The production process of  asphalt batching plant follows the systematic flow of “Precise Measurement – Drying and Dehydration – Grading and Screening – Mixing and Storing of Finished Products”, and every step of the process is designed to guarantee the quality of the mix:

Raw Material Storage and Precise Feeder

Aggregates of different particle sizes are deposited into the cold aggregate silo separately, and then conveyed to the next stage in preset proportion through the adjustable speed feeder to control flow rate to ensure precise proportion of aggregates. Raw material storage and precise feeding: Aggregates of different grain sizes are deposited into cold aggregate bins, where they are controlled by adjustable-speed feeders and transported to the next stage according to preset ratios, thus ensuring an accurate proportioning of the aggregates.

Drying and Heating

the aggregates are fed into the drying drum, where they are removed from moisture by the high temperature airflow generated by the diesel, heavy oil or pulverized coal burner, and at the same time are heated uniformly to the required temperature for the production, which directly affects the bonding strength of the mix.

Grading, Screening and Storage

The heated hot aggregates are transported to the vibrating screen through the elevator, graded and screened according to particle size and deposited into different hot bins, waiting for accurate batching.

Weighing and Forced Mixing

Aggregate, asphalt and additives are weighed from the hot bins, asphalt storage tanks and mineral powder bins, and then sent to the mixer for forced mixing to ensure that all the components are fully mixed to form a homogeneous mixture.

Quality Testing and Storage and Transportation

After quality testing, the finished mix is deposited into the insulated hot material silo to maintain the temperature, or directly loaded into the transportation vehicle and sent to the construction site to avoid affecting the paving effect due to temperature drop.

The whole production cycle is about 45 seconds/batch, and each batch can adjust the formula independently, realizing the flexible production of “one batch, one adjustment”.

The performance of the asphalt batching plant depends on the synergy of the core components, of which five components are particularly critical:

Cold Aggregate Feeder

The starting point of production, through the adjustable gate and frequency drive to control the flow of aggregates, to ensure that the proportion of the ingredients is accurate, to avoid uneven feeding of material resulting in fluctuations in the quality of the mixture.

Drying Drum

The core of aggregate drying and heating, adopting counter-current heating design with high efficiency burner to realize energy-saving heating, the internal spiral blade ensures that the aggregate is heated evenly and the moisture is removed thoroughly.

Hot Aggregate Elevator

Responsible for transporting hot aggregate from drying drum to vibrating screen, it should have the characteristics of high temperature resistance and stable transportation, so as to avoid affecting the continuity of production due to jammed material.

Mixing Tower

The “heart” of the equipment, double shaft paddle forced mixing design to ensure the homogenization of the mixture, mixing time can be adjusted according to the formula, to adapt to the mixing needs of different types of additives.

Asphalt Storage Tanks

The use of heat preservation design, to maintain the liquid state of asphalt and constant temperature, to avoid asphalt solidification or temperature fluctuations affecting the bonding effect, part of the tanks also has a heating function.

In addition, the fully automated control system (PLC system) is the “brain” of the precise production, which can monitor the production parameters in real time, adjust the formula, record the batch data, and minimize the human error; the dust removal system (such as pulse bag filter) ensures that the exhaust gas meets the standards and is in line with the requirements of environmental protection.

Many engineering parties will be entangled in the choice between batch and continuous mixing plant, and the core differences between the two are concentrated in the production mode, quality control and applicable scenarios, the specific comparison is as follows:

Comparison dimensions: Asphalt batch mixing plant vs Continuous (drum type) mixing plant

Production Mode

Periodic batch production, batch by batch adjustment of the formula; Continuous production, low flexibility in the adjustment of the formula

Mixing Quality

High precision, homogenization, adapted to the special formula; Basic Quality up to standard, not flexible enough

Applicable Scenarios

High-grade highways, airports, bridges and other high-end projects; Low-grade projects such as rural highways, temporary roads, etc.

