Time: May 21, 2023 – June 21, 2023
Location: Kokshetau, Kazakhstan
Model and output: ZAP-S100, 100T/H
In the construction of municipal road renovation project in Kokshetao City, Kazakhstan, local construction enterprises have been deeply involved in two major project problems: the capacity of standardized asphalt mixing plant does not match the construction demand, and the equipment delivery and commissioning cycle is too long to delay the project progress. We tailor-made the ZAP-S100 customized asphalt plant solution for customers ‘core project pain points, relying on precise personalized equipment customization capabilities and efficient full-process delivery services to help customers achieve stable production of equipment within a very short period of time and successfully ensure the orderly progress of local infrastructure projects.
The client of this cooperation is a professional engineering contractor of Kokshetao City in Kazakhstan, undertaking infrastructure projects such as local municipal road reconstruction and highway maintenance for a long time. With the upgrading of regional infrastructure projects, customers urgently need a stable, efficient and project-scale asphalt mixing plant to meet the daily continuous construction asphalt material supply needs. The project has clear standards for single batch capacity and continuous production stability of bitumen mixing plant equipment, and professional equipment with high matching degree is urgently needed to avoid the problems of insufficient capacity slowing down construction progress and waste of equipment resources caused by overcapacity.
In the early stage of purchasing an asphalt batching plant, after comparing the products of multiple manufacturers, the customer found that the general equipment on the market could not adapt to his own project scenario at all. Two major pain points seriously restricted the progress of the project:
Conventional asphalt mix plants on the market are designed with fixed parameters and adopt a one-size-fits-all capacity configuration mode, which cannot be flexibly adjusted according to customer project scale and daily construction consumption. For this Kazakhstan customer, the small batch capacity will lead to insufficient asphalt material supply and cannot support continuous road construction; the large capacity will cause idle equipment, high energy consumption, greatly increase project production cost, and it is impossible to find suitable cost-effective equipment.
Local municipal infrastructure projects have strict official construction deadlines, fixed construction periods and extremely low fault tolerance rates. The traditional asphalt batch plant has a long cycle from ordering, production, delivery to installation and production. Once the equipment cannot be put into production on time, it will directly lead to the interruption of road construction, which will not only cause high project delay losses, but also affect the project qualification and market reputation of customer enterprises. Therefore, short-term delivery and rapid production have become the core hard indicators for customers to select partners.
In view of the customer’s core pain point of “standard equipment does not match project conditions”, we did not apply the general model scheme, but adhered to the service principle of “one project, one customization”, combined with the construction intensity, material ratio demand, site conditions and local climate environment of Kazakhstan Kokshek project, customized ZAP-S100 asphalt mixer plant parameters and complete machine configuration for customers, and solved the common problems of unbalanced production capacity and poor equipment adaptability from the root.
According to the daily asphalt consumption of customers and the continuous operation demand of road construction, we customize the standard mixing capacity of single batch for this set of ZAP-S100 batch asphalt mixing plant, and the output of the whole machine can reach 100T/H. After accurate calculation, this capacity parameter will not cause material supply gap due to low capacity, slow down pavement paving progress, nor cause equipment idling, fuel and electricity consumption waste due to overcapacity, perfectly meeting the normal production demand of small and medium-sized municipal road projects of customers. Compared with the market fixed 1200kg or 1800kg standardized models, this customized parameter allows the customer to achieve an optimal balance between production utilization and cost control.
The successful landing of this Kazakhstan project fully reflects the flexible customization advantages of our all-series batch mix asphalt plant. We can complete all-round modular customization according to the differentiated needs of global customers, not simple parameter modification. In addition to the core batch capacity and adjustable hourly output, we also support customized services such as expansion of the number of cold bins, upgrading of drying drum power, optimization of dust removal system level, adaptation of asphalt heating and insulation system, and increase or decrease of automatic control system functions.
In view of the regional characteristics of Kazakhstan with temperate continental climate, low temperature in winter and large sandstorm, we strengthen the dustproof, cold resistance and rust prevention performance of equipment, optimize the temperature control accuracy of heating system of heat conduction oil furnace, ensure that asphalt materials can still maintain stable mixing quality under the environment with large temperature difference, avoid the problems of material agglomeration, uneven mixing and substandard temperature, and greatly improve the adaptability and service life of equipment under complex working conditions in Central Asia.
In order to ensure accurate landing of customized production capacity and long-term stable operation, ZAP-S100 batch mix plant is equipped with a complete set of mature high-profile systems, each set of structure is designed around efficient, stable and environmentally friendly production. The whole machine is equipped with four-bin cold material supply system, which can realize accurate proportion and uniform feeding of various aggregates; equipped with high-torque high-efficiency drying drum and full-automatic coal-fired burner, the materials are fully dried and heated evenly, suitable for continuous mass production.
In terms of environmental protection and stable operation, the asphalt batch mix plant adopts cyclone dust removal + water dust removal double combination dust removal process to effectively treat production dust, meet local environmental protection construction standards, and adapt to municipal close-distance construction scenarios. The whole bitumen batch mix plant is equipped with independent pneumatic system, asphalt insulation heating system and automatic computer control system. The core electrical components are all imported brands such as Siemens, with high control precision, low failure rate and strong anti-interference ability. It can effectively avoid downtime caused by electrical failure and ensure stable and continuous production of the equipment for 24 hours.
