Time: December, 2018
Location: Tbilisi, Georgia
Equipment: ZAP-S60 Stationary Asphalt Batch Mix Plant, 60T/H
With the acceleration of global infrastructure investment, Georgia, a key node along the Belt and Road is vigorously advancing the upgrading of its highway and municipal road infrastructure. As investment in road construction continues to grow, the demand for reliable and efficient asphalt production equipment is becoming increasingly urgent.
As the nation’s political, economic, and transportation hub, the capital city of Tbilisi is seeing a surge in municipal road renovation and regional highway maintenance projects. Small and medium-sized asphalt mixing plants, which are well-suited to local construction needs, have become the preferred choice in the local construction market.
The Georgian government places high priority on infrastructure development, designating sectors such as highways and municipal facilities as key areas for investment promotion. It grants national treatment to foreign investors, providing a favorable policy environment for asphalt mixing equipment to enter the local market.
According to relevant data, Georgia has continuously expanded its investment in road construction in recent years, with stationary asphalt mixing plants widely used in municipal road and highway projects. Among these, small-to-medium-capacity equipment with a throughput of 40–100tph has become the market mainstream due to its suitability for local road construction and maintenance scenarios.
As the capital, Tbilisi has particularly significant road construction needs, ranging from municipal projects such as the renovation of major urban thoroughfares and the upgrading of roads in older residential areas to the routine maintenance of highways in surrounding regions. This places clear demands on the daily supply volume and quality consistency of asphalt.
Unlike large-scale projects that rely on high-capacity equipment, construction sites in Tbilisi are dispersed, and individual project volumes are moderate. Excessively large asphalt mixing plants would result in wasted investment and idle capacity, whereas the 60tph capacity strikes the perfect balance between “investment costs and output efficiency,” making it the preferred choice for local contractors.
The client for this project is a well-known local road construction contractor in Tbilisi that has long specialized in urban road paving, municipal infrastructure construction, and regional highway maintenance.
With extensive construction experience and a stable project portfolio, the client is a key player in the local municipal construction sector. Previously, the client used small-scale asphalt mixing equipment; however, as project scales expanded, this equipment could no longer meet the demand for a stable asphalt supply, creating an urgent need to upgrade to a cost-effective solution suitable for medium-sized projects.
Production Capacity: The plant must have moderate production capacity to reliably supply the asphalt required for daily construction, thereby preventing project delays caused by insufficient output;
Quality Assurance: High mixing precision to ensure the uniformity and stability of the asphalt mixture, meeting local road construction quality standards in Georgia;
Cost Control: Low fuel consumption and economical operating costs to align with long-term construction cost management requirements;
Reliable Service: Comprehensive after-sales technical support and spare parts supply to ensure long-term, stable equipment operation and minimize downtime losses;
Stable Installation: Suitable for long-term fixed installation, meeting continuous production demands and adapting to fixed construction site scenarios.
Considering customer needs and local construction conditions in Georgia, the 60 tph asphalt mixing plant stands out as the optimal solution due to three core advantages.
First, outstanding cost-effectiveness: Compared to large-scale 80–160 tph equipment, the 60 tph unit requires a lower investment and offers a shorter payback period, helping customers achieve profitability quickly.
Second, scenario compatibility: It perfectly matches the construction needs of medium-sized projects such as municipal roads and regional highways in Tbilisi, ensuring production capacity is neither underutilized nor insufficient.
Third, it offers flexible adaptation, allowing production schedules to be adjusted according to project progress and demonstrating greater adaptability to local construction environments and raw material supplies.
Based on ZOOMLINE’s industry experience, 40–60 tph equipment is better suited for small-to-medium-sized municipal and rural road projects, and the 60 tph model strikes the optimal balance between production capacity and cost within this range.
Based on customer requirements and local construction conditions, the ZAP-S60 stationary asphalt mixing plant has been selected as the primary equipment for this project. Designed specifically for medium-sized infrastructure projects, this model combines stability, high efficiency, and cost-effectiveness, fully meeting the core requirements of Tbilisi’s municipal and highway construction projects.
