An asphalt recycling plant reuses reclaimed asphalt pavement (RAP) with virgin aggregates, new bitumen, and mineral filler to produce recycled hot mix asphalt. It is commonly used in highway rehabilitation, urban road reconstruction, resurfacing, and pavement maintenance by asphalt producers and road contractors. AIMIX offers central plant recycling solutions, including the AZS Series batch mix rap recycling plant and customized RAP systems for drum mix plants. Explore our recycled asphalt plant configurations, technical specifications, RAP processing capabilities, and equipment options below to find a suitable solution for your project.
Quick Facts About Asphalt Recycling Plants
| Item | Details |
|---|---|
| Equipment Type | Central Plant Hot Mix Asphalt Recycling Plant |
| Recycled Material & Final Product | Reclaimed Asphalt Pavement (RAP) → Recycled Hot Mix Asphalt |
| Production Solutions | Batch Mix + RAP (AZS Series Asphalt Recycling Plant); Drum Mix + Customized RAP System |
| AZS Models & Rated Capacity | AZS1000: 80 TPH; AZS1500: 120 TPH; AZS2000: Under Development |
| Maximum RAP Content | Up to 50% for the AZS series reference configuration; actual percentage depends on RAP properties, mix design, and operating conditions |
| Typical Applications | Highway rehabilitation, urban road reconstruction, road resurfacing, and pavement maintenance |
| Customization | RAP feeding, metering, material handling, and integration with drum mix asphalt plants, tailored to project requirements |
Different asphalt plants use different mixing technologies, so the RAP recycling system must be configured to match the production process. AIMIX offers two main central plant hot mix asphalt recycling solutions: batch mix asphalt production with RAP and drum mix asphalt production with a customized RAP system. Both solutions reuse reclaimed asphalt pavement (RAP) in new hot mix asphalt production, with the recycling equipment configuration determined by the plant type, material properties, and production requirements.
The AZS Series asphalt recycling plant for sale combines batch mixing with an integrated RAP recycling system to produce recycled hot mix asphalt. As a batch mix asphalt recycling plant, it is designed for asphalt producers and road contractors who need batch-based production, controlled material weighing, and reclaimed asphalt reuse.
The AZS configuration is selected according to production demand, RAP characteristics, and project conditions. RAP content and recycling performance should be evaluated for each model and configuration rather than assumed to be the same for every asphalt recycling facility.
For continuous asphalt production, AIMIX can integrate a customized RAP recycling system with a drum mix asphalt plant. The configuration covers RAP storage, feeding, metering, and the required material introduction and thermal arrangements. These RAP handling and processing components are configured to work with the selected drum mix plant.
Unlike the AZS Series, this is not a fixed model series. The RAP introduction point and heating method are determined through project-specific engineering and verified against the selected plant configuration.
| Comparison | Batch Mix + RAP | Drum Mix + RAP |
|---|---|---|
| Production Method | Batch production | Continuous production |
| Mixing Process | Separate batches with controlled material proportions | Continuous material feeding and mixing |
| RAP System | Integrated into the AZS Series configuration | Customized according to the drum mix plant |
| Production Adjustment | Suitable for production involving different batch mix designs | Suitable for continuous production under established operating settings |
| Configuration | AZS1000 and AZS1500 | Customized RAP system; no fixed model series |
The appropriate asphalt recycling plant solution depends on the required production method, mix design changes, RAP properties, production schedule, and investment plan. A batch mix configuration offers batch-based production and controlled material proportions, while a drum mix configuration is designed around continuous production. Neither batch mix nor drum mix is automatically suitable for every recycling project.
The AZS Series asphalt mixing recycling plant includes two reference configurations: AZS1000 and AZS1500, with rated production capacities of 80 TPH and 120 TPH, respectively. The following technical specifications cover the main asphalt production parameters, RAP recycling performance, material metering accuracy, and emission data for each configuration.
