Asphalt Plant Modernization: How Ace-Saginaw Paving Expanded Capacity with a New Gencor Ultraplant

Asphalt producers across the United States face a familiar challenge: demand grows faster than production capacity, and customers will not wait indefinitely. When a paving company reaches the point where every day is overbooked and trucks queue for hours, the decision to invest in new plant infrastructure becomes a business necessity rather than a strategic option. Ace-Saginaw Paving Company faced exactly this situation in Michigan and responded by installing a new Gencor Ultraplant in Burton, Michigan. This article examines the company’s journey, the technology behind its investment, and the broader lessons for asphalt producers considering plant modernization. For operations managers evaluating plant efficiency, understanding the Difference Between Chemical Oxygen Demand Cod and Biological in industrial water management can inform environmental compliance planning alongside production upgrades.

The Business Case Behind Plant Investment

Every plant investment begins with a gap between supply and demand. For Ace-Saginaw Paving, a member of the Edw. C. Levy Co. group, that gap became impossible to ignore. David Gohn, Michigan Asphalt Plant Manager, described a situation familiar to many producers: days where production was fully booked and customers had to wait. When a paving contractor cannot get asphalt when needed, project schedules slip, labor crews stand idle, and relationships suffer.

Drivers of Increased Demand

Several factors converged to push Ace-Saginaw toward expansion:

1. Economic growth in the Flint, Michigan area drove higher construction activity across residential, commercial, and infrastructure sectors.
2. Michigan passed an infrastructure tax that generated new public funding for road and bridge projects, increasing asphalt demand across the region.
3. The existing plant in Burton, installed in 1996 as a 400-tph dual drum conversion system, reached its capacity limits after two decades of operation.
4. Customer expectations for consistent, high-quality mix at reliable volumes pushed the company to modernize rather than patch an aging facility.

These drivers are not unique to Michigan. Asphalt producers nationwide are evaluating similar decisions as infrastructure funding flows from federal and state programs and private construction activity grows in key markets.

The Edw. C. Levy Co. Legacy

Understanding the investment requires looking at the parent company. The Edw. C. Levy Co. began in 1918 as a trucking contractor in Detroit. Over a century, it grew into a diversified industrial company with global reach handling asphalt, aggregates, cement, slag, and steel mill services. Key milestones include:

Collectively, the Levy group companies produce upwards of five million tons of hot and warm mix asphalt each year for their own construction crews and for customers in the paving, construction, and commercial industries.

Selecting and Installing the Gencor Ultraplant

Choosing the right plant requires evaluating production capacity, fuel efficiency, environmental compliance, RAP processing capability, and manufacturer support. For Ace-Saginaw, the decision to go with Gencor came from existing relationships and proven performance. The company already operated Gencor plants at other locations and trusted the equipment design and the manufacturer’s commitment to after-sale support.

Key Features of the New Plant

The installation replaced the 1996-era 400-tph system with a Gencor Ultraplant rated at 500 tons per hour. The old plant was dismantled, site elevation changed, drainage improved, and environmental requirements met or exceeded. Key technology features include:

• A.R.E. System (Aggregate Reclaim Energy): Uses combustion zone gases and convective heat to preheat RAP and release internal moisture before mixing. This staged release allows RAP percentages up to 50 percent.
• Dual RAP collars: Provide more retention time for recycled material, increasing usable RAP content when specifications allow.
• Volatile Reclaim System: Captures hydrocarbons and steam vapors from mixing and returns them to the burner as supplemental fuel, improving overall plant efficiency.
• Variable Frequency Drives (VFDs): Installed on all main components for improved energy efficiency and precise process control.
• Ultralogiks Plant Control System: Windows-based interface with advanced PLC platform managing blending and loadout functions, plus backup computer and redundant hard drive for data security.

Material Process Flow

Virgin aggregate enters at the feed end and is quickly heated approaching the burner. Recycled asphalt, previously reduced in size, enters the combustion zone behind specially designed flighting. This allows RAP to cascade around the flame, absorbing conductive and convective energy that releases internal moisture before the mixer. Virgin aggregate, RAP, and baghouse dust combine in the mixing zone away from direct radiant heat. Asphalt cement is then added to the thoroughly dried mixture, producing a fully coated homogenous mix.

