Asphalt batch mixing plant, essentially a precise measurement as the core, according to the batch cycle of asphalt mixture production of advanced manufacturing equipment, and the biggest difference between the asphalt drum mixing plant is that the production process has a clear cycle, each batch of asphalt mixture production through the complete “feed – measurement – mixing – discharge” cycle, this production mode allows the equipment to be used for the production of asphalt mixture. Each batch of asphalt mixture is produced through a complete cycle of “feeding-measuring-mixing-discharging”, which enables the equipment to realize more accurate control of the quality and composition of asphalt mixture, and safeguard the quality of asphalt from the source.

The core positioning of asphalt batch mixing plant is “customized production”, according to the specific requirements of different projects, flexible adjustment of asphalt mixture formulations, such as high temperature optimization of high temperature resistance for highway, for heavy highway load-bearing capacity, for urban roads to improve the noise reduction effect, etc., to meet the individual needs of all types of projects on asphalt mixture.

The core of asphalt batch mixing plant is “step-by-step cycle, accurate and controllable”, the entire production process follows a fixed process steps, each step is centered on “to ensure accurate measurement, mixing and uniformity” to start, while combining the functions of various parts of the equipment to achieve high efficiency production. The first step is cold aggregate batching:

The first step is cold aggregate batching. The operator will use the loader to load different specifications of aggregate into the cold bin, each cold bin is equipped with a variable speed drive device, according to the preset formula ratio, accurately control the delivery flow of each type of aggregate, to ensure that the proportion of aggregate into the next link in line with the requirements of the formula of the asphalt mixture, to avoid deviations due to the proportion of aggregate affecting the quality of the asphalt, the core of this step is to provide a homogeneous, compliant raw material base for the subsequent production. The core of this step is to provide a uniform and compliant raw material base for subsequent production.

The second step is drying and heating. After preliminary screening of the cold aggregate will be conveyed to the drying drum through the conveyor belt, the drying drum is equipped with an energy-saving burner, you can choose diesel fuel, heavy oil, coal and other different fuels, through the high temperature heating way to remove the moisture in the aggregate – the complete removal of moisture is to ensure that the asphalt and aggregate bonding degree is the key to avoid subsequent mixing process of hollowing, cracking, etc. The complete removal of moisture is the key to ensure the adhesion of asphalt and aggregate, avoiding the subsequent mixing process, such as hollowing and cracking.

The energy-saving design of the burner not only reduces energy consumption, but also realizes the uniform heating of the aggregate, ensuring that the temperature of each grain of aggregate reaches the preset standard.

The third step is screening and storage. The heated aggregate will be transported to the vibrating screen through the hot elevator, which will separate the aggregate into different sizes according to its particle size, and then transported to the corresponding hot material silo for storage. The hot silo has good heat preservation performance, can maintain the temperature of the aggregate, to prevent the aggregate from cooling down and affecting the subsequent mixing effect, but also can realize the classification of the aggregate storage, convenient for the subsequent proportion of accurate transfer.

The fourth step is the measurement of mixing. This is the core of the entire production process, the equipment will be based on the preset asphalt mixture formula, from each hot bin to accurately adjust the corresponding weight of the aggregate, sent to the measuring hopper for accurate measurement – measuring hopper is equipped with a high-precision weighing device, which can ensure that aggregates, asphalt, mineral powder and other raw materials are controlled in the permissible range of measurement error. The weighing hopper is equipped with a high-precision weighing device, which can ensure that the measurement error of aggregate, asphalt, mineral powder and other raw materials is controlled within the allowable range. After the measurement is completed, the aggregate, heated asphalt and mineral powder will be fed into the mixing cylinder together, and the two rotating mixing arms inside the mixing cylinder will rotate in the opposite direction, driving the mixing blades to mix all the raw materials fully until a uniform asphalt mixture is formed.