| Parameter | AZS1000 | AZS1500 |
|---|---|---|
| Asphalt Production Specifications | ||
| Rated Production Capacity (t/h) | 80 | 120 |
| Feeder Belt Width (mm) | 600 | 600 |
| Number of Cold Material Bins | 2 | 2 |
| Cold Material Bin Volume (m³) | 10 | 10 |
| Elevator Capacity (t/h) | 100 | 140 |
| Drying Drum Specifications (D × L, mm) | φ2050 × 7200 | φ2220 × 9500 |
| Weighing Hopper Volume (t) | 1 | 1.5 |
| RAP Recycling Performance | ||
| Maximum RAP Content | Up to 50% | |
| Static Hot RAP Metering Accuracy | ±0.5% | |
| Dynamic Hot RAP Metering Accuracy | ±2% | |
| Dust Emission Concentration (Bag Filter) | ≤50 mg/Nm³ | |
| Flue Gas Blackness (Ringelmann Scale) | Grade I | |
| Operating Conditions & Notes | ||
| ||
The RAP percentage indicates the proportion of reclaimed asphalt pavement (RAP) used in a recycled asphalt mixture. It is calculated according to the material proportions specified in the asphalt mix design, with the calculation basis defined by aggregate mass or total mixture mass. This distinction is important when comparing the RAP content and recycling rate of different asphalt recycling plants and projects.
The AIMIX AZS Series batch mix asphalt recycling plant supports up to 50% RAP content. This is the maximum reference capability of the series, not a guaranteed percentage under all production conditions. The actual RAP addition rate depends on RAP material testing, mix design requirements, and the selected equipment configuration.
RAP GradationThe particle size distribution and aggregate composition of reclaimed asphalt pavement affect blending, aggregate gradation requirements, and the amount of RAP that can be incorporated into a new asphalt mixture.
RAP Moisture ContentHigher RAP moisture content requires more energy for heating and drying, potentially limiting the practical RAP addition rate and overall asphalt production output.
Reclaimed Asphalt BinderThe aged asphalt binder content and properties in RAP affect the amount of virgin bitumen required and the design of the recycled asphalt mixture.
Mix Design RequirementsAggregate gradation, total binder content, and specified mixture performance determine the acceptable RAP proportion for each road construction or rehabilitation project.
RAP Heating and Feeding CapacityThe RAP recycling system’s feeding rate, metering accuracy, and heating arrangement affect how much reclaimed asphalt pavement can be processed and incorporated during production.
Production ConditionsAsphalt plant capacity, virgin aggregate temperature, ambient conditions, and required production output influence the practical RAP addition rate and recycling performance.
The RAP percentage can be calculated on an aggregate-mass basis or a total-mixture-mass basis, depending on the mix design and project specifications. These two calculation methods use different denominators and should not be treated as interchangeable.
For example, if a mix design specifies RAP content based on aggregate mass, the calculation should use the aggregate portion recovered from RAP rather than the entire RAP material weight. Always identify the calculation basis when specifying or comparing RAP percentages between asphalt recycling projects.
A higher RAP percentage does not automatically mean a better asphalt recycling solution. The target RAP content should balance reclaimed material reuse, recycled mixture performance, production capacity, and operating cost. The appropriate RAP recycling rate should therefore be determined through material testing and mix design rather than by the plant’s maximum reference capability alone.
A central plant hot recycling process uses reclaimed asphalt pavement (RAP) and new materials to produce recycled hot mix asphalt. The asphalt recycling process generally includes RAP collection, crushing and screening, material feeding, heating, metering, and mixing. The specific RAP processing steps, material flow, and RAP introduction arrangement depend on whether the recycled asphalt plant uses batch mixing or drum mixing.
Reclaimed asphalt pavement (RAP) is obtained from milling or removing existing asphalt pavement during road rehabilitation and reconstruction. The material is transported to the asphalt recycling facility, inspected, and prepared for reuse. Oversized particles, foreign materials, and unsuitable material may need to be removed before entering the RAP recycling process.
When required, RAP crushing and screening equipment processes reclaimed asphalt pavement to obtain a suitable particle size distribution. The prepared RAP material is then stored in designated stockpiles or feeding bins to support controlled material handling and consistent feeding during asphalt production.
Virgin aggregates are proportioned through the cold aggregate feeding system and heated in the drying drum according to the target asphalt mixture design. Their temperature and moisture condition are important because they influence the thermal balance when RAP is introduced into the asphalt mixing and recycling process.
Prepared RAP is delivered through the configured RAP feeding and metering system. The RAP feeding rate, metering accuracy, and thermal treatment must match the selected plant design, target RAP content, and production conditions. Depending on the asphalt recycling plant configuration, RAP may be introduced at different points in the production process, with the heating arrangement designed to suit the selected system.
RAP is combined with virgin aggregates, new bitumen, and mineral filler according to the approved recycled asphalt mix design. In a batch mix asphalt recycling plant, materials are proportioned and mixed in separate batches. In a drum mix configuration, material feeding and mixing take place continuously. The required mixing sequence and material proportions depend on the plant’s mixing technology and production configuration.
