Astec’s BG Series Batch Plants have grown to become a premier option for asphalt production for infrastructure projects of all sizes. Astec’s Rodney Clarke takes Roads & Infrastructure behind the curtains of the unit’s growing success.
Ever since its introduction to the market at Buama 2019, Astec’s BG Series Batch Plants have been making waves in the asphalt market.
Suitable for small- to medium-sized asphalt manufacturers, the BG Series Batch Plant is a modular asphalt plant design that’s able to be downscaled or built upon to cater for asphalt and storage demands.
For Astec, the best barometer of performance is the application of its technology in major infrastructure works, as well as repeated and constant use. And if the popularity of the BG Series Batch Plants is anything to go by, Astec has yet another key tool in its equipment arsenal.
This high level of activity is not only proof of concept, but a reflection of the BG Series’ versatility, as Rodney Clarke, Business Line Manager (Asphalt) and Director of Service – Astec Industries explains.
“We recently had a lot of success supporting the production of asphalt on a major project for Fulton Hogan in Darwin. In the past few months we’ve made significant advancements to the plant for upcoming projects as well,” he says.
“We’ve got a busy slate ahead and we’re always looking to work with our customers to improve the units when and where we can.”
Building blocks
Regardless of the requirements, Clarke says Astec has been more than happy (and even benefitted) from challenging requests, ultimately helping to push the BG Series forward.
“One of the biggest changes throughout the past few months has been expectations. Interest has been significant and it’s also making a name internationally. We’ve taken a home-grown concept, combined it with international expertise to make a plant that’s highly suitable to Australian conditions and projects,” Clarke says.
Astec’s BG Series Batch Plant supports a modular and expandable design, meaning customers can adjust the superstructure to best cater for the unique aspects of different projects. On top of an additional 30 tonnes of hot aggregate capacity, the BG Series Batch Plants also support cold feed bins and optional grizzly bars.
This highly adjustable design allows the user to produce anywhere from 80 to 240 tonnes per hour, despite being a simplified design to set up and relocate.
A counterflow dryer drum provides improved heat transfer into the aggregate, while also being powerful and well balanced. This is matched by a whisper jet air-burner, that allows burns to be clean and efficient.
Engineering improvements have also been considered for the vibrating screens, as well as to the Twin-Shaft Pugmill to reduce the frequency of maintenance and the replacement of components.
Clarke says these are just some examples of features that are internationally certified and stand up against some of the best designs globally.
“Now we’ve got a plant that can be built to be robust, easy to move and most importantly, can provide longevity,” he says. “There’s a lot of other plants out there that require maintenance more frequently, that’s why we wanted to have a lot that could operate consistently with an extended maintenance regime. That’s down to materials use and heavy-duty parts.”
Project longevity was another consideration, as well as the need to produce asphalt in regional applications. Astec has a range of patented long-term storage silos that are available upon request, as well as short-term storage between 30 to 200 tonne with capacity surge bins.
Related stories:
Greater control
Clarke says another big focus for Astec has been updating the BG Series Batch Plant system, helping to make it easier and quicker for the user to benefit from real-time information.
“There’s a mix between manual and automated features,” Clarke says. “It can conduct maintenance scheduling itself, it’s got a full data recovery and operational recordings. You can easily view exactly what’s been mixed and when.
“It’s a great way to see where you can achieve greater efficiencies, whether that’s tracking the use of raw materials or fuel savings.”
The intelligence and access to data provided by the BG Series Batch Plant range could also help to inspire long-term changes to mix designs and the implementation of sustainable materials.
The Batch Control System can clearly display ingredients, targets, fill levels, motor status and more from a single screen. These reports can be printed for further circulation.
Astec prides itself on its extensive history of in-house innovation. That’s one of the many reasons why the company decided to establish a control system internally, rather than outsourcing for its control components as many other companies do.
“Because we worry about designing and manufacturing the controls, we’re not at the mercy of other companies. We can provide direct support and repairs where needed,” Clarke says.
“We own it and can tailor it to what the customer wants. That’s always been our focus.”
Clarke says Astec is looking to push both its design and capabilities even further.
“We’re always learning and identifying where we can go from here,” Clarke says. “It’s about getting better and better. When you design something on paper, the unit will do what it’s designed to do. But once you’re on the ground, that’s where you can really see all the options.
“In some ways it’s like manufacturing cars, the process and the unit itself improves with every iteration that comes out. That’s happening every day.”
This article was originally published in the August edition of our magazine. To read the magazine, click here.