Sustainability to order

Green technology from a green factory:

BENNINGHOVEN’s main factory and its contribution to energy-efficient and environmentally friendly production.

BENNINGHOVEN’s ultra-modern facility in Wittlich produces long-lived asphalt mixing plant and technologies for maximising the volume of asphalt fed back into recycling processes. Even the production of these plant components is designed to be as sustainable as possible. BENNINGHOVEN is also state-of-the-art in all of the areas where ‘being green’ matters – from the economical use of resources to organising production that is as environmentally friendly as possible.

Sustainability is a core value for BENNINGHOVEN and follows the basic principles defined by WIRTEN GROUP. So which specific activities and actions are pursued in order to achieve these goals?

Sustainability principles from WIRTGEN GROUP:

Cutting CO₂ emissions

Lowering fuel consumption

Using less energy

Using less water

Expanding recycling

Restricting noise

Avoiding waste

Reducing vibration emissions

Improving energy efficiency …

Located between the Mosel and Eifel in western Germany, BENNINGHOVEN’s factory in Wittlich is one of the most modern factories within the WIRTGEN GROUP and the world’s most advanced production facility for asphalt mixing plant. This location is characterised not only by its modern and advanced production methods but also by the efficient handling of the renewable energy deployed by the site. Every effort is made to protect the soil, water and air from contamination.

… while also reducing the CO₂ footprint

Designed according to the German Energy-Saving Ordinance (EnEV), a whole series of sustainable technologies are deployed to ensure that these strict regulations are fulfilled or even exceeded. This starts with insulating the building to the very latest technical standards. Ventilation systems for cooling and heating with integrated heat recovery guarantee high indoor air quality, and deactivate automatically as soon as windows are opened. Some of the electricity required by the facility is sourced from renewable wind power. The interior lighting is also designed as a smart system: Motion detectors are used to ensure that artificial light is actually required. If someone enters a room, energy-saving LED systems regulate the level of illumination depending on available daylight, while automated blinds activate in response to strong sunlight to avoid wasting energy on cooling down the building again.

At BENNINGHOVEN, advanced systems and sustainable design combine to ensure that stringent legal requirements are fulfilled or even exceeded.

Powder coating plant – a ‘green highlight’

This pioneering surface treatment is ecofriendly, since it requires significantly smaller amounts of solvent than conventional coatings. BENNINGHOVEN now ‘powders up’ around 90% of its parts.

‘Zero-litres’ production saves water

Drinking water is a precious resource and its responsible handling will continue to grow in importance. BENNINGHOVEN’s production processes need no process water and therefore produce no industrial effluent. But we do still make use of water at BENNINGHOVEN – for our employees. Hot water is heated locally to ensure energy efficiency.

More than just asphalt recycling

BENNINGHOVEN is well-known for its leading recycling technologies. Operating companies using the hot-gas generator combined with RPP-series plants are now able to achieve feed ratios of 90 + X%. The RPP technology also prioritises the asphalt recycling material flow. BENNINGHOVEN plants that integratehot-gas generator systemsinclude the RPP 3000 Plus, RPP 4000, RPP X 4000 and RPP 4000 Plus.

Thanks to asphalt recycling, recycling has been part of company DNA at BENNINGHOVEN for many years now. As a result, many items of production equipment were not simply disposed of during the relocation to the new factory. As just one example, thegantry craneshave been reconditioned and are still in regular use at the new factory.

Gantry crane before restoration work at the site of the former main factory in Mülheim an der Mosel

Production waste is also separated into fractions and returned to the material loop for recycling.

Going for green with sustainable workspaces

Keeping production as green as possible is also always good for the health of our employees. And that’s not all that BENNINGHOVEN is doing to keep its employees healthy.

A positive atmosphere

Two innovative energy recovery ventilators keep the air clean throughout the site. This state-of-the-art technology processes waste air into fresh air while also recovering energy. The system also keeps ambient air free of dust.

Another important contribution is made by the extraction system at our welding work centres.

Nor do our industrial trucks pollute the environment, since they are all-electric.

Keeping things in focus

Various steps have been taken to create an environment that promotes concentrated, uninterrupted work, such as soundproofed windows and partitions to reduce noise in welding booths.

In office buildings, sound-absorbing flooring and suspended ceilings also work to suppress ambient noise.

Safety is paramount

Safety is a top priority at the BENNINGHOVEN factory. Processes have been optimised to ensure that only a few forklifts are in operation at any one time. The vehicles are also equipped with a visual warning system: a blue spot of light warns of an approaching vehicle and therefore helps to avoid collisions – especially in areas with a restricted field of view.

Safety mirrors mounted at the front of warehouse racking systems also help to improve safety by allowing a look ‘around the corner’, i.e. into the narrow gangways, so as to also avoid accidents where personnel suddenly appear without warning.

Excellent ergonomics

Workspaces are designed according to ergonomic guidelines. In Pre-Fabrication, for example, grippers are used to help with lifting heavy parts during drum construction.

Mixer Construction also uses electrical, height-adjustable access platforms and equipment as standard to provide easy access for employees.

Work centres are kitted out with adjustable tables and chairs that can be easily reconfigured to suit individual needs and requirements.

Combatting Covid with high tech
  • Employees are also well-protected during the Covid-19 pandemic at BENNINGHOVEN by a direct extraction ventilation system.
  • Unlike a recirculating system, this unit exchanges waste air for fresh air.
  • This proactive occupational safety measure is a further example of how BENNINGHOVEN takes responsibility for the health of its entire workforce.
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State of the art — BENNINGHOVEN has been following this approach for over a century. Through consistent further development, growing from a trade workshop to a globally active company, BENNINGHOVEN is a pacesetter in the field of asphalt mixing plants today.

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