The fifth step is storage and loading. After mixing the asphalt mixture, it can be directly sent to the finished product silo for temporary storage; it can also be directly loaded into the transportation vehicle and quickly transported to the paving site, realizing the efficient connection of “production – transportation – paving” and shortening the project cycle.

Overall, this batch cycle production mode, to ensure that each batch of asphalt mixture formula, temperature, mixing uniformity are consistent, effectively avoiding the continuous production of quality fluctuations that may occur, which is the asphalt batch mixing plant to ensure the stability of asphalt quality of the core reasons.

The stable operation and high quality output of asphalt batch mixing plant is inseparable from the synergistic effect of the core components – the performance of the core components directly determines the production efficiency of the equipment, metering accuracy and asphalt quality, the following are the four major core components of the asphalt batch mixing plant equipment:

Cold Aggregate Feeding System

The system is mainly composed of cold material silo, conveyor belt, speed control drive device, and its core function is to realize the classification of aggregate storage and accurate delivery. In actual production, the aggregate will be loaded from the site pile into the cold material silo through the loader, each cold material silo corresponds to a specification of the aggregate, and is equipped with an independent extraction belt to ensure that the aggregate is not mixed in the delivery process. At present, the common asphalt batch mixing plant is equipped with at least 4 cold silos, according to the flexibility of the project needs and aggregate grading requirements, increase the number of cold silos, adapted to the different formulations of the production needs. The ultimate goal is to deliver the required aggregates to the drying drum in proportion to provide qualified raw materials for the subsequent drying and heating process.

Drying Drum

The drying drum is essentially a rotating cylinder, with a series of internal blades, the core role of these blades is to continuously lift and sprinkle the aggregate, so that it can fully contact with the hot air generated by the burner, and realize the drying and heating of the aggregate by means of heat radiation.

During the heating process, a large amount of exhaust gas, dust and combustion residues will be generated inside the drying drum, and these pollutants will be transported to the bag filter for treatment, and then discharged into the atmosphere after reaching the standard, which is in line with the requirements of environmental protection, and also avoids dust pollution of the surrounding environment. The rotating speed and heating temperature of the drying drum can be adjusted according to the characteristics of the aggregate and the production demand to ensure uniform drying of the aggregate and the temperature is up to standard.

Mixing Tower

The mixing tower is the “core hub” of the asphalt batch mixing plant, integrating the vibrating screen, hot material bin, mixing unit and other key structures. After the drying drum heated aggregate (temperature usually reaches 150-160 ℃), will be conveyed through the bucket elevator to the vibrating screen in the mixing building, the vibrating screen will be according to the preset requirements of the particle size, through the different specifications of the screen mesh on the aggregate for grading again, after the classification of the hot aggregate will be sent to the 4 to 6 corresponding hot material silo insulation storage until the need to measure the use of. Mixing cylinder is located in the lower part of the mixing building, consisting of a hopper and two counter-rotating mixing arms, the blades on the mixing arms will mix the measured aggregate, asphalt, mineral powder until the formation of a uniform, fine asphalt mixture, the uniformity of mixing directly determines the final performance of the asphalt mixture.

Bag Dust Collector

With the increasingly stringent environmental regulations, the environmental performance of the equipment has become the focus of the industry, the bag filter is the key component of the asphalt batch mixing plant to achieve environmental emissions. It can efficiently filter the exhaust gas and dust emitted from the drying drum, and the collected dust will be transported to the buffer hopper through the screw conveyor, which can then be accurately measured and re-fed into the mixing cylinder according to the recipe requirements, realizing the recycling of dust – which not only reduces the emission of pollutants, but also saves the cost of raw materials, and at the same time, has a significant effect on the regulation of the adhesion between asphalt and aggregates, and on the adhesion between asphalt and aggregates. Adhesion with the aggregate, enhance the combination of asphalt mixture has an important role.

