling the precise mixing of high proportion RAP: Most of the modified asphalt plants in the industry can not realize the precise linkage of the old and new systems, and it is difficult to stably control the homogeneous mixing of 30%-40% of high proportion of recycled materials under the premise of retaining the original production capacity of 120t/h. It is easy for the materials to be segregated, imbalance in the ratio, and fluctuations in the performance of the finished products, and other problems.
High standard official acceptance threshold is harsh: Thailand’s road performance testing standards for recycled asphalt mixtures are extremely high, covering Marshall stability, flow value, void ratio, saturation, water damage, fatigue and other indicators. Ordinary retrofit asphalt plant in the high RAP mixing conditions of the finished product indicators generally do not meet the standards, can not pass the official acceptance.
High construction requirements for in-situ renovation: the customer requires to maximize the preservation of the original structure of the asphalt plant, shorten the renovation period, reduce the loss of production downtime, and realize the dual-mode switching of “virgin + recycled production” and put into operation in the shortest possible time.
In view of a number of technical difficulties in the project, we adopt non-intrusive incremental upgrading process, retaining the mainframe system, mixing logic, primary aggregate batching system and 120t/h full-load production capacity of the ZAP-S120 asphalt plant, and independently installing a set of 60t/h RAP thermal recycling processing module, realizing the recycled material feeding, accurate weighing, constant temperature heating, independent conveying, synchronous mixing, and the recycling of the recycled material, as well as the production of the recycled material. By independently installing a complete set of 60t/h RAP thermal regeneration processing module, it realizes the closed-loop control of the whole process of feeding, accurate weighing, constant temperature heating, independent conveying and synchronous mixing of the regenerated material, and the new and old systems operate in synergy without interfering with each other, and in both directions.
The equipment is equipped with intelligent frequency conversion proportioning control system, which can precisely adjust the proportion of recycled material within the range of 30%-40% according to the requirements of the construction design, with high metering precision and constant proportion without drift, completely solving the industry’s common problem of chaotic proportion and big quality fluctuation of the traditional reforming equipment. The whole set of production process is strictly in line with the national standards of Thailand, through the optimization of low-temperature activation of recycled materials, synchronous mixing of old and new materials, mixing performance of balanced control and other core technologies, to ensure that a high proportion of RAP mixing conditions, the finished mixture of various performance indicators are stable and meet the standards, fully meet the official testing and acceptance requirements.
Mode de transformation: the original ZAP-S120 asphalt mixing plant without loss of functional expansion and upgrading (pure incremental superposition, no equipment replacement, no capacity degradation)
Original production capacity retention: complete retention of 120t/h new asphalt mixture stabilization production capacity
Recycling system configuration: independent 60t/h RAP waste asphalt recycling processing system (equipment design upper limit capacity, support dynamic frequency adjustment)
Controllable RAP mixing ratio: 30%-40% precisely adjustable in the whole range, suitable for all levels of road engineering specifications in Thailand.
Compliance certification results: 30%-40% high blending recycled asphalt mixes have passed all tests and formal completion acceptance by the Thai local government.
This transformation is a purely functional overlay upgrade, retaining 100% of the customer’s original ZAP-S120 asphalt mixing plant assets and mature production capacity, without the need to eliminate the old equipment, without the need for heavy investment in new equipment. Customers with very low incremental costs, quickly unlock the high-end recycled asphalt production capacity, to achieve “one equipment, two kinds of production capacity, two-way profitability”, asset utilization maximization.
Different from the market ordinary low-end transformation can only achieve a low percentage, unstable regeneration blending shortcomings, our independent 60t / h recycled asphalt plant can be accurately matched to the total output of 120t / h asphalt mixing plant host, according to the project demand for a stable output of 30% -40% of the high proportion of recycled mix. The material ratio is uniform, no segregation, no performance fluctuations, can fully meet the needs of Thailand’s municipal roads, high-grade highways and other high-standard recycled construction projects.
