From 0 to 63,000 t of asphalt in six weeks

Benninghoven ECO 3000 in the Bukovel region, Ukraine

Bukovel is an up-and-coming ski resort in the Eastern Carpathians, located in western Ukraine. Nearby, construction company PBS has invested in a Benninghoven mixing plant: In future, the ECO 3000 will produce both rolled and mastic asphalt – offering maximum flexibility for the construction and repair of the mountain roads in the region with many bridges.

The Ukrainian Carpathians are home to the largest ski resort in Eastern Europe. Bukovel has very quickly made a name for itself as a modern alpine destination and attracts a large number of visitors. The nearby city of Ivano-Frankivsk is where PBS is based.

Bukovel | Ukraine

With its fleet of machines, including various milling machines, finishers and rollers from the Wirtgen Group, PBS enjoys success in its home region as well as in the neighbouring Transcarpathian region.

The construction company has now also invested in a Benninghoven type ECO 3000 asphalt mixing plant for the construction and repair of roads in the region, which features numerous mountain roads with lots of bends and bridges.

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A successful start:

Watch the video below to find out more about how PBS is using the ECO 3000 in Ukraine.

Video of Benninghoven ECO 3000 in operation in Bukovel, Ukraine

Mixing plant with high reliability and performance required

“To supply our asphalt crews, the plant needs to produce asphalt virtually day and night,” said Oleksiy Pasternak, Managing Director of PBS. “Consequently, we gathered extensive information about the latest plant technology and, in particular, its reliability. Ultimately, the ECO 3000 was a clear winner. It impressed us on all counts.” Things also got off to a promising start: “In the first six weeks, we’ve already produced 63,000 t of asphalt with the new Benninghoven plant. If you consider that 100,000 t is the total annual production of other plants, this is truly an outstanding figure," said Olexandr Vasylovych Shnaideruk, foreman at PBS.

Mykhailo Pereginets, Project Manager at PBS (left) with Kanan Samadov, Regional Sales Manager at Benninghoven)

“Our plant needs to produce asphalt virtually day and night. The ECO 3000 impresses us with its reliability.”

Mykhailo Pereginets, Project Manager at PBS (left) with Kanan Samadov, Regional Sales Manager at Benninghoven

ECO series demonstrates its advantages

One important advantage of the ECO series is the ideal practicability of the plants, which was a key factor for PBS: They can cope with quick changes of location without any loss of quality, providing a crucial advantage for large temporary construction sites. Benninghoven fulfilled the requirement for the plant’s maximum flexibility and mobility with transportable steel foundations and cabling based on the “plug & work” principle. This enables easy assembly and disassembly of all the electronics.

In any case, the ECO type of plant offers operating companies maximum flexibility and ease of transport. This is because most of the components of this type of plant are designed with transport-optimised container dimensions, which makes relocation much easier. The modular design also enables the integration of a large number of high-tech components which can be quickly and easily adapted to the specific needs of operating companies, even at a later stage. Benninghoven ensures this with its pre-configured interfaces, which can be activated at any time. This enables operating companies to increase both the economic efficiency and investment security of the plant.

New ECO 3000 in the Ivano-Frankivsk region, near the Bukovel ski resort in the Ukraine: In addition to the high-quality consultancy, key factors in the decision to opt for Benninghoven were the reliability and flexibility of Benninghoven's ECO plant series, plus the fact that these plants were designed with the future in mind.

Fully prepared for future requirements

Pre-configured interfaces for the subsequent integration of a cold recycling system, for example, also help make this a future-proof solution. At the moment, there are still many new construction projects in Ukraine and comparatively few resurfacing projects involving reclaimed asphalt. In the future, if the addition of reclaimed asphalt such as milled material should play an important role in the production process, the ECO 3000 is already prepared for this. This means that PBS can retrofit a recycling system without any problems.

Forward planning

The ECO 3000 from PBS includes a screen with 6-fold screening, although one less screen deck is common in Ukraine. This allows PBS to comply with regulations for mix production that are already currently in force in the EU.

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Mastic asphalt for the mountain region and the ski resort

In the region covered by PBS, which is also home to Eastern Europe's largest ski resort, Bukovel, customers ask for mastic asphalt as well as rolled asphalt. This is mainly used for asphalt paving on the many bridges on the mountain roads. This is where the ECO 3000 can offer further advantages: Benninghoven plants are ready to produce mastic asphalt at any time, as soon as they leave the factory. This is because its production requires higher production temperatures than that of rolled asphalt: While for conventional mixtures, the virgin mineral is heated to 180 °C, for mastic asphalt it’s 250 °C to 350 °C .

“The higher temperature of mastic asphalt places a high thermal load on the plant technology. Benninghoven has a variety of solutions to counteract this. For example, wear protection up to 450 °C.”

Kanan Samadov, Regional Sales Manager at Benninghoven

Heat-resistant equipment is standard for Benninghoven plants

To withstand the higher production temperatures of mastic asphalt, heat-resistant equipment is already included in Benninghoven's standard scope of delivery. This applies to multiple components – from the screen decks of the screen to the option of direct loading. “The higher temperature of mastic asphalt places a high thermal load on the plant technology. Benninghoven has a variety of solutions to counteract this. For example, wear protection that is resistant to temperatures of up to 450 °C. The material, a particularly resistant steel, can permanently withstand heavy loads,” said Kanan Samadov, Regional Sales Manager at Benninghoven.

Specifications of the ECO 3000 in Bukovel, Ukraine

  • Mixing capacity of 240 t/h
  • 6 feed units, each 16 m³
  • Dryer drum TT 9.23 (9 m x 2.3 m)
  • Burner: EVO JET combination burner for oil and natural gas
  • Benninghoven dust collection system with a capacity of 65,000 Nm²/h
  • 6-fold screen
  • Hot bin section 55 t
  • Benninghoven weighing and mixing section with 3 t mixer
  • Granulate dosing system
  • Mixed material loading silo with 60 t capacity (two chambers, each 26 t plus direct loading)
  • Four filler silos (one reclaimed filler silo 60 m² , three imported filler silos, each 80 m² )
  • Six thermal oil-heated bitumen tanks, each 53 m³ in horizontal design
  • Model with steel foundations (mixing tower and filler silos) for flexible, fast relocation of the plant