Initial Investment

Relatively high; Low

Operation Cost

Slightly high (partly offset by the increase in utilization rate of raw materials brought about by precise control); Low

Environmental Protection

Equipped with high-efficiency dust removing system, supports RAP recycling, excellent environmental protection Simple dust removing; average environmental protection

Flexibility

A wide range of additives, real-time adjustment of oil-rock ratio, and the flexibility to add a variety of additives. Additives can be added, real-time adjustment of oil-rock ratio; Difficult to add additives, fixed formula

Suggestions For Selection

If the project scale is large, the grade is high (such as highways, airports), or the formula needs to be adjusted frequently, give priority to the intermittent type; if the project scale is small, the requirements are low, and the budget is limited, the continuous type is more cost-effective.

Daily maintenance is the key to ensure long-term efficient operation of the equipment, the core around the “inspection, cleaning, lubrication, calibration” to start:

Regular Inspection and Repair

Daily inspection of the mixer, conveyor belt, elevator, burner and other key components, to detect cracks, leaks, abnormal noise and other problems. Regular inspection and maintenance: Daily inspection of key parts such as agitator, conveyor belt, elevator, burner, etc. to check for cracks, leakage, abnormal noise, etc., and timely replacement of worn-out parts (e.g., agitator paddles, conveyor belt).

Cleaning and Maintenance

Regularly clean the residual mixture on the inner wall of the mixer, hot material bin and drying drum to avoid lumping and contamination of the subsequent batches; clean the filter bag of the dust removal system to ensure the ventilation and dust removal effect.

Lubrication and Maintenance

Regularly add lubricant to bearings, chains, gears and other moving parts to reduce friction and wear and prolong service life.

System Calibration

Calibrate the weighing system, temperature sensor and flow controller regularly to ensure accurate measurement and avoid affecting the quality of mixture due to parameter deviation.

Electrical System Maintenance

Check the line connection, control system operation status, replace the aging electrical components to prevent electrical failure in production.

Personnel Training and Records

Operators need to be professionally trained and familiar with equipment operation and emergency treatment; establish maintenance accounts to record the content, time and effect of each maintenance, so as to facilitate the prediction of equipment failure.

In addition, after the installation of equipment or long-term shutdown, need to carry out test run: through the no-load and with material test run, to verify the performance of the equipment, debugging process parameters, test system linkage, while training operators, checking the safety risks, to ensure that the formal production of all foolproof.

With the core competitiveness of “precise control, flexible customization and high quality output”, batch asphalt mixing plant not only meets the stringent requirements of high-grade projects, but also realizes green production through the design of RAP recycling and high-efficiency dust removal, etc. Whether it is a stationary plant with large-scale stable output or a mobile plant with flexible transfer, it can meet the diversified needs of different projects. Whether it is the large-scale stable output of stationary equipment or the flexible transfer of mobile equipment, it can meet the diversified needs of different projects.

The choice should focus on capacity (60-400 TPH optional), mobility, fuel type, automation level and environmental configuration, and make a comprehensive decision in combination with project scale, budget and technical requirements. Good routine maintenance and commissioning can prolong the life of the equipment as well as ensure production efficiency and mix quality for the construction project.

In the context of high-quality development of infrastructure construction, intermittent asphalt mixing plant has become the core equipment to build durable, safe, environmentally friendly roads, choose the right equipment for the equipment, can make the project quality and efficiency to achieve double enhancement.

The core of selection is to “match the project needs”, there is no absolute advantage or disadvantage, only different adaptive scenarios, accurate matching in order to maximize the cost-effective and avoid waste of resources.

Mobile Asphalt Batching Plant  is more suitable for these scenarios: short construction period (such as temporary repair works, short-term road construction), multi-project transfer (need to frequently change the construction site), rental construction (no need to invest in equipment for a long period of time to reduce the upfront costs). Its core advantage is the fast deployment speed, without complex infrastructure, can be quickly commissioned after the arrival of the commissioning, low foundation requirements, suitable for all types of temporary construction sites.