In the infrastructure industry, asphalt batch mixing plant can be widely used, the core lies in its ability to accurately solve the industry’s core pain points – such as asphalt mixture quality is not stable, the formula is difficult to adjust, the waste of raw materials is serious, environmental protection does not meet the standards, etc., and its advantages are centered around the project demand, not only to protect the quality of the project, but also to Enhance production efficiency and reduce production costs:

High Flexibility

Asphalt batch mixing plant adopts batch production mode, which can flexibly adapt to the formula requirements of different customers and projects. Whether it is necessary to adjust the ratio of aggregates, asphalt content, or optimize the mixture’s heat resistance and load-bearing properties, the production specifications can be quickly switched without a long period of downtime for debugging. This advantage is especially suitable for manufacturers serving multiple customers and undertaking multiple types of projects at the same time, which can not only meet the individual needs of different projects, but also maintain high production quality, solving the industry pain point of “a single formula can not be adapted to multiple projects”.

Stable Production Quality

Different from the continuous production equipment, the asphalt batch mixing plant adopts the mode of “one batch one measurement, one batch one mixing”, the raw material measurement, mixing time and heating temperature of each batch of asphalt mixture can be executed in strict accordance with the preset standards, which avoids the uneven mixing of the raw materials and fluctuation of temperature that may occur in the continuous production. At the same time, the equipment is equipped with double mixing arms and mixing blades, which can further enhance the mixing uniformity of the mixture, especially for the special formula of the asphalt mixture, which can better reflect its quality advantages, to ensure that each batch of products meet the project quality standards.

Precise Control of Raw Materials

The asphalt batch mixing plant is equipped with high-precision weighing sensors in various aspects such as aggregate measurement, asphalt measurement, mineral powder measurement, etc., which can accurately control the input amount of each raw material, and the measurement error is controlled within a very small range. This accurate measurement can not only guarantee the quality stability of asphalt mixture, but also effectively reduce the waste of raw materials – to avoid excessive input of raw materials due to measurement deviation, thus reducing production costs and improving the economy of production, solving the industry’s “serious waste of raw materials, high cost Solve the industry’s “serious waste of raw materials, high costs” pain points.

Superior Environmental Performance

Equipped with advanced bag filter, it can efficiently filter the dust and waste gas generated during the production process to ensure that the emission meets the standard, which is in line with the increasingly stringent environmental regulations. At the same time, the equipment supports the integrated application of RAP (Recycled Asphalt Pavement), which can recycle and reuse waste asphalt pavement materials, not only reduce the generation of construction waste, but also save asphalt raw materials, and promote the green and sustainable development of the infrastructure industry.

In the asphalt mixing equipment market, asphalt batch mixing plant and continuous asphalt mixing plant is the two most mainstream types of equipment, both in the production mode, efficiency, cost and other aspects of the obvious differences, to understand these differences can help industry practitioners and buyers according to their own engineering needs and accurate selection, the following will be from the buyers most concerned about the dimensions of the accurate comparison, to facilitate the rapid distinction between the two types of equipment Suitable for the scene.

Production Process

Asphalt batch mixing plant adopts intermittent batch production mode, each production cycle has a clear start and end, can only produce a batch of asphalt mixture, a batch of production is completed, need to stop running, waiting for the next batch of raw material input and measurement;

The asphalt drum mixing plant adopts continuous production mode, which can input raw materials and mix without interruption, realizing the continuous output of asphalt mixture, and the production process is more coherent.

Production Efficiency 

Asphalt batch mixing plant due to its intermittent production characteristics, production efficiency is relatively low, more suitable for small batch production, high asphalt quality requirements, and does not pursue the ultimate production speed of the project, such as small municipal roads, bridges and other ancillary projects;

Asphalt drum mixing plant by virtue of the advantages of continuous production, production efficiency is higher, suitable for large-scale mass production of projects, such as long-distance highway rapid Paving, can quickly meet the project’s large amount of asphalt demand.

