Asphalt Plant Engineers Since 1988
We design, build, install and refurbish asphalt and aggregate processing plant, from a single dryer drum to a complete mobile plant. And when something wears, the genuine parts are already on our shelves in Suffolk.
What We Do
A new plant, an upgrade that has to fit inside a shutdown, or a part you needed yesterday: you deal directly with the engineers who design it.
Dryers, filters, mixers, feeders, elevators, silos and complete mobile plants, engineered to your site, your materials and your output.
Drum shells and flights, pulse-jet filter sections, screens, pugmills and storage extensions, prepared in our workshop so the work on site fits your shutdown.
Barber Greene, Astec and FMA Ullrich parts, and parts for the plant we build, held in our stores in Suffolk.
Explore the Plant
Pick a stage to see what we build, upgrade and stock for it. We design around the plant you already have, whoever made it.
Tap any part of the drawing, or use the stage buttons.
Stage 01 of 07
Holds your aggregates and RAP, and meters them onto the gathering conveyor in the right proportions.
Ronaldsway Airport, Isle of Man, 2011: our mobile RAP feeder worked alongside a mobile asphalt plant on night-time runway works, then moved on to the Falklands.
Ask About Cold FeedStage 02 of 07
Carries aggregate from the cold feed up to the dryer, with a scalping screen to keep oversize out.
South west England, 2011: a RAP system with a 29.5 m lattice-framed conveyor and weigh conveyor on a Parker batch plant, commissioned within the allotted time.
Ask About ConveyingStage 03 of 07
Dries and heats the aggregate. The drum sets much of your output and most of your fuel bill.
Tarmac, Skipton Rock Quarry, 2011: drum refurbished in five days with new flights, trunnion rings, seals and wear bands. The quarry manager said it “helped us to reduce our energy costs”.
Ask About DryingStage 04 of 07
Cleans the exhaust air before it leaves the stack, and returns the collected fines to the mix.
Aggregate Industries, Bardon Hill, 2015: a reverse-air filter replaced by our SF20/2 pulse-jet filter in the same footprint, with more exhaust and filtration capacity.
Ask About FiltrationStage 05 of 07
Lifts the hot, dried aggregate to the screen at the top of the tower.
Tarmac, Minffordd Quarry, 2008: a new section of hot stone elevator with chain and buckets, fitted alongside a new screen over the Easter shutdown.
Ask About ElevatingStage 06 of 07
Screens, weighs and mixes the aggregate with filler, bitumen and RAP.
CEMEX, Salford, 2009: a five and a half deck screen for a Barber Greene BA2250 batch plant, installed ahead of schedule.
Ask About MixingStage 07 of 07
Keeps finished mix hot, so you can load lorries fast, take small orders and cover nights and weekends.
Aggregate Industries, Westleigh, 2014: an FMA Ullrich S200/4, with 200 tonnes in four bins to one loading point, installed while the plant kept running.
Ask About Hot StorageProjects
For national producers, independents and contractors, in the UK and overseas. A few of the jobs behind the reputation:
The dryer drum had reached the end of its economic life, and the plant needed to take more recycled asphalt without adding equipment. We designed and built a new 3.1 by 15 metre drum mixer shell with our own recycle breaching, trunnion rollers and an underslung chain drive.
The old drum came out the week before Christmas. A 200 tonne crane lifted the new one in over the bitumen tank farm, and the job was finished safely inside the time allowed, in some of the worst weather in years.
“BG Europa offered us a solution that would provide an increase of recycled asphalt from 20 to 50 per cent.”
Our SF20/2 pulse-jet filter replaced a reverse-air unit on a Standard Havens drum plant: more exhaust and filtration capacity, 1,438 m² of cloth, on the existing foundation fixings.
An FMA Ullrich S200/4, with 200 tonnes in four bins discharging to one loading point, added to a plant first installed in 1972. On time and in budget.
Pre-assembled on its new base frame inside the dust housing in our workshop, then lifted into the Barber Greene batch tower in one piece.
A stationary KS60 stabilisation plant supplied to stabilise the sub-base for the new Grand Prix track.
“The overall service provided by BG Europa was extremely comprehensive and has helped us to reduce our energy costs. We would not hesitate in choosing them again.”
“BG Europa’s installation crew are to be applauded for their dedicated attitude to on site safety.”
“BG’s delivery of the plant on schedule was not compromised by their impressive flexibility of design in accommodating our specific requirements.”