The biggest core advantage of this project is the high proportion of recycled product compliance and control. Most of the modified asphalt mixing plants can only “produce recycled materials”, but cannot guarantee the acceptance, ZOOMLINE from the structure of the equipment, heating process, proportioning logic, mixing parameters of all-round optimization, to ensure that high RAP mixing under the stability of the finished product of the road performance to meet the standards, and successfully passed the official sampling and completion of the government acceptance, completely eliminating the customer project scrapped, delivery of the project, and the official acceptance of the project. Eliminate the business risks such as the customer’s project bid cancellation, delivery default and so on.
The upgraded asphalt mixing plant supports dual-mode free switching: it can produce conventional new asphalt mixture around the clock to meet the supply of traditional road projects; it can also stably produce a high proportion of compliant recycled asphalt mixture to undertake green maintenance and new recycling projects, market adaptability has been greatly enhanced.
ZOOMLINE always adheres to the one-stop landing service of “program customization, precise production, professional installation, and full delivery” to provide overseas customers with full life cycle technical protection.
Pre-survey and program customization: The technical team combines the customer’s original asphalt mixing plant conditions, site layout, local construction standards and RAP ratio requirements, and customizes a non-destructive, efficient, and compliant recycling transformation program, eliminating the poor adaptability of universal template transformation.
Precise production and on-site construction: all the core components of the recycling system are produced in a standardized and precise manner, and the overseas professional engineering team carries out on-site standardized construction, which can shorten the transformation cycle to the maximum extent, without destroying the structure of the original asphalt mixing plant, and guarantee the quality of the transformation and the progress of the construction period.
Multi-condition debugging and technical training: After the completion of different mixing ratios such as 30%, 35%, 40%, etc. for full-load simulation of production debugging, to ensure stable operation of the asphalt mixing plant, the proportion of accurate. At the same time, we provide systematic operation, parameter adjustment, daily operation and maintenance, and troubleshooting training for the operators, so as to realize the independent production of customers.
Closed-loop delivery of the whole process: from program design, equipment production, on-site installation, system integration, commissioning and trial operation to the later after-sales operation and maintenance, the whole process of one-on-one technical follow-up, to achieve a worry-free landing, compliance and commissioning.
All the finished products of high proportion recycled asphalt mixtures of this project have successfully passed several rounds of sampling tests and official completion acceptance by the local government of Thailand, and all the road performance indexes are in line with the national standards. This indicates that ZOOMLINE’s recycled asphalt mix technology is fully compatible with Thailand’s local high-standard engineering requirements, with stable quality and credible compliance.
Relying on the mature high-ratio recycling production process, customers can consume large quantities of waste asphalt milling materials, effectively replacing high-priced virgin aggregates and brand new asphalt, significantly compressing the cost of raw material procurement. At the same time, with the compliant recycling production qualification, the customer can smoothly undertake local government green infrastructure maintenance and new construction projects, in the industry environmental protection policy tends to tighten, the market competition intensifies the environment, significantly broaden the business boundary, enhance the core competitiveness of the local project bidding.
Recycled asphalt mixing plant can be a large number of waste asphalt milling material, an effective alternative to high-priced virgin aggregates and new asphalt, significantly reducing the cost of raw material procurement. At the same time, relying on compliant recycling production qualification, the customer can smoothly undertake government green infrastructure projects, significantly broaden the scope of business, enhance the core competitiveness of the local market.
The successful landing of the ZAP-S120 asphalt plant upgrade project in Thailand has verified ZOOMLINE’s leading technology in the fields of non-destructive expansion of old plants, precise control of high percentage of RAP, and compliance with overseas standards, and has provided a mature, replicable, and acceptance-acceptable benchmarking program for similar asphalt mixing plant upgrading projects in Thailand and the whole Southeast Asian region.
ZOOMLINE has been plowing into the field of asphalt mixing plant R&D and manufacturing and upgrading of old plants for many years, relying on solid technical deposits, and has accumulated rich experience in the regeneration and expansion of ZAP series and mainstream asphalt mixing plants in the industry. Under the premise of retaining the original machine structure, original production capacity and operation performance with zero damage, it can accurately realize the stable mixing production of 30%-40% high-ratio RAP, with high precision of equipment operation and strong stability of working conditions, thus completely circumventing the technical drawbacks of traditional transformation.
