Ammann India scales up with indigenous tech and global reach

As demand for sustainable construction rises, Ammann India is advancing road recycling through specialised machinery that enables high-recycled asphalt content. In an exclusive interaction with B2B Purchase, Ammann India shares insights on their technology, training, and commitment to sustainable infrastructure.

Can you describe Ammann India’s manufacturing capabilities and product range nationwide?

We are headquartered in Ahmedabad and have a cutting-edge manufacturing plant that spans roughly 37 acres. This facility produces our asphalt plants under the Ammann and Apollo brands. In addition, we manufacture a complete line of mechanical and track pavers, with screed lengths ranging from 5.5 to 13 metres. Our range also comprises a whole line of compactors, including soil compactors and tandem rollers for all compaction requirements.

We also make concrete plants and stationary pumps. In around three months, we’ll introduce our boom pumps. Our complete concrete product offering, including plants and pumping systems, is being modernised to guarantee we can fully assist our customers.

We have regional offices throughout India and work through a dealer network, notably for machines like pavers and, to some degree, for compactors. In several states, we also handle the sales and distribution of concrete plants via our dealers. We have a strong sales and service team of over 300 direct engineers who interact with clients and manage service and sales. Our dealers also support these activities through their local offices.

Our sales, marketing, and support personnel are widely scattered nationwide. In addition to our central mother warehouse, we manage approximately 13 direct depots and warehouses across India. This network allows us to properly manage and support the geographical spread of our operations throughout the country.

What are the environmental benefits of Ammann’s RAH systems and Foam Generator, and how are they made cost-effective for Indian road projects?

We discovered that incorporating recycled asphalt pavement (RAP) in new mixes helps conserve precious resources such as aggregates and bitumen. This technique provides major economic benefits to both us and our consumers and clear environmental advantages. The larger the ratio of RAP in the mix, the less fresh raw materials we need. This is the main advantage of RAP technology. In terms of cost-effectiveness, adding RAP lowers the costs of using a fresh mix or more aggregates.  

How is Ammann India using software and IoT to enhance its asphalt plants and equipment?

We provide Ammann Software 1 (AS1) proprietary software, a patented solution that assures consumers receive the appropriate quality mix via advanced software functions. We have also implemented IoT services across a wide range of our gear, which are fully linked with the AS1 software. Users can connect remotely via a mobile application to monitor machine performance and receive real-time updates. These IoT features are now standard in all our plants, including the entry-level drum mix plants.

Furthermore, we’ve created a new program called Apollo Mix Master, which combines all of the features of a batch mix plant with IoT capabilities. This puts us at the cutting edge of technology in the Indian market.

How does Ammann India ensure real-time data compliance for asphalt plants?

One of the most important characteristics of asphalt is its long-term quality. To maintain openness and accountability, we provide real-time plant performance data directly to government servers. While many claim to use such procedures, we provide entire, real-time data from the plant to the government’s server. The project approval procedure begins after this data has been examined and validated.

Certain initiatives, such as those authorised by the NHAI or specific state authorities, require users to upload production data. In such circumstances, we ensure that the data is posted properly. However, this is not a universal need or necessary across all projects; the rule exists but is only applicable where mentioned.

How do Ammann Academy train operators and customers to ensure effective asphalt plant operation and maintenance?

We have a program called Ammann Academy that gives training and SOP development for customers, including their operators and supervisors, as well as our service engineers and sales staff. Customers attend training sessions at the academy, and our team of specialists and dedicated trainers provides site-specific training in different locations. Training includes crucial topics like RAP management and plant operations. As an asphalt plant is essentially a series of interconnected units, with material flow beginning with the feeder and finishing with the truck being loaded from the pug mill, operators and customer supervisors may find it difficult to operate the plant and use the AS1 software.

