BLS 4 control system makes Alkesta plant fit for the future again
Retrofit milestone in Lithuania
As a recent Retrofit project with asphalt producer Alkesta has shown, Benninghoven is also well-known in the Baltic states as a reliable and solution-focused service and business partner: This integration of a modern BLS 4 control system has given the existing third-party plant in Marijampolė a significant technological upgrade – with support and rapid response times all part of the package.
Future-proof plant retrofit solution for the plant control system
The Marijampolė site is home to the Benninghoven type TBA plant as well as a Teltomat plant that has been in operation since 1998. While this plant remained productive and in good working order, its outdated control system had become an increasing source of problems. The braking system for the inclined skip on the adjacent loading silo – one of the most important components for conveying material – had repeatedly caused issues. Malfunctions were a regular occurrence: In the worst case, these resulted in the skip slamming back unbraked into its starting position while fully loaded. This was not only extremely dangerous but also caused mechanical damage. Support from the manufacturer was no longer available and the cause of the brake malfunction could not be reliably determined. Something had to be done. Apart from minimizing the risk of downtime, Alkesta also wanted to future-proof the plant and therefore opted for a comprehensive upgrade of the control system.
60 years of experience in road and bridge construction
Alkesta was founded in 1966, at the same time as the Alytus Road Construction Association. In 1993, the company incorporated as AB Alkesta and then converted to a private limited company as UAB Alkesta in 2002. The company takes pride in being one of Lithuania’s largest road and bridge construction businesses and celebrates its 60th anniversary in 2026.
Alkesta operates several asphalt mixing plants that supply infrastructure projects nationwide. In 2004, Lithuania’s first Benninghoven plant was brought into service in Alytus, followed by another in Marijampolė in 2016.
Benninghoven: the first and only choice
Thanks to the strong track record of the existing plants in Alytus and Marijampolė and the productive working relationship to date, the Lithuanian company chose to contact Benninghoven directly. Benninghoven enjoys an excellent reputation in the Baltic states and is known for its future-proof Retrofit solutions. With the innovative BLS 4 control system, the Benninghoven engineers also have a stable, powerful, and reliable control system ready to go, offering straightforward integration with third-party plants. The customer was also impressed by the fact that Benninghoven offers comprehensive, dependable support without language barriers thanks to its well-established local service team. A fast turnaround on spare parts, good availability, and a 24/7 remote support service are all part of the package.
“Customers really appreciate having someone local they can call if they need expert advice or a service engineer.”
Tadas Varnelis, Regional Sales Manager Benninghoven, Wirtgen Lietuva UAB
The BLS 4 plant control system makes the difference.
The powerful BLS 4 plant control system features user-friendly, intuitive operation, intelligent lifecycle management with regular updates and hardware upgrades, and a high level of IT security. This was the first time it had been integrated into a third-party plant operated by Alkesta. Simply replacing the brake control unit in the adjacent loading silo would not have been sufficient to make the plant future-proof and ensure full functionality across all areas. The project also involved replacing several components, such as sensors and the frequency converter, to make full use of the potential of the new control system.
Functional and user-friendly
Many processes have become much easier with the new control system, which not only achieves outstanding performance but also offers a significantly more streamlined control interface and a high level of usability. As a comparison: The old control system was very much of its time, featuring a control panel with a bewildering array of buttons. It was complicated, awkward to use, and time-consuming. Now, on the other hand, the tasks are intuitive and require only a few clicks.
Interested in discovering the many highlights of the new BLS 4 control system?
“It is so much easier to work with the new control system. It is very user-friendly and the customer was highly satisfied.”
Tadas Varnelis, Regional Sales Manager Benninghoven, Wirtgen Lietuva UAB
Economical: Smart Weighing System integrated without hardware changes
To get the most out of the new control system, Benninghoven recommendeds opting for the Smart Weighing System. Alkesta was initially undecided, as this would normally have meant replacing the hardware components – such as the dosing systems – to ensure compatibility with the new environment. Not in Marijampolė, however, where Benninghoven successfully integrated the Smart Weighing System into the BLS 4 control system circuit.
The results speak for themselves: The plant delivers precise and reliable results across the board. This offers true added value for Alkesta, while once again demonstrating that Benninghoven identifies challenges early on and develops cost-effective solutions that are tailored to the customer’s requirements.
Smart Weighing System
The Smart Weighing System enables precise recipe dosing, ensuring that the produced asphalt mixtures have precisely the properties specified. The adaptive system responds to material changes and irregular material flows in real time, adjusting the dosing as required. Optimization by the mixing foreman is no longer required.
A name to trust in the Baltics
For Benninghoven, this project once again highlights its comprehensive know-how and strong presence in the region. As an experienced solution provider and innovator, capable of seeing demanding projects through to completion, Benninghoven is a competent and sought-after partner in the Baltics. Best of all, the company’s regional sales and service teams make rapid response times and reliable support possible whenever needed.
“The control system is the heart of the plant. So, if you integrate a new control system into a third-party plant, you’ve just won yourself a new customer.”
Tadas Varnelis, Regional Sales Manager, Wirtgen Lithuania