By releasing moisture gradually rather than all at once, the A.R.E. system avoids the steam explosions that can limit RAP percentages in conventional drum mixers. The result is consistent, high-quality mix with up to 50 percent RAP content.

Safety, Sustainability, and Operational Excellence

Modern plant investments go beyond production capacity. Safety and sustainability were central to the Burton plant design, reflecting the Levy group’s corporate values. Gohn emphasized safety as a top priority when choosing plant components and layout, working directly with Gencor to specify features that would protect workers and reduce risk.

Safety Design Choices

• Stairs installed instead of ladders throughout the plant, reducing fall risks during routine access and maintenance.
• Electric chain hoists on silos eliminating the need for manual lifting of heavy components.
• Extra guards and access doors added to exceed standard equipment safety requirements.
• Backup computer and redundant hard drive ensuring data security and system integrity.

These design choices reflect a broader industry trend toward safety-by-design in asphalt plant engineering. When producers specify safety features during procurement rather than retrofitting later, the result is a more integrated safety program.

Environmental Commitment

The Levy Group is committed to reducing waste, minimizing CO2 emissions, and conserving energy. Practical steps for building sustainability into plant operations include:

1. Maximize RAP utilization: Higher RAP reduces virgin aggregate and new asphalt cement needs, cutting material costs and carbon footprint. The A.R.E. system enables 50 percent RAP without quality loss.
2. Specify VFDs on major drives: VFDs match motor speed to actual load, reducing electrical consumption significantly.
3. Capture process emissions: Volatile reclaim systems return hydrocarbons to the burner, lowering both fuel consumption and stack emissions.
4. Use redundant control systems: Backup computers prevent data loss and unplanned downtime.
5. Offer diverse mix types: Warm mix, ultra-thin, crumb rubber, and SMA extend pavement life and reduce lifecycle environmental impact.

Ace-Saginaw produces warm mix asphalt, ultra-thin overlays, crumb rubber mixes, latex and polymer modified mixes, stone matrix asphalt (SMA), and commercial and DOT mixes incorporating recycled materials. A sister company, Lyon Sand and Gravel, processes all recycled material, with average RAP content at the new Burton plant reaching 35 percent. This mix diversity allows the company to match the right product to each application while maximizing recycled content. For contractors scaling operations, Scaling an Asphalt Paving Business Strategies for Growth provides guidance on workforce development and customer relationship management alongside equipment investments.

Lessons for Asphalt Producers Evaluating Plant Investments

The Ace-Saginaw experience offers takeaways for producers considering their own modernization projects. Whether replacing an aging plant, adding capacity in a growing market, or improving sustainability, the decision requires evaluating multiple variables.

Key Decision Factors

Manufacturer Partnership and Culture

Gohn specifically cited Gencor’s personal commitment to standing behind their product as a deciding factor. When investing millions in plant infrastructure, the relationship with the equipment manufacturer matters as much as the technical specifications. Producers should evaluate local service availability, manufacturer customization willingness, track record in similar environments, and references from comparable installations.

Ace-Saginaw operates five Michigan locations: Davisburg (600-tph), Burton (500-tph), Port Huron (500-tph), Saginaw (500-tph), and Ubly (300-tph), producing approximately 1.1 to 1.4 million tons of asphalt annually. The company anticipates increased production driven by new state infrastructure funding. For commercial paving contractors working alongside asphalt producers, Paving Utility Cuts Paths and Parking Lots Best covers best practices for small commercial paving projects that depend on reliable material supply from plants like the Burton facility.

Plant technology alone does not guarantee success. Gohn described a culture of continuous improvement: always searching for a better way to make a product or process the best it can be. This approach requires employees who are involved in decision-making and understand company goals. The culture extends to educating customers, listening to concerns, being trustworthy, and following through with service. Why Hpcr Fuel Systems Demand a New Approach explores how maintenance practices evolve alongside operational changes, reinforcing the need for comprehensive fleet and plant management. The best results come when advanced technology is paired with a committed workforce, a clear safety framework, and a manufacturer that stands behind its equipment long after installation.

Based on reporting from For Construction Pros, published November 28, 2016.