We have a clear commissioning and training process. Depending on the plant’s capacity (120, 180, or 260 tonnes per hour) and the site’s complexity and remoteness, the commissioning phase can last anywhere from 15 to 40 days. During this time, we extensively educate the operators and ensure that the plant produces about 3,000 to 5,000 tonnes before handing it over to the customer.

Our training takes the PSB approach (Problem, Solution, Benefits), which assists participants in identifying challenges, finding solutions, and understanding their benefits.  At Ammann Academy, we use innovative simulators to simulate defects and circumstances, allowing learners to practise asphalt production and recycled mix preparation in a safe environment without risking equipment damage.  We also provide paver-specific simulations for operator training.  Ammann Academy is India’s largest of its kind, and it has an official partnership with the Indian government under the Skill India project.

How does incorporating rejuvenators and low-emission burners enhance the performance of asphalt-mixing plants? 

When we discuss rejuvenation in high recycling content, the utilisation of old asphalt grows. In such instances, using a rejuvenator is critical to maintaining the proper asphalt-to-mastic ratio. While the rejuvenator does not directly contribute to fuel savings, high-recycled asphalt combined with technologies such as foam bitumen or low-temperature asphalt does.

Using foam bitumen allows you to lower the mixing temperature drastically. Instead of heating aggregates above 250°C, we can operate at roughly 150°C. This decrease in aggregate heating temperature results in significant fuel savings and directly lowers carbon emissions, making the entire process more energy-efficient and environmentally benign.

How has Ammann supported road recycling in India, and what progress has been made in increasing the recycling rate?

Road recycling in India has already begun, and we have actively supported and equipped the sector to handle the recycling process successfully successfully. Recycling asphalt is a complex process that starts with reclamation and ends with production. Using recycled materials will be impossible without the initiative to notify the sector that the necessary machinery is available. It’s a two-way street: market demand for recycled mix and the ability to manufacture it must exist.

That is why we began with a 25 percent recycling rate, increased to 40-50 percent, and have now achieved 60 percent in India, where we are the sole provider of such specialised machinery.

Looking ahead, we are certain that 100 percent recycling is possible. The technology is already in place. The market demand drove us to provide these solutions, and we have ensured that the technology is easily available to meet that demand.

How does Ammann envision supporting India’s sustainable infrastructure goals as part of the Viksit Bharat initiative by 2047? 

We are an active member of ICEMA (Indian Construction Equipment Manufacturers Association). Sustainability and developing an environmentally sound ecosystem following ESG principles are well established in industrialised countries, and India is rapidly catching up. The government’s objective for India is to become a developed economy by 2047, and we are glad to state that Ammann India is already playing a leadership role in manufacturing and contributing considerably to this goal.

Our factory is roughly 95 percent indigenised, and looking at Ammann India’s manufacturing evolution, it is apparent that it has directly contributed to India’s industrial growth. Importantly, we are not waiting for production-linked incentive programs to encourage localisation; we have already invested significantly in localising and enhancing domestic skills.

Currently, we employ over 1,000 full-time employees and work with about 600 vendors.  As we grow, we actively contribute to expanding the Indian economy, or “Bharat,” by creating jobs and strengthening local industries.

Instead of relying on imports, we emphasise local sourcing. Ammann operates worldwide, including Germany, the Czech Republic, China, Turkey, and Brazil. However, we see our India facility as an important worldwide hub for serving growing, low-emission markets, including Latin America, Africa, the Middle East, and Southeast Asia. This strategic vision enables us to contribute significantly to India’s manufacturing GDP and export capabilities.

We are also committed to social responsibility. Through our involvement in the National Apprenticeship Accreditation Program, we bring in approximately 100 apprentices each year, providing them vital skills. Whether joining Ammann full-time or pursuing other options, they depart with skills that contribute to overall job growth.

In essence, employment creation, skill development, and manufacturing excellence are firmly ingrained in Ammann India’s mission and philosophy, and through them, we make a significant contribution to India’s development path.

For more information, visit: https://www.ammann.com/en-IN/