Asphalt Recycling

As Finland’s leading asphalt contractor, Asfalttikallio sets industry standards with their advanced operations. Their Ylöjärvi facility showcases excellence in modern asphalt production, featuring a sophisticated setup with two drums, twelve aggregate feeds, and two recycled material feeds. This scale of operation demands solutions that can maintain high quality while processing significant volumes of recycled material.

Challenge:

When Asfalttikallio approached ALLU, they faced the complex task of efficiently processing recycled asphalt while maintaining strict quality standards. With recycled content making up between 30-60% of new mixes, precise material sizing and consistent quality were crucial for their production process. Most of their incoming recycled material arrives in blocks, with only about 10% being pre-milled, creating an additional processing challenge.

Solution:

After evaluating Asfalttikallio’s needs, the ALLU DS 3-23 with TS25 drum emerged as the perfect fit for their operation. The screening bucket’s ability to handle both blocked and milled asphalt, combined with its precise sizing capability, made it ideal for their quality control requirements. Working directly at the plant site, the attachment transforms recycled asphalt through a streamlined process that maintains both efficiency and material quality.

• Fill screener bucket with material
• Screen to specification
• Remove oversized material
• Direct screened material to production

Operational details:

At the heart of Asfalttikallio’s recycling operation, the ALLU DS 3-23 processes thousands of tons of material each season. The screening bucket handles both milled asphalt with stone fragments under 16mm and bitumen material up to 50mm, achieving the required final product size of 25-35mm consistently. This precision is crucial as all road material specifications in Finland are tracked in a national database, demanding reliable quality control.

• Process grinded asphalt (<16mm) and bitumen material (<50mm)
• Achieve final product size of <25-35mm
• Handle 3,000-4,000 ton batches
• Maintain quality for database tracking
• Process both milled and block material

Benefits:

The implementation of ALLU’s solution has transformed Asfalttikallio’s recycling operation both operationally and financially. By reducing processing costs from €3 to €1 per ton, the screening bucket has proven its value in daily operations. Beyond the immediate cost savings, the ability to process material on-site and feed it directly into production has streamlined their entire operation.

• Processing cost reduced from €3/ton to €1/ton
• On-site material processing
• Consistent quality control
• Direct integration into production
• Efficient material handling
• Significant cost savings compared to mobile crushers

The success at Asfalttikallio’s Ylöjärvi plant proves that efficient asphalt recycling isn’t just possible – it’s profitable. With processing costs cut by two-thirds and consistent quality maintained, ALLU’s screening solution has proven its worth in one of the industry’s most demanding environments. As sustainability requirements grow and recycling becomes increasingly crucial, Asfalttikallio’s approach shows how the right equipment can transform challenges into opportunities.

For asphalt producers looking to boost recycling capabilities while controlling costs, the path forward is clear. ALLU’s screening solutions deliver the precision, efficiency, and reliability needed to turn recycled material into valuable product.

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