Benninghoven CORE: Wirtgen Group launches new asphalt mixing plant with focus on low operating costs

The Wirtgen Group has introduced the CORE by Benninghoven, a new asphalt mixing plant that consistently meets the requirements of plant operators. The focus is on low operating costs throughout the entire lifecycle, streamlined construction and transport logistics, and flexible retrofit options. The mobile plant operates on the batch principle and enables a recycled asphalt (RAP) content of up to 40 percent – a value that should be of particular interest to you, especially with rising material costs and stricter sustainability requirements.

What sets the CORE apart from previous asphalt mixing plants?

Benninghoven relies on a defined option spectrum and pre-configured interfaces for the CORE. Instead of a multitude of custom solutions, you receive a plant that is prepared for expansions from the start. Should your order volume or product mix change, you can retrofit components – such as various feed systems – without extensive modifications. The modular concept is specifically designed for companies that want to start with a base variant and react flexibly later, without having to invest in a completely new plant.

The CORE is based on proven Benninghoven technologies and combines them with modern control components. The plant delivers reliable performance and high asphalt quality – whether used in road construction, on mobile construction sites, or in projects with tight implementation schedules.

How does the CORE reduce your ongoing operating costs?

A central development goal was to reduce energy and fuel costs – the two largest items in the ongoing operation of an asphalt mixing plant. The following measures contribute to this:

For you, this means: calculable and transparent operating costs that have a long-term positive impact on your telematics-based fleet planning and your total cost of ownership calculations.

Transport and setup: fewer special transports, lower permit requirements

The CORE was designed so that transport width and height (maximum three meters) often eliminate special transports, escort vehicles, and additional permits – or at least reduce them. This not only lowers logistics costs but also accelerates commissioning on new construction sites.

During setup, cranes with load capacities under 90 tons are used. Such equipment is significantly more available and cost-effective worldwide than heavy-duty cranes. Additionally, the optimized design allows for smaller foundations, which reduces material and construction costs for you. Prefabricated cable trays minimize on-site installation effort and increase operational safety.

Maintenance, ergonomics, and workplace safety

Those who want to minimize downtime need maintenance-friendly technology. With the CORE, all components are easily accessible, and maintenance openings are at ergonomic height. The safety concept includes:

These measures facilitate service and increase acceptance among your operators and maintenance teams – an often underestimated factor for your plant's availability.

RAP content up to 40 percent: flexibility in recipes

With a RAP content of up to 40 percent, the CORE covers most current road construction specifications. The wide range of recipes enables the production of high-quality asphalt mixes for different applications – from base layers to demanding surface layers. Especially in markets with strict sustainability regulations or recycling quotas, this flexibility gives you competitive advantages.

Modular concept: base today, expanded tomorrow

You can initially operate the CORE as a base model and expand it gradually. Pre-configured interfaces allow for later retrofits without extensive modifications – such as for additional feed systems or enhanced control functions. This investment security is particularly attractive for mid-sized construction companies and asphalt plants that want to start with manageable initial investments and retrofit as needed.

International deployment capability and worldwide service

The CORE is designed for worldwide deployment. Benninghoven and the Wirtgen Group offer worldwide service and support. By reducing the number of packaging units and smart logistics planning, shipping costs for international projects decrease. At the same time, administrative and customs processes are simplified – a significant advantage when operating asphalt mixing plants in emerging markets or remote regions.

Classification: CORE as a response to increased cost pressure

The asphalt mixing plant market is under increasing pressure: energy prices fluctuate sharply, material costs rise, sustainability requirements tighten, and competition in road construction grows simultaneously. The CORE addresses these challenges through consistent optimization of operating costs and investment security. With its focus on energy efficiency, fuel flexibility, and modular expandability, Benninghoven positions the plant as an economical alternative for operators who want to plan long-term.

Competitors such as Ammann and other mobile asphalt mixing plant manufacturers also focus on modularity and energy efficiency. The CORE differentiates itself through the combination of pre-configured interfaces, multi-fuel capability (up to four fuels), and design consistently optimized for transport logistics. Whether this concept achieves the hoped-for market penetration will depend on how quickly operators weigh the long-term TCO advantages against lower purchase prices of standard plants.

Who benefits from the CORE?

The plant is primarily aimed at:

However, if you already operate a fully equipped stationary large-scale plant and require maximum throughput performance, you will find alternatives in other product lines. The CORE is deliberately designed as a flexible, mobile solution – not as a high-performance plant for permanent locations with constant maximum capacity.

Availability and next steps

The CORE was officially unveiled on August 11, 2026, in Wittlich. Interested parties should contact the Wirtgen Group directly or local distribution partners to clarify delivery times, regional configurations, and financing options. As with other new plant types, expect longer lead times for custom modifications – plan accordingly if you want to integrate the CORE into ongoing or planned projects.

With the CORE, Benninghoven sends a clear signal toward operating cost optimization and modular flexibility. Whether the concept succeeds in the market will depend on how strongly operators weight long-term savings against cheaper entry-level models – and how consistently the Wirtgen Group implements worldwide service and spare parts supply.