RAP Machine (Reclaimed Asphalt Pavement Processing Unit)

High-Efficiency Crushing, Screening & Feeding System for Recycled Asphalt Mixes

Product Overview

The RAP Machine is a specialized equipment system designed to process reclaimed asphalt pavement into reusable, high-quality recycled material for Hot Mix Asphalt (HMA) and Warm Mix Asphalt (WMA). It crushes, screens, separates, and feeds RAP with precision, ensuring consistent gradation, low dust, and maximum binder recovery. DPC offers compact, high-capacity, and batch-mix compatible RAP machines suitable for both small and large asphalt plants.

Key Features

• High-Efficiency Crushing System : Breaks reclaimed asphalt chunks into controlled sizes; Prevents over-crushing to retain binder coating; Adjustable rotor and hammer settings.

• Integrated Screening Unit : Segregates RAP into different gradations (0–5 mm, 5–10 mm, 10–20 mm); Ensures uniform particle size for mix design compliance; Low-dust, sealed screen housing.

• Temperature-Controlled Feeding : The RAP hopper includes temperature sensors; Optimal feeding designed for cold, ambient RAP to avoid binder aging; Smooth, variable speed feeding into the mixing drum.

• Anti-Sticking Drum & Conveyor Design : Special anti-build-up lining prevents material sticking; Belt cleaning system keeps operations continuous.

• Reduced Bitumen Aging : Retains maximum aged binder content for recycling; Ensures stable asphalt mix performance.

• Compatible with WMA Water-Foaming Units. : Allows higher RAP usage when combined with WMA technology; Improves coating, dispersion, and mixing at lower temperatures; Technical Specifications (Typical).

Technical Specification

• Feeder Volume: 3–8 m³

• Crusher Type: Impact / Hammer / Jaw (site-dependent)

• Screen Decks: 2–3 deck vibrating screen

• Gradation Output: 0–5 mm / 5–10 mm / 10–20 mm

• Power Requirement: 75–150 kW

• Conveyor Width: 500–800 mm

• Dust Control: Cyclone + baghouse compatible

• Control System: PLC automation with emergency shutdown

How the RAP Machine Works (Process Flow)?

• Raw RAP is fed into the hopper.

• Crusher breaks the material into controlled sizes.

• Vibrating screen classifies RAP into required gradations.

• Clean, sized RAP is transferred by conveyor.

• Cold RAP enters the asphalt plant via the RAP collar or mixing drum.

Advantages for Asphalt Producers

• Saves Cost

• Reduces virgin aggregate usage.

• Major savings on bitumen (4–6% aged binder recovery).

• Improves Mix Performance; Stable, stiff binder improves rutting resistance; Consistent gradation improves mix uniformity.

• Environment Friendly

• Supports recycled road construction targets (IRC, MoRTH).

• Higher RAP Usage with DPC Technology; 20–30% RAP even in surface courses using WMA foaming.

• Easy installation beside existing batch-mix plants

Why Choose DPC RAP Machines?

• Engineered for Indian aggregate conditions

• Works even in high-dust, high-moisture environments

• Full installation, commissioning & training support

• Optional integration with WMA foaming systems