The core technical specifications of the ZAP-S60 model deployed for this project precisely align with project requirements, as detailed below:
Rated Capacity: 60 tons/hour, capable of reliably meeting daily asphalt supply demands for construction, thereby avoiding capacity shortages or idle time;
Equipment Type: Fixed batch-type mixing with flexible batching ratios, enabling precise control of asphalt mix quality and meeting the requirements of high-standard municipal road construction;
Combustion System: Pulverized coal burner, customized to suit local fuel supply characteristics, balancing economy and stability;
Dust Collection System: Two-stage baghouse filtration, compliant with local Georgian environmental standards, reducing dust pollution during construction;
Control System: Fully automatic PLC-based intelligent control, offering user-friendly operation and enabling precise weighing and automatic mixing, thereby reducing labor costs;
Supporting Systems: Equipped with an insulated asphalt tank, multiple cold aggregate bins, and a finished product silo to ensure the quality stability of raw materials and finished asphalt.
The decision to specifically select a pulverized coal burner for this project was driven by the need to align with Georgia’s local conditions while balancing cost-effectiveness and practicality.
First, fuel costs offer a significant advantage. Compared to diesel burners, the cost of pulverized coal fuel is substantially lower, leading to significant long-term operational savings that meet the client’s cost control requirements;
Second, local fuel supply is stable. Georgia has abundant pulverized coal resources, ensuring long-term continuous production and minimizing downtime losses caused by fuel shortages;
Finally, pulverized coal burners are well-suited for long-term continuous operation. Their high thermal efficiency meets the continuous output requirements of a 60 tph production capacity, thereby enhancing project construction efficiency.
The ZAP-S60 model features a precise weighing system that accurately measures aggregates, asphalt, and fillers, ensuring the uniformity and stability of the asphalt mixture.
A uniform mix enhances the pavement’s compressive strength and wear resistance, meeting local road construction quality standards in Georgia, extending the road’s service life, and reducing long-term maintenance costs.
In addition to the fuel cost advantages provided by the pulverized coal burner, this equipment features high thermal efficiency, effectively reducing energy consumption.
At the same time, the equipment’s rational structural design ensures low energy consumption and a low failure rate, minimizing maintenance costs and downtime losses. This further reduces operating costs and helps clients increase project profitability.
As global environmental awareness grows, Georgia’s environmental requirements for infrastructure construction are also becoming increasingly stringent. The baghouse secondary dust collection system included in this configuration effectively filters dust generated during construction.
Dust emissions fully comply with local environmental standards, preventing both environmental pollution and project shutdowns caused by non-compliance, thereby ensuring the smooth progress of the project.
Compared to mobile mixing plants, the fixed design is better suited for continuous production at long-term, fixed sites. The equipment features a stable structure and high operational reliability, capable of meeting the long-term, continuous asphalt supply requirements of Tbilisi’s municipal projects.
Additionally, the equipment is highly resistant to interference and can adapt to local construction environments, reducing schedule delays caused by equipment failures.
The ZAP-S60 model features a durable structural design with reliable core components and a long service life. The equipment is easy to maintain, with ample maintenance space provided and simple spare part replacement.
Additionally, a comprehensive spare parts supply system ensures rapid replenishment of necessary components, minimizing equipment downtime and reducing long-term maintenance costs.
Compared to continuous drum mixing plants, the core advantages of batch mixing plants lie in their flexible mix ratios and high mixing precision. For projects like Tbilisi’s municipal road construction, which demand high pavement quality, batch-type plants offer better control over mix ratios and ensure superior pavement construction quality, making them the optimal choice.
Prior to installation, our professional team completed four key preparatory tasks based on the actual conditions of the project site, laying the groundwork for equipment installation.
Foundation Construction: A specialized foundation was poured according to the equipment’s dimensions and load-bearing requirements to ensure stable operation after installation;
Power Supply: The local power grid was connected, and power connection and commissioning were completed to ensure a stable power supply for equipment operation;
Asphalt Tank Installation: Installed insulated asphalt tanks and applied proper insulation to ensure stable asphalt quality during storage;
Raw Material Storage Planning: Planned storage areas for aggregates, pulverized coal, and other raw materials, optimized material transport routes, and improved construction efficiency.