In the overseas asphalt mixing plant industry,”customized equipment = long production cycle, slow delivery” is a common pain point, and it is also the most worrying problem for Kazakhstan customers this time. The customer project schedule is tight and the nodes are rigid, which makes it impossible to accept the 4 – 6 month lead time of traditional bitumen hot mix plant. In response to this core demand, we launched an urgent special delivery mechanism for overseas projects. Through standardized process control, full link priority scheduling, refined quality inspection and rapid landing services, we broke the industry barrier of slow delivery of customized equipment and realized rapid production in three months.
After the project is confirmed and cooperated, we will set up a dedicated project team as soon as possible, equipped with foreign trade specialists, mechanical engineers and process engineers to connect with each other in the whole process, skipping the cumbersome approval process. For customer-customized parameters, on-site installation conditions, shipping requirements, construction period nodes to carry out one-time accurate confirmation, quickly finalize production drawings and asphalt hot mix plant configuration list, avoid repeated modification, repeated communication caused by the loss of construction period, reserve sufficient time for back-end production.
This project is included into VIP urgent scheduling plan of the factory, and priority is given to occupying raw material inventory, production line station and technical manpower. The production process strictly follows the standardized process flow, from steel plate blanking, structural welding, parts assembly, system commissioning to implement the segmented responsibility system, daily synchronization of production progress and customers, to ensure that each production node is delivered on time. At the same time, relying on a mature supply chain system, the factory has a standing inventory of core accessories, electrical components, dust removal systems and heating systems, completely eliminating the problem of downtime due to shortage of raw materials and delay of accessories, and greatly reducing the overall production cycle.
Efficient is not equal to extensive, in order to avoid defects caused by hot mix asphalt plant factory debugging rework overseas, delay production, we implement a three-level factory quality inspection system. Class I workshop self-inspection, class II process re-inspection, class III finished machine joint inspection, comprehensive inspection of equipment mechanical operation performance, ingredient accuracy, temperature control system, dust removal effect, electrical control system, safety protection device and other modules. Ensure that 100% of the hot asphalt mixing plant meets the standard before leaving the factory, eliminate delivery with defects, and avoid problems such as on-site debugging failure, secondary maintenance, and delay in construction period from the source.
After the asphalt mixer machine quality inspection is completed, we will immediately arrange the whole container land transportation, follow up the logistics timeliness, give priority to customs clearance and delivery, and minimize the cross-border transportation cycle. After the equipment arrives at the construction site of Kokeshe in Kazakhstan, we will provide long-distance technical guidance and standardized installation and commissioning process support to assist customers in quickly completing equipment assembly, pipeline docking, system electrification, parameter calibration and machine commissioning.
At the same time, we provide free systematic training for customer operators, covering daily operation of equipment, parameter adjustment, material ratio setting, daily maintenance, troubleshooting and other contents, so as to ensure that the equipment can directly enter full-load production state after installation. In the end, the project only takes three months to complete the whole process of customized production, delivery, installation, commissioning and commissioning from the receipt of advance payment from customers, perfectly meeting the strict construction period requirements of customers.
At present, this customized ZAP-S100 asphalt mixing machine has been put into stable production operation in Kazakhstan Kokshetao Project. The equipment has accurate batching, uniform asphalt mixing, environmental protection emission standards, continuous and stable discharge throughout the process, fully meeting the long-term and mass production needs of local municipal road renovation projects, low equipment failure rate, strong stability, and adaptability to local outdoor construction environment.
This project has completely solved the two core problems of customers and created practical engineering and economic value for customers. Accurate customized capacity allocation enables customers to get rid of the mismatch between asphalt plant equipment capacity and construction demand, realize efficient and low-cost asphalt production, and optimize project cost control; the delivery capacity of rapid production in three months ensures the timely progress of road projects, avoiding economic losses and reputation impacts caused by construction delays; the long-term stable operation performance of equipment greatly reduces the operation and maintenance costs in the later period, and effectively improves the overall profit margin of customer projects.
After the project was successfully put into operation, customers spoke highly of our comprehensive service ability. Customers fully recognize our precise bitumen plant customization solutions, efficient full-process delivery system and professional overseas landing services. They believe that our ability to accurately capture project pain points and solve construction problems is the core advantage different from ordinary asphalt hot plant manufacturers, and also lays a solid foundation for long-term in-depth cooperation between the two parties.
In the overseas asphalt mixing plant market, many engineering contractors prefer our equipment and services. The core reason is that we always focus on the pain points of customer projects, abandon the traditional model of simply selling equipment, and focus on practical problems of projects to provide one-stop solutions:
Strong personalized customization capabilities: It is not limited to standardized equipment output. It can tailor the asphalt mixing plant according to infrastructure projects in different countries, different scenarios, and different scales to comprehensively solve the industry pain points of poor equipment adaptability;
Efficient and controllable delivery and production cycle: relying on mature production system and standardized process, effectively solve the common problems of long delivery cycle and slow production in the industry, and comprehensively guarantee the customer project period;
One-stop service for the whole life cycle: from pre-customization, mid-production delivery, on-site installation and commissioning, to post-operation and maintenance support, technical training, providing full-process exclusive services, completely eliminating overseas customers ‘procurement and use concerns.
Whether it is municipal roads, highway maintenance or large-scale infrastructure projects, different construction scenarios have different requirements for the capacity, configuration and production cycle of asphalt mixing plants. If you are facing project problems such as hot mix plant capacity mismatch, tight construction period, long equipment delivery cycle, etc., please feel free to contact us. We will rely on our rich experience in overseas projects to customize highly adaptable and efficient asphalt mixing plant solutions for you, provide rapid delivery and commissioning services, and fully guarantee the efficient progress of your infrastructure projects.