Stationary Asphalt Batching Plant, on the other hand, is suitable for long-term and stable construction needs: long-term projects (such as large-scale highways, municipal projects, construction cycle of more than 1 year), high-capacity demand (the need for sustained mass production of asphalt mixtures), the deployment of industrial parks (fixed sites, you can set up a perfect supporting system). Advantages include high operational stability, long-term continuous operation, even capacity output, and easy upgrading to meet high-standard production requirements.

Technical parameters directly determine the capacity, energy consumption, environmental protection and service life of the equipment, the core parameters are indispensable, especially pay attention to the key details that can be easily ignored, to avoid the hidden danger of later operation.

The core technical indicators are summarized as follows:

Mixing Capacity (Actual Capacity)

The total amount of qualified asphalt mixture that can be produced by the equipment in a unit of time, which directly matches the demand of the project’s construction progress, avoiding delays in the construction period due to insufficient capacity or wasting costs due to overcapacity.

Mixing Time (Single Pot Mixing Time)

Single mixing time of asphalt mixture, affecting the efficiency of production capacity and uniformity of the mixture, mixing time is too short easily lead to unqualified mixture.

Fuel Consumption

the fuel loss of the equipment operation, directly related to the long-term operating costs, the lower the energy consumption, the later the more cost savings.

Dust Emission

The core indicator of environmental compliance, need to comply with the environmental standards of the project location, to avoid being suspended for rectification due to excessive emissions.

Automation Level

Affecting labor costs and operational stability, the higher the level of automation, the fewer operators required, which can reduce human error and improve production efficiency.

RAP Ratio

To adapt to the demand for asphalt recycling utilization, the higher the proportion of recycled material, the more you can save raw material costs, in line with the trend of green construction.

Asphalt batching plant price is not a fixed standard, the core of the equipment configuration, capacity and other factors, different specifications, different configurations of the equipment, the price gap is large, do not just look at the low price ignore the configuration.

The core factors affecting the price are as follows:

Capacity Size

The higher the capacity, the larger the equipment volume, the larger the specification of the core components, the higher the price, is the primary factor affecting the price.

Dust Removal Standards

The higher the environmental standards, dust removal system configuration, the more sophisticated, the higher the price (such as in line with the European standard, the U.S. standard dust removal equipment, the cost is much higher than ordinary dust removal configuration).

Burner Brand

High-quality brand burners (such as imported brands) with low energy consumption and high stability, the price is higher than ordinary domestic burners.

Whether or Not With Installation

Including manufacturers of door-to-door installation, commissioning services offer, will be higher than only the price of the equipment itself, but to avoid the pitfalls of self-installation.

Electrical System Configuration

The degree of automation, electronic control components brand, directly affect the price, high-end electronic control system can enhance the equipment control and stability.

Reference price range in the international market (for reference only, subject to the manufacturer’s customized offer):

60TPH (60 tons per hour): $250,000-$400,000

120TPH (120 tons per hour): $400,000-$700,000

200TPH (200 tons per hour): $700,000 or more

Professional Advice

A truly reliable The reliable asphalt batching plant manufacturers will not give a fixed offer, but will customize the exclusive offer program according to your project capacity requirements, environmental standards, construction locations and other details to ensure that the configuration matches the demand and avoid unnecessary cost investment.

Many customers only pay attention to the price of the equipment itself when purchasing, but ignore the hidden costs in the later operation, and these hidden costs accumulated, often beyond the expected, and even up to 30% -50% of the price of the equipment itself (within the 5-year cycle), be sure to plan ahead.

Summary of core hidden costs, it is recommended to focus on:

Foundation Construction Costs

Especially fixed asphalt mixing plant, you need to build a concrete foundation, site hardening, this part of the cost is often ignored, and according to the site conditions, the cost varies greatly.

Transportation and Lifting

Equipment components are large and heavy, long-distance transportation and on-site lifting require professional vehicles and equipment, which is costly and affected by transportation distance and site road conditions.