Equipment installation strictly followed standardized procedures, proceeding in an orderly, step-by-step manner to ensure installation quality and long-term operational stability. The specific steps are as follows:
Step 1: Main Building Hoisting: Use professional hoisting equipment to precisely position the mixing main building at its designated location and secure it firmly;
Step 2: Burner Installation: Install the pulverized coal burner in place, connect the relevant piping, and commission the combustion system;
Step 3: Dust Collection System Assembly: Assemble the baghouse dust collection system, connect the ductwork, test the dust removal efficiency, and ensure compliance with environmental standards;
Step 4: Control Room Setup: Install the PLC control system, debug equipment operating parameters, and ensure the control system functions properly;
Step 5: Pipeline and Electrical Connections: Connect all equipment pipelines and electrical circuits, conduct a comprehensive inspection to prevent leaks, short circuits, and other issues.
Upon completion of installation, the project enters the commissioning and staff training phase to ensure normal equipment operation and that the client’s operators are proficient in using the equipment.
System Integration Testing: Conduct comprehensive integration testing of all equipment systems, troubleshoot faults, optimize operating parameters, and ensure the equipment reaches its rated production capacity;
Production Testing: Conduct small-scale production tests, inspect the quality of the asphalt mixture, adjust mix design parameters, and ensure compliance with construction standards;
Operator Training: Provide one-on-one training for the client’s operators, explaining equipment operating procedures, precautions, and basic troubleshooting methods;
Maintenance Guidance: Provide maintenance training to the client’s maintenance staff, covering key points of daily maintenance and care methods for core components to extend the equipment’s service life.
Following rigorous installation, commissioning, and trial runs, the 60 tph asphalt mixing plant was successfully commissioned on the first attempt and went into operation smoothly. The equipment operates stably, achieves rated production capacity, and produces high-quality asphalt mix that fully meets the client’s construction requirements, earning high praise from the client.
According to customer feedback, since the equipment was put into operation, it has consistently achieved its rated capacity of 60 tph, continuously meeting the daily asphalt supply needs for construction. This has completely resolved the previous issue of insufficient production capacity caused by smaller equipment.
Additionally, the asphalt mixture is uniformly mixed and of consistent quality. Testing has confirmed full compliance with local Georgian road construction quality standards, and the paved surfaces are smooth and durable, earning recognition from the project client.
In terms of economic benefits, the client is highly satisfied with the equipment’s performance. The use of pulverized coal burners has significantly reduced fuel costs, resulting in substantial monthly savings compared to the diesel-fired equipment previously used.
Furthermore, the equipment operates stably with a low failure rate, reducing downtime losses and maintenance costs. Construction efficiency has also been significantly improved, further increasing the project’s profit margin.
The client stated that they received professional technical support and service assurance throughout the project. During the installation phase, a professional team was on-site throughout the process, efficiently completing installation and commissioning. During equipment operation, technical personnel responded promptly, quickly resolving various inquiries and minor malfunctions.
Furthermore, the supply of spare parts is reliable, with timely replenishment of necessary components to ensure long-term, stable operation of the equipment, completely alleviating the client’s concerns.
The successful implementation of this 60 tph asphalt mixing plant project in Tbilisi, Georgia, fully demonstrates the suitability of the 60 tph fixed batch-type asphalt mixing plant for local municipal and highway construction. This model combines cost-effectiveness, stability, and economic efficiency, perfectly meeting the construction needs of small and medium-sized infrastructure projects in Georgia.
Drawing on ZOOMLINE industry experience, we offer the following model selection recommendations for contractors interested in entering the Georgian asphalt equipment market:
Municipal, rural road, and regional highway maintenance projects: We recommend 40–60 tph models, which offer outstanding value for money, are suitable for decentralized construction scenarios, and have a short return on investment cycle;
Medium-sized trunk roads and large-scale municipal projects: 80–160 tph models are recommended to meet high-capacity demands and enhance construction efficiency for large-scale projects.
ZOOMLINE can provide customized asphalt mixing plant solutions tailored to specific project requirements, complete with full-process installation, commissioning, technical training, and global after-sales support. We are committed to advancing the high-quality development of Georgia’s road construction sector and helping our clients achieve efficient profitability.