| Year | Client and Site | What We Did |
|---|---|---|
| 2012 | Anglia Lime, Sudbury | SD 0.8 parallel-flow dryer and SFC 20 pulse-jet filter, wired and tested in our workshop before delivery |
| 2012 | National aggregate producer | RAP systems on Gencor and Barber Greene batch plants: 20% RAP nominal, up to 25% at full capacity |
| 2011 | Tarmac, Skipton Rock Quarry | Dryer drum refurbished in five days: new flights, trunnion rings, seals and wear bands |
| 2011 | Ronaldsway Airport, Isle of Man | Mobile RAP feeder for night-time runway works, then on to the Falklands |
| 2010 | O’Keefe, London | Bespoke relocatable KS55 to treat utility arisings that used to go to landfill |
| 2010 | Tarmac, Bayston Hill | Dryer drum taken out over Christmas, re-flighted in our workshop and back for the New Year |
| 2009 | FCC Construction, N6 Galway | KS60 CBM plant, up to 550 t/h: 270,000 tonnes for the N6, erected in five days |
| 2009 | Lafarge, Ackworth | FMA Ullrich S200/4 II hot storage, 200 tonnes in four bins, installed in a programmed shutdown |
| 2009 | CEMEX, Salford | Five and a half deck screen for a Barber Greene BA2250 batch plant, fitted ahead of schedule |
| 2008 | AG Thomas, Swaziland | Mobile SF4 pulse-jet fabric filter, sited without foundations, for road projects in Botswana |
| 2007 | Tarmac, Eaton Hall | SD1.5 dryer for a bagged aggregates plant, 45 t/h, with burner, controls and hot elevator |
| 2004 | Foster Yeoman, Micheldever | KSF55 foam mix plant producing Foamix at 200 tonnes an hour |
| 2004 | Maputo to Xai-Xai road, Mozambique | KS50 mobile unit mixing sandy lean concrete for sub-base and base courses |
Clients have included Aggregate Industries, Breedon, Brett Aggregates, CEMEX, Hanson, Tarmac, Lafarge, Anglia Lime, O’Keefe, Harsco, European Metal Recycling, Calumite, NCC Roads and Colas CZ.
Shutdown Work
Every day your plant stands idle is mix you can’t sell. So we do as much as we can before we arrive: design, fabrication, pre-assembly and testing. On site, we run the installation and commissioning, and leave the site clean.
We survey the plant and design the work around it. For Barber Greene plant we still hold the original engineering files.
Drums, filters, screens, mixers and steelwork are fabricated in the UK to our designs.
Sections are built up and tested before they leave. Complete KS plants are run up in the workshop, and you’re welcome to inspect yours before delivery.
We plan and run the site work, often lifting a whole section in one go.
Spares for what we fit stay on our shelves in Suffolk.
Minffordd Quarry, Easter 2008
“A very professional and extremely well executed operation carried out safely and to a high standard.”
A corroded reverse-air filter can be converted to pulse-jet over a weekend: the new sections arrive with their filter bags already fitted.
Talk to us now, while there’s still time to design and build before your plant stands down.
Recycled Asphalt
Reclaimed asphalt is worth the virgin aggregate and bitumen it replaces, tonne for tonne. But the more you add, the more your plant has to do. Slide to see what each level takes.
Sources: National Highways, net zero roadmap for concrete, steel and asphalt; MPA, Profile of the UK Mineral Products Industry 2025.
RAP in the mix, by weight
Up to 20%
Cold RAP can go straight into the pugmill, where the superheated aggregate dries and heats it. The catch is steam: cold, wet RAP hitting hot aggregate makes a burst of it, so extraction matters.
20 to 30%
A drum mix plant can take about 30% through a recycle breaching in the drum. From 20% up, split the RAP into the same sizes as your virgin aggregate, so gradation and binder content stay consistent.
30 to 40%
Superheating the virgin aggregate stops being enough, and costs more fuel the harder you push it. Drying and warming the RAP first takes the load off, as long as the RAP dryer’s blue smoke and light oils are kept out of the filter. Astec rates its Double RAP dryer at up to 40% RAP with zero opacity at the stack.
40 to 50%
Double-barrel dryer-mixers, such as Astec’s Double Barrel, add RAP in an outer mixing chamber away from the burner’s gases, so light oils aren’t driven off and any smoke is drawn back into the flame. Astec reports fuel use virtually unchanged at 50% RAP.
50 to 70%
At these levels only specialist equipment makes consistently good mix with no odour and a clear stack. Astec’s Double Barrel XHR, for example, is built for RAP additions from 50% up to 70%.
Typical levels from BG Europa’s own guidance and manufacturers’ figures. Your mix designs, materials and permit decide what’s right for your plant.
Talk to Us About Higher RAPFoaming the bitumen with a little water lets mix be made 30 to 50°C cooler with no additives, and foaming systems can be retrofitted to batch plants.
Pulse-jet filters clean with a short burst of compressed air, not cold, damp outside air, so steam from RAP is less likely to condense, corrode the casing and blind the bags.
Seal the transfer points, collect the fume at the mixer, silo tops and loadout, then burn it in the flame or filter it out, and blue smoke stops reaching the neighbours.
Mobile and Cold Mix Plant
Our KS mixers grew out of the original Barber Greene stabilisation mixers. They mix soils, cement-bound material, foam mix and emulsions close to the material or the job, and most of our mobile plant stands on level, compacted ground with no concrete foundations.
Twin-shaft mixers for soil stabilisation, CBM and lean mix, bentonite and emulsions. Stationary, relocatable or mobile, with loss-in-weight fines dosing.
100 to 725 tonnes an hour
Self-erecting plants with a foamed bitumen system developed with Soter, and their own generator, built within 3 m wide and 4.875 m high so they move without notification.
