Kleemann demonstrated a mobile plant train for asphalt recycling in operation at IFAT Munich 2026. The live demo in the Crushing Zone made one thing clear: recycling is becoming standard practice. For construction companies and demolition contractors, this means new business areas, but also investments in plant technology.
The plant train: crusher and screener working together
The Wirtgen Group, to which Kleemann belongs, relied on a mobile impact crusher combined with a screening plant. The impact crusher reduces asphalt slabs to grain size, the screening plant then separates them by fraction. The material goes directly back into production.
Typical throughput capacity: 200 to 350 tons per hour, depending on the input material and desired final grain size. This corresponds to the milling capacity of two to three road milling machines in continuous operation. Those who process the material on site save transport costs and landfill fees.
Profitability: What really pays off?
A mobile plant train costs between 800,000 and 1.2 million euros, depending on throughput and equipment. Payback depends on capacity utilization. At 1,200 operating hours per year and a contribution margin of 8 to 12 euros per ton, the payback period is 4 to 6 years.
Logistics is crucial: if you can reuse the recycled material directly on the construction site, you save twice. No landfill, no external aggregate. For your fleet, this means fewer truck trips and lower diesel costs.
The Wirtgen Group offers complete solutions: milling machine, crusher, screener and recycler from a single source. This facilitates coordination and reduces interfaces. Those who invest now benefit from increasing recycling rate requirements.
Operating costs: diesel, wear, labor
An impact crusher consumes 25 to 40 liters of diesel per hour depending on the engine. At 2 euros per liter, that's 50 to 80 euros in pure fuel costs. Add to this wear parts: impact plates last 800 to 1,500 operating hours, depending on the hardness of the material. A set costs 8,000 to 15,000 euros.
Labor: At least one machine operator for the crusher, a second for the screening plant. On larger construction sites, a wheel loader is added for loading. Budget for 3 people per shift for a complete recycling operation.
Asphalt recycling in practice: What quality is possible?
Recycled asphalt now achieves qualities that were unthinkable 10 years ago. The grain size ranges from 0/32 mm to 0/45 mm, depending on the crusher type and settings. The key is purity: concrete, reinforcing steel and plastics must be sorted out beforehand.
Most construction companies use recycled asphalt for base layers. Proportion: up to 60 percent. For surface layers, the rate is lower, usually between 15 and 30 percent. This is technically possible, but often limited by standards.
The IFAT demo showed: modern equipment consistently produces usable material. The challenge is not technology, but logistics and client acceptance.
Mobile vs. stationary plants: When is each worthwhile?
Mobile crushing plants are flexible but more expensive to operate. Stationary plants have higher throughput and lower costs per ton, but are location-bound. The decision depends on the application profile.
Those who mainly handle large road construction projects with tens of thousands of tons of milled material are better off with a stationary plant. Those who work decentrally and frequently change construction sites need mobile technology.
Kleemann clearly positions itself in the mobile segment. The plants are track-mounted, quickly set up and ready for operation after 2 to 4 hours. This makes them attractive for construction companies managing multiple projects in parallel.
Regulatory tailwind: recycling rates rising
The EU is demanding higher recycling rates for construction materials. From 2025, stricter regulations will apply in several member states. Germany is planning a minimum quota of 50 percent for asphalt recycling in public construction projects. This creates planning certainty for investments.
Those who invest in recycling technology today will have an advantage tomorrow. Demand is rising, margins remain stable. The IFAT shows this: exhibitors report significantly more interest than three years ago.
For construction contractors, this means: asphalt recycling will become standard practice. Those who don't master the technology will lose contracts. Those who do will open up new markets – not just in road construction, but also in demolition and recycling.
Conclusion: From niche segment to standard application
The IFAT demo showed: asphalt recycling is technically mature and economically viable. The investment pays for itself with constant utilization within 5 to 6 years. Logistics is key: the shorter the distances, the higher the return.
Kleemann and the Wirtgen Group focus on mobile solutions. This hits the market: flexibility becomes more important than maximum throughput. For construction companies managing multiple construction sites in parallel, this is the right strategy.
Those who invest now benefit from rising requirements and growing demand. Asphalt recycling is no longer a trend, it's standard.