The finished recycled hot mix asphalt is discharged for transport to the paving site. Quality checks are carried out according to the applicable project specifications and mix design requirements to assess mixture properties before the material is used in road construction, pavement rehabilitation, or reconstruction.
RAP, or reclaimed asphalt pavement, is recycled asphalt material recovered from existing roads, parking areas, airport pavements, and other asphalt surfaces. It generally contains aggregates coated with aged asphalt binder. As a key material used in asphalt recycling plants, its suitability for reuse in recycled hot mix asphalt depends on its source, composition, particle size, moisture content, and overall material condition.
| RAP Material Property | Why It Matters for Asphalt Recycling |
|---|---|
| Particle Size and Gradation | Determines how RAP can be crushed, screened, fed, and blended to meet the target aggregate gradation of the recycled asphalt mixture. |
| Moisture Content | Affects RAP heating requirements, material flow, thermal balance, and asphalt production efficiency. |
| Binder Content | Helps determine the contribution of aged asphalt binder in RAP and the amount of new bitumen required in the recycled asphalt mix design. |
| Aged Binder Properties | Influence the performance of the recycled asphalt mixture and the need for virgin bitumen or other approved mix design adjustments. |
| Foreign Materials | Contaminants and unsuitable materials may affect RAP processing, mixture quality, and the usability of reclaimed asphalt pavement. |
| Material Variability | Differences between RAP sources and stockpiles can require separate storage, material testing, and mix design adjustments. |
Before selecting an asphalt recycling plant or RAP recycling equipment configuration, contractors should test representative RAP samples and establish the material properties of each stockpile. The test results help determine the required RAP crushing, screening, storage, feeding, and metering arrangements, as well as the appropriate production process and recycled asphalt mix design.
An asphalt recycling plant combines an asphalt mixing plant with RAP storage, feeding, metering, conveying, and other material handling systems. Depending on the condition of the reclaimed asphalt pavement (RAP), additional RAP processing equipment, such as crushing and screening machines, may be required before production. The complete asphalt recycling equipment configuration varies with the selected batch or drum mix process, RAP characteristics, target RAP content, and required production capacity.
| Asphalt Recycling Equipment or System | Main Function | Configuration Considerations |
|---|---|---|
| Asphalt Mixing Plant | Produces the final recycled hot mix asphalt by combining RAP with virgin aggregates, new bitumen, and mineral filler. | Batch mix or drum mix according to production requirements and the selected recycling process. |
| RAP Feeding System | Stores and supplies reclaimed asphalt pavement to the production line at a controlled rate. | Bin volume, feeding rate, and RAP material flow characteristics. |
| RAP Conveyor | Transfers RAP between storage, processing, and feeding equipment. | Conveying capacity, plant layout, and material transfer points. |
| RAP Metering Equipment | Measures and controls the quantity of RAP entering the asphalt production process. | Required metering range, accuracy, and coordination with the plant’s production capacity. |
| RAP Heating System | Provides the required thermal treatment according to the selected asphalt recycling system design. | RAP introduction point, heating method, material temperature, and overall thermal balance. |
| RAP Crushing Equipment | Breaks down oversized reclaimed asphalt material to obtain a suitable particle size for further processing. | Incoming RAP particle size, material condition, and required output size. |
| RAP Screening Equipment | Separates processed RAP into suitable size fractions for storage and controlled reuse. | Target aggregate gradation, screening capacity, and material separation requirements. |
| RAP Storage Area or Silo | Stores processed RAP before asphalt production and helps maintain an organized material supply. | Stockpile management, storage capacity, moisture protection, and material separation. |
| Dust Collection System | Collects dust generated during RAP handling, material processing, and asphalt production. | Dust generation points, airflow requirements, and applicable emission limits. |
Not every asphalt recycling project requires every item listed above as a separate machine. For example, additional RAP crushing and screening equipment may not be necessary when incoming reclaimed asphalt pavement has already been processed to a suitable particle size. The RAP handling, feeding, metering, and heating arrangements also depend on whether the project uses a batch mix or drum mix configuration. AIMIX can determine the required asphalt recycling equipment combination according to RAP test results, production requirements, and the selected plant configuration.