Foam mix, CBM and emulsions
From the transport position to upright in under two minutes on their own hydraulics, with gravimetric or volumetric fines dosing.
Upright in under two minutes
A complete drying plant on one chassis: feed hopper, parallel-flow drum, pulse-jet filter and discharge screw, for sand, glass and minerals.
SD 1.0: 6 t/h at 5% moisture removal
Since 1 April 2026 it’s £130.75 a tonne at the standard rate, and the lower rate for inert soil and stone more than doubled to £8.65. Every tonne of arisings treated and reused on site is a tonne that doesn’t go to the tip. Landfill Tax rates on GOV.UK
The asphalt plant permit guidance says reclaimed asphalt containing coal tar may only be processed cold, with bitumen emulsion, foamed bitumen or a hydraulic binder. That’s exactly what KS and KSF plants do. Process Guidance Note 3/15, paragraph 5.22
Approximate figures; every plant is specified to the job.
| Model | KS45 | KS50 | KS55 | KS60 | KS70 |
|---|---|---|---|---|---|
| Maximum mixing capacity (t/h) | 100 | 240 | 350 | 550 | 725 |
| Mixer length (m) | 1.50 | 2.10 | 2.28 | 2.40 | 3.05 |
| Mixer section (m) | 1.1 × 0.55 | 1.1 × 0.55 | 1.35 × 0.86 | 1.35 × 0.86 | 1.35 × 0.86 |
| Electric drive (kW) | 30 | 37 | 55 | 75 | 90 |
| Optional drive (kW) | 37 | 45 | 75 | 90 | n/a |
Spare Parts
Our 600 m² stores in Suffolk hold a large stock of genuine parts for immediate dispatch, close to the port of Felixstowe and the London airports.
Genuine parts for all plants made by Barber Greene (England) Ltd, made to the original specification.
They can look like standard items, but many are made to special tolerances, alloys or heat treatments. Fit a look-alike unknowingly and serious problems can follow.
Parts for Astec plants, held in our UK stores.
We know the export paperwork too, so parts can go on to Europe, the Middle East and Africa.
Parts for FMA Ullrich skip systems and hot storage silos.
Not on our shelf? It can come by express straight from Germany.
Parts for the plant we design and build: KS and KSF mixers, dryers, filters, feeders, conveyors and elevators, including the foamed bitumen systems on KSF plants.
Tell us the plant and its serial number if you have it, and we’ll match the part to our records.
Send a part number, a description or a photo, and we’ll check stock and come back with a price.
Any Make of Plant
We grew out of Barber Greene England, so we know those plants inside out and still hold their original engineering files. Our retrofit drum shells and pulse-jet filters fit any asphalt plant, and our project files include work on all of these:
Plants are designed to break down into road loads or shipping containers, and an engineer can travel with them to supervise erection.
About BG Europa
BG Europa (UK) Ltd was formed in 1988 from Barber Greene England, after Astec bought Barber Greene. The technology and expertise came with us, and so did the original engineering files.
In 1994 we moved into purpose-built 800 m² premises at Wickhambrook, ten miles from Barber Greene England’s old home in Bury St Edmunds, bringing the design office, spares department and stores together under one roof.
We’re a small, family-owned specialist firm, so you deal directly with the people who design your plant. And we build it to last: low running costs and a long working life, at a competitive price.
Yes. Our retrofit drum shells and pulse-jet filter sections fit any asphalt plant, our pugmill mixers fit most batch towers, and we’ve fitted recycling systems, hot storage and filters to Parker, Gencor and Standard Havens plants as well as Barber Greene.
Yes. We supply genuine parts for all plants made by Barber Greene (England) Ltd, made to original specification and identified from the original engineering files. We keep two machine sets of wearing parts in stock.
Stock parts go out on routine pallet and parcel collections, or by same-day courier when it’s urgent. Our stores are within easy reach of Felixstowe and the London airports, so we ship worldwide. Call 01440 821155 with the part number or a photo.
That’s how most of our installations are planned. We fabricate and pre-assemble so the site work is as short as possible: a screen section can go into a tower in one lift, and a reverse-air filter can be converted to pulse-jet over a weekend.
Usually not. Relocatable and mobile KS plants, KSF foam mix plants, DA silos, mobile RAP feeders and mobile baghouses are designed to stand on level, compacted ground.
Yes. KS plants are built up in full and tested in our workshop before they ship, and you’re welcome to inspect yours before you take delivery.
Yes, across Europe and beyond, from Ireland and Bahrain to Nigeria, Mozambique and Trinidad and Tobago. Plants break down into road loads or containers, and an engineer can travel with the plant to supervise erection.
Yes. Depending on your plant, that might mean a better RAP feed and weighing system, a recycle breaching in the drum, a pulse-jet filter that copes with steam, or a double-barrel dryer-mixer for 50% RAP and more. See what each level takes.
Contact
Send us the details and we’ll come back to you. Rather talk it through? Call 01440 821155.
BG Europa (UK) Ltd
Pipers Drove, Giffords Lane
Clopton, Wickhambrook
Newmarket
Suffolk CB8 8PQ