Raw Material Input

Asphalt batch mixing plant needs to be in each batch of production before the start of a one-time input of sufficient raw materials, to be completed after the completion of the batch of production, and then replenish the next batch of raw materials, raw material input has a cyclical nature;

Asphalt drum mixing plant can be in the process of production of continuous replenishment of raw materials, without stopping to wait for the raw materials to achieve an uninterrupted supply of raw materials to reduce the raw material input of the waiting time.

Flexibility and Adjustability

Asphalt batch mixing plant production parameters are relatively difficult to adjust, once the production formula is determined, adjust the parameters need to be down for debugging, more suitable for a long period of time in the stable production conditions, the production of a single or a few formulations of asphalt mixture;

Asphalt drum mixing plant can be flexibly adjusted in the process of production parameters, without the need for a long period of time downtime, the ability to quickly adapt to the production of different formulations of production needs, suitable for the need to frequently adjust the formula of the project. The continuous asphalt mixing plant production parameters can be flexibly adjusted during the production process, without long downtime, and can quickly adapt to the production of different formulations, suitable for projects that require frequent adjustment of the formula.

Equipment Costs and Maintenance

The equipment volume of asphalt batch mixing plant is usually small, the equipment procurement cost, installation cost is relatively low, and at the same time, due to its relatively simple structure, the subsequent maintenance difficulty and low cost, suitable for limited budget, focus on the long-term operation of the economy of the purchaser; while the continuous asphalt mixing plant has a larger volume of equipment, procurement and installation costs are higher, and the equipment structure is complex, the subsequent maintenance difficulty and cost is relatively high, suitable for sufficient budget, focus on the long-term operation of economic buyers;

Asphalt drum mixing plant has a larger volume of equipment, procurement and installation costs, and equipment structure is complex, subsequent maintenance difficulty and cost is also Relatively high, suitable for purchasers with sufficient budget and the pursuit of large-scale and efficient production.

How to Choose?

Comprehensive view, if the project pursuit of asphalt mixture of high quality, small batch production, and the need to flexibly adapt to a variety of formulations, while the budget is limited, give priority to asphalt batch mixing plant; if the project needs to be a large-scale mass production of asphalt mixture, the pursuit of the ultimate production efficiency, and budgetary adequacy, you can choose drum mix asphalt mixing plant.

Asphalt batch mixing plant is widely used in all kinds of infrastructure industries, covering a variety of different engineering scenarios, thanks to its accurate measurement capability, stable quality performance and flexible production mode:

In terms of application scenarios, the core application of asphalt batch mixing plant is highway construction, whether it is a national/state highway, provincial highway, or rural highway, urban expressway, it can provide asphalt mixture in line with the engineering standards by virtue of stable performance – highway load-bearing capacity of asphalt, high-temperature performance requirements Highway requirements for asphalt load-bearing capacity, high temperature resistance is extremely high, asphalt batch mixing plant’s accurate measurement and uniform mixing ability to ensure the smoothness and durability of highway pavement; rural highways and urban bypasses, although the quality of asphalt requirements are relatively mild, but the flexibility of the equipment can be adapted to the formula needs of different road sections, while controlling production costs.

In addition to conventional highway construction, asphalt batch mixing plant is also widely used in special infrastructure projects, the most representative of which is the airport runway and bridge pavement. Airport runway on the asphalt of the flatness, abrasion resistance and high temperature performance requirements are extremely stringent, small quality deviations may affect the safety of aircraft landing and takeoff, asphalt batch mixing plant can be accurately controlled through the asphalt mixture formula and quality, to ensure that the runway pavement of high precision and high stability; bridge paving requires asphalt mixture with good adhesion and crack resistance, the equipment’s customized production capacity to be able to The customized production capacity of the equipment can adapt to the special stress requirements of bridges, avoiding problems such as cracking and peeling of bridge decks.