Before entering an asphalt recycling plant, reclaimed asphalt pavement (RAP) may require crushing, screening, and stockpile management, depending on its incoming particle size, gradation, moisture content, and material condition. Proper RAP preparation helps produce suitable material size fractions, improve feeding conditions, and support the target recycled asphalt mix design.
Oversized RAP chunks and agglomerated reclaimed asphalt material may need to be crushed and screened into suitable size fractions before asphalt production. RAP crushing and screening equipment helps control material particle size and gradation. The required processing equipment and screening arrangement depend on the incoming RAP condition and target aggregate gradation.
RAP should be stored separately according to its source, particle size, gradation, moisture content, and material properties. Proper reclaimed asphalt stockpile management helps control material variability, prevent unnecessary mixing between different RAP sources, and support accurate recycled asphalt mix design adjustments.
RAP crushing and screening equipment handles material preprocessing, while the asphalt recycling plant combines prepared RAP with virgin aggregates, new bitumen, and other required materials to produce recycled hot mix asphalt. These processes serve different but complementary functions in a central plant hot recycling system.
Recycled hot mix asphalt is used in road construction, pavement rehabilitation, resurfacing, and maintenance projects when the recycled asphalt mixture meets applicable design and construction specifications. Common applications include highways, urban roads, industrial pavements, access roads, and eligible airport pavement works. Its suitability depends on RAP material quality, recycled asphalt mix design, pavement layer requirements, traffic conditions, and local engineering standards.
Reclaimed asphalt pavement can be processed and incorporated into approved recycled asphalt mixtures for highway resurfacing, pavement rehabilitation, and road renewal projects, subject to the required mix design and performance specifications.
RAP recovered from municipal road projects can be reused in new asphalt mixtures for urban road reconstruction, road widening, intersection upgrades, and pavement surface renewal when the material meets project requirements.
Recycled asphalt mixtures can be used for eligible pavement maintenance applications, including overlays, resurfacing, and road repairs, depending on the required mixture properties and local specifications.
Suitable recycled hot mix asphalt can be used for factory roads, logistics areas, parking facilities, and other paved access roads. The mixture design should account for expected traffic loads and site operating conditions.
Recycled asphalt mixtures may be used in eligible airport pavement rehabilitation and resurfacing works when their material properties and performance meet applicable aviation engineering standards and project-specific requirements.
The suitable RAP content and application depend on RAP quality, recycled asphalt mix design, pavement layer, traffic requirements, and project specifications. Not all reclaimed asphalt materials or recycled hot mix asphalt mixtures are suitable for every pavement application.
The asphalt recycling plant price depends on production capacity, mixing technology, RAP recycling configuration, auxiliary equipment, and project installation requirements. The initial investment includes the asphalt mixing plant, RAP handling and recycling systems, and other supporting equipment. Operating costs depend on material consumption, fuel and energy use, labor, maintenance, and transportation. A complete asphalt recycling production line generally requires a different investment from an existing asphalt mixing plant upgraded with a RAP recycling configuration.
The operating cost of an asphalt recycling plant depends on production volume, RAP characteristics, material prices, energy consumption, and local operating conditions. The main cost components of asphalt recycling production include:
| Cost Item | Main Cost Drivers |
|---|---|
| Fuel and Energy | RAP and virgin aggregate moisture content, heating requirements, fuel type, electricity consumption, and production hours. |
| Virgin Materials | Consumption and local prices of virgin aggregates, new bitumen, and mineral filler required by the recycled asphalt mix design. |
| RAP Processing and Handling | RAP collection, crushing, screening, stockpiling, conveying, and material handling requirements. |
| Labor | Plant operators, maintenance personnel, and material handling staff required for daily production. |
| Maintenance and Spare Parts | Operating hours, equipment wear, replacement parts, lubrication, and routine maintenance requirements. |
| Transportation and Logistics | RAP collection and delivery distances, virgin material transportation, and finished asphalt delivery to construction sites. |
Yes. Using reclaimed asphalt pavement (RAP) can reduce asphalt production costs by replacing part of the virgin aggregates and new bitumen required in the recycled asphalt mixture. However, the actual cost savings depend on the usable RAP content, recovered material properties, local material prices, and additional expenses associated with RAP processing and production.
Overall Economic Benefit: A higher RAP percentage does not automatically result in greater cost savings. The actual economic benefit should be evaluated by comparing reduced virgin material consumption with RAP collection, processing, transportation, and additional production costs under the project-specific mix design and operating conditions.