Fuel Cost

In long-term operation, fuel consumption is one of the main expenditures, the higher the energy consumption of the equipment, the higher the fuel cost in the later stage, need to pay attention to the Fuel consumption parameters of the equipment in advance.

Labor Cost

According to the degree of automation of the equipment, it needs to be equipped with operators and maintenance personnel, the lower the degree of automation, the more labor is required, and the accumulation of long-term labor expenditure can be considerable.

Replacement of Wearing Parts

During the operation of the equipment, the mixing blades, liners and other parts will gradually wear out and need to be replaced regularly. The quality and frequency of replacement of wearing parts directly affects the maintenance cost in the later stage.

Electricity and Maintenance Costs

Equipment operation requires the consumption of a large amount of electricity, and regular maintenance, repair (such as lubrication, parts overhaul), this part of the cost needs to be included in the long-term operating budget.

There is no fixed standard for the installation cycle, which is mainly affected by equipment specifications, site conditions, worker proficiency and other factors. Knowing the reference cycle in advance, you can reasonably plan the project schedule to avoid construction delays.

Reference cycle for installation of equipment of different specifications:

Small Asphalt Batching Plant

7-10 days (e.g. mobile asphalt mixing plant below 60TPH, modular design, easy installation)

Medium Asphalt Batching Plant

10-15 days (e.g. 60-120TPH equipment, need to build part of the supporting system, installation process is relatively complex) Large equipment: 15-30 days (e.g. 60-120TPH equipment, need to build part of the supporting system, installation process is relatively complex) Large equipment: 15-30 days (such as 120TPH or more fixed asphalt mixing plant, complex foundation construction, cumbersome installation of components, requiring the cooperation of multiple teams)

Core Factors Affecting The Installation Cycle:

Site conditions: the higher the degree of hardening of the site and the completion of the foundation construction, the faster the installation; if the site is muddy, the foundation is not built in advance, it will significantly extend the installation cycle.

Worker Proficiency

Professional installation team (especially the manufacturer’s own engineers) is skilled in operation, which can reduce installation errors and improve installation efficiency; non-professional team is prone to installation errors, resulting in rework delays.

Whether Pre-installed Modular Structure

Mobile asphalt batching plant is mostly modular design, pre-installed in advance to complete the site can be quickly spliced, the installation cycle is much shorter; the traditional fixed equipment components scattered, the installation cycle is much longer.

The answer is: strongly recommended! Whether it is a mobile or stationary asphalt batching plant, the standardization of the installation process directly affects the service life of the equipment, operational stability, and even related to construction safety, the manufacturer’s engineers on-site guidance is the key to avoid the risk.

The core reasons are as follows:

Avoid Wrong Installation Leading to Structural Deformation

The core components of the asphalt batching plant (such as mixing tanks, batching plant) is heavy, the installation precision requirements are high, the wrong installation will lead to structural deformation of the equipment, the later operation of the equipment is prone to failures, and even the existence of safety hazards.

Ensure That The Electric Control Parameters Are Correct

The electric control system is the core of the equipment, the wrong parameter setting will lead to the equipment can not run normally, or even burn the electric control components, the manufacturer’s engineers can accurately debug the parameters to ensure that the equipment starts normally.

Reduce The Risk of Trial Machine

After the completion of the installation of the need for trial machine debugging, manufacturers of engineers can control the entire trial process, timely detection and resolution of problems in the trial machine, to avoid waste of equipment idling, reduce the risk of failure of the trial machine.

Improve the Stability of The First Month of Production Capacity

Professional guidance for installation + commissioning, can ensure that the equipment can be put into production at the beginning of a stable output capacity, to avoid downtime due to installation problems caused by maintenance, to protect the progress of the project.

Industry Status

Most of the current international projects, manufacturers are explicitly required to provide “on-site installation + remote support” double guarantee, not only to ensure that the installation specifications, but also to deal with unexpected problems in the operation of the later period, to minimize the risk of the project.