In addition, asphalt batch mixing plant is also suitable for industrial area roads, toll station paving, parking lot paving and other scenarios. Roads in industrial areas are usually subject to frequent crushing by heavy vehicles, which requires high load-bearing capacity and abrasion resistance of asphalt; toll booths, parking lots and other areas of the pavement focuses on flatness and anti-skid, the equipment can be customized according to the needs of these scenarios, the appropriate asphalt mixture formula, to provide products that meet the requirements.

The reason why asphalt batch mixing plants are essential for high-quality infrastructure projects is that their value goes far beyond the production of asphalt mixtures themselves, and is reflected in the all-around guarantee of project quality, production efficiency, environmental compliance and long-term economics.

Customized Formulation

asphalt batch mixing plant can be customized according to the individual needs of road construction, tailored to the exclusive asphalt mixture formula, adapted to highways, municipal roads, rural roads and other different scenarios of performance requirements, to ensure that the asphalt mixture and engineering needs are highly compatible;

Environmental Compliance

Modern asphalt batch mixing plants are generally equipped with advanced dust collection systems, which can effectively deal with the dust pollution generated during the production process, and also support the integrated application of RAP (Recycled Asphalt Pavement), which realizes the recycling and reuse of waste asphalt pavement materials and practices the concept of green and sustainable road construction, which is in line with the requirements of the current environmental policy;

Efficient Operation

Equipped with a fully automated control panel, the asphalt batch mixing plant can minimize human errors, which not only improves the safety of equipment operation, but also ensures that the quality of each batch of asphalt mixture remains consistent, avoiding quality fluctuations caused by human errors;

Capacity Adaptability

The fast processing cycle of asphalt batch mixing plant can efficiently meet the asphalt supply demand of the project, guaranteeing the completion of the project on time, effectively reducing the project management costs and the risk of delay; long-term economic high-quality asphalt output can significantly extend the service life of the road, reducing the later road maintenance of manpower, material and financial resources, and further reducing the overall operating costs of the project.

To choose a suitable asphalt batch mixing plant, you need to combine the actual needs of the project, budget costs, production scale and other factors for comprehensive consideration, in order to achieve an accurate match between equipment performance and project needs, maximize the project cost-effective.

Project Needs and Scale

First of all, combined with the project demand and scale, clear project expected asphalt production, asphalt mixture formula type and the proportion of each raw material, accordingly select the corresponding model and specifications of the equipment, to avoid insufficient capacity can not meet the project demand, or overcapacity resulting in a waste of resources;

Production Efficiency Requirements

Secondly, we should refer to the project production efficiency needs, according to the project overall production cycle and asphalt supply time requirements, select the appropriate capacity of the equipment to ensure that asphalt production can keep up with the progress of the project paving;

Raw Material Quality Requirements

At the same time need to consider the quality of raw materials requirements, if the project on the raw material quality standards are high, need to choose a more sophisticated configuration, technical support more perfect equipment, to ensure that the equipment can be stable to protect the quality of asphalt mixture;

Budget and Cost Considerations

In terms of budget and cost, the need for comprehensive integration of equipment procurement costs, energy costs in the operation process, maintenance costs and other long-term expenditures, abandon the “only look at the purchase price” of a single cognitive, the pursuit of equipment throughout the life cycle of the maximization of the cost-effective;

Working Environment and Site Conditions

But also adapt to the operating environment and site conditions, combined with the project location of the environment and climate, site size and other constraints, choose the structure of the equipment to match, for example, the site of the project can be prioritized to choose a compact structure, small footprint equipment, to enhance the site utilization rate;

Technical Support and After-Sales Service

In addition, technical support and after-sales protection is also a key consideration, should choose reliable equipment suppliers and manufacturers, to ensure that after the procurement of equipment can obtain perfect technical support and after-sales maintenance services, to protect the long-term stable operation of equipment;

Environmental Requirements

Finally, we need to strictly comply with the environmental regulations and policies of the project location, and select the equipment equipped with qualified environmental protection facilities that can effectively deal with waste gas, waste water and various pollutants in the production process to ensure compliant production.

