A coordinated plant train from Kleemann forms the core of this process chain, supporting the targeted production of defined aggregate fractions for reuse in asphalt mixing plants. The concept is complemented by application support and service structures within the Wirtgen Group portfolio.
The processing cycle begins with selective milling of surface, binder and base courses using milling machines from Wirtgen. Layer-specific removal improves the quality and homogeneity of the recovered RAP material. The milled material is subsequently processed by a Kleemann plant train consisting of a Mobiscreen MSS 502 EVO scalper, a Mobirex MR 100 NEO impact crusher and an MBT 20 stacker. The system enables the production of homogeneous grain fractions in line with grading curve requirements for asphalt mix production. The processed material is then transferred to the asphalt mixing plant, where it is incorporated into new asphalt mixes. Paving and compaction are carried out using machines from Vögele and Hamm, completing the material cycle from reclamation to reuse.
Construction contractor Kutter, based in the Allgäu region near Memmingen, operates the plant train in daily practice. Reclaimed asphalt with feed sizes of 0–120 mm is initially supplied to the scalper. Larger agglomerated slabs resulting from stockpiling are reduced in size during this stage. The MSS 502 EVO produces an immediately reusable fraction with a high bitumen content. A second fraction bypasses the impact crusher via the middle grain conveyor and the MBT 20 stacker and is subsequently blended with the crushed final product. Oversize material is processed in the MR 100 NEO impact crusher to generate an additional defined fraction. The resulting products are suitable for direct feed into the asphalt mixing plant at high throughput rates. An additional MBT 24 stacker can be integrated to expand stockpiling capacity.
The plant train achieves a processing capacity of up to 240 tonnes per hour. After crushing, the material is separated into two specified grain sizes: 0–11 mm for surface and binder courses, and 0–22 mm for base and binder courses. These fractions are supplied to the asphalt mixing plant for incorporation into new asphalt mixes in accordance with relevant specifications.
Operational aspects such as accessibility and maintenance are supported by features including the Lock & Turn system, which allows rapid opening of the crusher housing for inspection and servicing. Reduced downtimes contribute to stable production processes, particularly in applications involving frequent site changes. The mobility of the plant components allows relocation and adaptation to varying project conditions.
Digital process monitoring is provided by Spective Connect. The system supplies real-time data on fuel consumption, production output, plant utilisation and fault messages. Localised fault diagnostics support faster intervention in the event of operational interruptions. Continuous access to plant status data contributes to improved coordination of maintenance and service activities.
Beyond individual machine performance, the coordination of milling, processing, mixing, paving and compaction stages is central to overall process efficiency in asphalt recycling. Within the Wirtgen Group, brands including Wirtgen, Vögele, Hamm, Kleemann and Benninghoven provide equipment and application support across the entire value chain. In practice, integrated consulting and service structures can contribute to optimised process design, spare parts availability and the implementation of digital tools in asphalt production and recycling operations.