For an accurate asphalt recycling plant price quotation, the complete required configuration should be evaluated, including the asphalt mixing plant, RAP feeding and recycling systems, necessary preprocessing equipment, auxiliary systems, and project-specific installation requirements. AIMIX can assess these requirements to prepare an equipment configuration and investment proposal for your project.
Selecting the right asphalt recycling plant requires evaluating your asphalt production demand, available reclaimed asphalt pavement (RAP), target recycling rate, and site conditions. These factors help determine the suitable mixing process, RAP handling system, and auxiliary equipment. Follow these four steps to identify an asphalt recycling solution that matches your project requirements.
Start by determining how much recycled hot mix asphalt your project needs and how many hours the plant can operate each day. Consider:
Estimate the required hourly output by dividing daily asphalt demand by available production hours. Then compare this requirement with the plant’s rated capacity. Actual output may be lower than rated capacity depending on RAP and aggregate moisture, mix design, production conditions, and operating efficiency. Allow for these factors when selecting the plant capacity.
Assess the available reclaimed asphalt pavement and determine the target RAP content according to material testing, recycled asphalt mix design, and project specifications.
These factors help determine the required RAP storage capacity, feeding rate, metering range, and heating arrangement. The selected system should also accommodate variations in RAP supply and material properties.
Once the required production output and RAP recycling target are established, select a suitable mixing process and RAP integration arrangement. AIMIX offers two main central plant hot recycling configurations:
| Project Requirement | Recommended Configuration | Reference Capacity |
|---|---|---|
| Batch production with integrated RAP recycling | AZS Series Asphalt Mixing Recycling Plant | AZS1000: 80 TPH AZS1500: 120 TPH |
| Continuous production with customized RAP integration | Drum Mix Asphalt Plant + Customized RAP System | Configured according to the selected asphalt mixing plant capacity |
The AZS Series combines batch mixing with an integrated RAP recycling configuration and supports up to 50% RAP content under suitable material and production conditions. For drum mix asphalt plants, the RAP feeding, metering, and heating arrangements are customized according to the selected plant, target RAP content, and project requirements.
Before finalizing the asphalt recycling plant, evaluate the installation site, auxiliary equipment, and operating requirements:
Based on these conditions, the plant capacity, RAP recycling system, auxiliary equipment, and installation plan can be finalized to match your project requirements.
Need a project-specific asphalt recycling plant configuration? AIMIX can evaluate your required production capacity, RAP supply, target RAP content, material properties, and installation site to recommend a suitable batch mix or customized drum mix recycling solution.
As an asphalt recycling plant manufacturer and supplier, AIMIX combines in-house manufacturing resources, engineering expertise, and international project support to provide asphalt recycling equipment solutions for asphalt producers and road construction contractors worldwide. Our support goes beyond equipment supply, covering project evaluation, plant configuration, installation coordination, and after-sales technical assistance.
AIMIX operates a 200,000 m² manufacturing facility with more than 600 skilled staff. Our manufacturing capabilities support the production, assembly, and quality inspection of asphalt mixing plants and related equipment for different project requirements.
With more than 30 engineers worldwide, AIMIX provides technical support for asphalt recycling plant configuration, RAP feeding and metering arrangements, plant layout, installation planning, and project-specific production requirements.
AIMIX serves customers in international markets, with overseas offices in 10 countries. Our teams coordinate equipment supply and project communication while considering regional construction practices, operating conditions, and customer requirements.
Our network of more than 120 global service points supports installation coordination, equipment commissioning, operator guidance, technical assistance, and spare parts services across different markets.
From initial project evaluation and asphalt recycling plant selection to installation and ongoing technical support, AIMIX provides equipment and service support to help customers establish and operate asphalt recycling production facilities.
A conventional asphalt mixing plant primarily uses virgin aggregates, new bitumen, and mineral filler to produce asphalt mixtures. An asphalt recycling plant incorporates reclaimed asphalt pavement (RAP) into the production process, reusing recovered aggregates and aged asphalt binder in new asphalt mixtures. Depending on the plant configuration, central plant hot recycling can use an integrated batch mix recycling arrangement or a drum mix asphalt plant equipped with a customized RAP system.
RAP stands for Reclaimed Asphalt Pavement. It is asphalt material recovered from existing roads through milling, excavation, or pavement removal. RAP generally contains two main components: recovered mineral aggregates and aged asphalt binder. In asphalt mixing, processed RAP is incorporated into a new mixture according to the recycled asphalt mix design, reducing the amount of virgin aggregates and new bitumen required.