In order to meet the needs of different infrastructure projects, ZOOMLINE has launched several types of asphalt batch mixing plants, which can meet the needs of projects with different site conditions and production scales:

Stationary Type Asphalt Batch Mixing Plant: It is mainly suitable for long-term fixed site, large-scale stable production projects, with stable performance and sufficient production capacity, which can continuously provide high-quality asphalt mixture for large-scale infrastructure projects;

Mobile Type Asphalt Batch Mixing Plant: designed for projects that require frequent transfer of work sites, with flexible and convenient, fast dismantling advantages, can be flexibly deployed according to the progress of the project, suitable for decentralized, multi-point construction scenarios;

T-type Mobile Batch Mix Asphalt Plant: on the basis of mobile equipment to further strengthen the flexibility of mobility, more compact size, more convenient deployment, especially for small, decentralized construction scenarios;

Super Mobile Batch Mix Asphalt Plant: With higher flexibility and adaptability, the plant can be flexibly deployed according to the site conditions, which greatly improves the operational efficiency and meets the production requirements of various special scenarios.

The long-term smooth operation of asphalt batch mixing plant is the key to ensure the continuous progress of the project and reduce the operation cost, which requires a good all-round operation and maintenance management.

1. Regular Inspection and Preventive Maintenance

Regular inspection and preventive maintenance is the foundation: we need to focus on checking the wear, loosening and operating status of core components such as burners, drying drums, mixing cylinders, conveyor belts, etc., so as to investigate potential failures in a timely manner, and to avoid small failures from expanding into costly failures, which will affect the project progress and increase the cost of maintenance;

2. Calibrate Equipment for Precision

Precise calibration of equipment is indispensable: the weighing device of the equipment needs to be calibrated regularly to ensure the measurement accuracy of various raw materials such as aggregate, asphalt, mineral powder, etc., to maintain the stability of the asphalt mixture formula and guarantee the consistency of the product quality;

3. Monitor Fuel and Energy Efficiency

Fuel and energy efficiency monitoring needs to be normalized: energy-saving burners can be used to enhance energy efficiency, the drying drum insulation to reduce heat loss, regular cleaning of filters and vents to ensure smooth ventilation of the equipment, not only to reduce the cost of energy consumption, but also in line with the concept of green and sustainable production;

4. Train Operators and Staff

Operator training needs to be comprehensive in place: systematic professional training should be carried out to ensure that the operators are proficient in the safe operation of the equipment, common troubleshooting methods and manufacturer’s maintenance guidelines, to enhance the operational standardization and emergency response capabilities, and to reduce equipment failures and safety hazards caused by improper operation;

5.Keep Spare Parts and Tools Handy

Core spare parts and tools need to be stocked in advance: conveyor belts, mixing blades, filters and other easy-to-wear core spare parts should be kept, and long-term cooperation with reliable equipment suppliers should be established to ensure the rapid supply of spare parts and minimize equipment downtime;

6. Clean and Lubricate Moving Parts

Equipment cleaning and lubrication need to be carried out regularly: timely cleaning of dust and debris on the moving parts of the equipment, standardized lubrication of gears, bearings, chains and other components to reduce friction and wear of the components, extend the service life of the equipment, and reduce the cost of maintenance;

7. Leverage Technology for Monitoring

Precise monitoring can be realized with the help of modern technology: using the advanced monitoring system that comes with the equipment, real-time tracking of raw material consumption, output quality, monitoring the temperature and mixing uniformity in the production process, discovering potential problems in advance through predictive analysis, and realizing proactive maintenance and precise maintenance;

8. Schedule Seasonal Inspections

Seasonal inspection needs to be carried out in a targeted manner: adjusting the operation and maintenance focus with the climate characteristics of different seasons, for example, focusing on raw material handling in low temperature season to avoid raw material freezing affecting the production, and focusing on checking the hidden dangers of the cooling system in the high temperature season to prevent the equipment from malfunctioning due to overheating to ensure stable operation of the equipment throughout the year.