Guaranteed Government Acceptance Under High RAP Ratio
Differing from the sloppy service mode of most manufacturers in the industry, which is “only equipment modification without guaranteeing the quality of finished products”, we take the compliance of finished products and official acceptance as the core delivery standard. From the pre-treatment of recycled materials, heating activation, accurate proportioning to synchronous mixing, the whole process of process precision control, all-round protection of a high proportion of recycled asphalt mixture of road performance indicators up to standard, fully compatible with Thailand and Southeast Asia’s official testing specifications, from the root of the project to avoid acceptance of the risk of acceptance.
Flexible Customisé Ttransformation Ssolution
Abandon the industry’s one-size-fits-all standardized transformation templates, relying on the customer’s existing equipment type, actual production capacity and working conditions, the project’s recycled material mixing needs and local environmental protection and construction policies, tailored to the exclusive non-destructive expansion and transformation program. Highly adaptable to different sites, different equipment, different projects, personalized production scenarios, so that the transformation program more closely match the customer’s actual business needs, cost-effective and practical at the same time.
Un arrêt Dlivraison Service for the Wtrou Life Ccycle
Build a full-process service system from pre-site survey, personalized customization, standardized production of asphalt mix plant equipment, on-site standardized installation, multi-condition debugging and operation training to lifelong operation and maintenance. One-on-one technical docking, simplify the customer docking process, significantly reduce the risk of equipment transformation and production, and help customers quickly land the equipment, comply with mass production, and efficient revenue generation.
We have a 60t/h old asphalt plant regeneration and transformation project in Thailand that has been realistically landed, stably operated for a long period of time, and passed the official completion and acceptance inspection, with real and traceable working condition data and on-site inspections. Mature overseas landing experience and successful cases provide strong strength endorsement and technical reference for all kinds of old station regeneration and transformation cooperation in Southeast Asia.
After the project was put into operation, the customer highly evaluated the results of the old station upgrade. Customers said that the ZOOMLINE non-destructive incremental transformation program retains the stability of the original ZAP-S120 asphalt mixing plant to the greatest extent possible, and the new 60t/h recycled asphalt plant system is stable and accurate proportioning, 30%-40% flexible and adjustable RAP blending ratio, which is perfectly adapted to the mainstream road construction technical requirements of the Thai road projects, and greatly enriches the construction technology requirements for the old plant. It is perfectly suited to the technical requirements of the mainstream road projects in Thailand, which greatly enriches our product capacity structure and project bidding advantages.
At the same time, the customer highly recognized our strict quality control ability, in the industry is generally difficult to control the high proportion of recycled material production conditions, our asphalt plant output mixture is still stable performance, a one-time official acceptance of the government, to completely solve the quality of recycled production pain points and compliance risks. Based on the excellent cooperation experience, the customer has reached a long-term strategic cooperation intention, and will continue to give priority to ZOOMLINE for all subsequent equipment upgrades, capacity expansion, and recycling transformation projects.
If you have a traditional asphalt mixing plant in use, and hope to unlock the production capacity of recycled asphalt in a low-cost way, realize a high percentage of 30%-40% RAP-compliant production, and meet the acceptance standards of the local government projects, ZOOMLINE can provide you with one-on-one exclusive non-destructive regeneration of the old asphalt plant expansion and transformation program.
We support all series of mainstream virgin asphalt mixing plant recycling system retrofitting and functional upgrading, retaining the original plant capacity and operational performance, customizing the recycling system of 60t/h and above specifications according to the needs of each country, accurately adapting to the construction standards of high-ratio recycling, to ensure that the finished product is of stable quality and compliant with the acceptance standards.
We welcome all kinds of engineering enterprises and asphalt plant equipment holders to consult with us for free program evaluation, technical docking and precise quotation, to revitalize the stock of equipment assets, realize green and compliant production, and help enterprises reduce costs and increase efficiency and market expansion.
