Small asphalt mixing plant is a professional asphalt mixing equipment designed for small-scale road construction or road maintenance projects, with a core capacity range of 10 to 80 tons per hour, which is a key feature that distinguishes it from large-scale mixing plants. Its most prominent technical highlight is the convenient site migration ability, can be easily transferred from one construction site to another, perfectly suited to small-scale projects, “small scale, scattered, short cycle” characteristics.

From the perspective of industry positioning, small asphalt mixing plant fills the gap of large-scale equipment in the field of small-scale projects, not only has a stable asphalt mixture production capacity, but also can effectively control the initial investment, simplify the installation process, reduce operating costs, is the ideal choice for small and medium-sized project contractors, municipal maintenance units, remote areas of the construction team to effectively solve the resource constraints of large-scale equipment. Large equipment can effectively solve the problem of waste of resources.

The stable operation of small asphalt mixing plant depends on the synergy of the core components, each component has a clear division of labor, compact design, and jointly guarantee the production efficiency and product quality, the specific components and functions are as follows:

Cold Aggregate Supply System

This component is the raw material basis of asphalt mixture production, usually equipped with 1~4 aggregate silos, which can realize the classification of different specifications of aggregate storage and accurate supply. The bottom of the silo is equipped with a special door, which has the function of filtering unqualified aggregates, which can effectively improve the quality of coarse aggregates by about 27%, and protect the basic quality of the mixture from the source. At the same time, the feeding belt and aggregate belt are controlled by frequency conversion speed control, and the aggregate proportioning accuracy can reach 94%, ensuring the accuracy of mix gradation.

Bitumen Supply System

The system takes on the core task of asphalt heating, insulation and transportation, mainly composed of asphalt tank, asphalt pump, thermal oil boiler. The asphalt tank is made of insulated stainless steel, which can effectively reduce heat loss and maintain the constant temperature of liquid asphalt; the thermal oil boiler as the core heating equipment, accurately controlling the asphalt heating to the construction temperature required, and when the temperature reaches the standard, the high-pressure asphalt pump will steadily transport the asphalt to the mixing drum, which provides raw material guarantee for the subsequent mixing process.

Drying and Mixing Drum

Drying and mixing drum is the core production unit of small asphalt mixing plant, when the aggregate, mineral powder and asphalt into the drum according to the ratio, the drum synchronization to complete the heating and mixing operations, a one-time realization of the aggregate drying, asphalt coating and mixing the whole process of mixing. The drum adopts 4-wheel support structure, including 2 rotating wheels and 2 fixed wheels, which can guarantee 100% stability during the operation of the equipment and avoid the shaking of the drum affecting the mixing uniformity and heating effect.

Bag House Dust Collector

As an environmentally friendly core component, the emission control concentration of bag filter is less than 20mg/Nm³, which is fully in line with the requirements of modern environmental protection construction. It adopts American DuPont NOMEX high-temperature resistant filter bag, which has the characteristics of high-temperature resistance and long service life, and the replacement of the filter bag does not require special tools, which makes the operation convenient and efficient. Meanwhile, it is equipped with intelligent temperature control system, when the dust temperature exceeds the set value, it will automatically open the cold air valve to cool down the temperature, avoiding the damage of the filter bag due to high temperature; with the high-pressure pulse cleaning technology, it can effectively reduce the wear and tear of the filter bag, prolong the service life and improve the dust removal effect.

Storage System

The storage system includes the finished product elevator and asphalt concrete storage silo, which are the key components to ensure the turnover of finished materials. Mixed and qualified mixes are transported to the storage silo through the elevator for classification and storage, waiting for the transfer of transportation vehicles, which can effectively connect the production and construction links to avoid the backlog of finished materials or supply interruptions.

Small asphalt mixing plant has become the mainstream choice for small-scale road projects, the core is that it has five outstanding advantages, accurately match the actual needs of the project, as follows:

Less installation

The equipment adopts modular component design, which greatly reduces the difficulty of the overall installation requirements, without the need to carry out the whole process of complex construction. At the same time, equipped with a mobile chassis, the installation process is more simple, even when installing a small drum asphalt mixing plant, there is no need to pour a concrete foundation, only need to level the site to complete the deployment, significantly shortening the installation cycle and reducing the cost of site modification.

Low fuel consumption

Adopting the special counter-current heating technology, it can greatly reduce the heat loss in the production process, and reduce the fuel waste from the root, compared with the traditional heating method, the fuel consumption is significantly reduced, which is in line with the concept of green construction, and also can effectively control the operating costs.

Robust structure

The core components of the equipment are made of stainless steel, with excellent anti-wear and anti-scratch performance, which can effectively cope with complex working conditions in long-term construction, prolong the overall service life of the equipment, reduce the frequency of replacement of wear parts, and reduce maintenance costs.

Strong adaptability

Perfectly adapted to small road construction, construction in remote areas, short-term road and bridge projects, etc., it is more suitable for small-scale operation sites by virtue of its smaller production capacity and continuous production capability. Whether it is county and township highway paving, municipal small-scale road maintenance, or small-scale projects in remote mountainous areas, it can be flexibly applied to solve the problem of large-scale equipment difficult to enter the field.

Low initial investment

Component design simplicity, corresponding to the lower factory cost, without investing a lot of money for equipment procurement and site construction, is the ideal choice for contractors with limited initial investment budget, effectively reducing the risk of investment in the project, and enhance the profitability of the project.

Standardized operation is to ensure efficient operation of small asphalt mixing plant, production safety and product quality is the key, combined with the industry’s practical experience, summarizes the following core operating points for practitioners to refer to:

Compliance with the front, complete formalities

Before installing the mixing plant, you need to contact the local authorities to confirm the legality of the asphalt mixing plant set up to complete the filing process; at the same time, according to the law to deal with the business license and other necessary qualification certificates to ensure that the construction of the whole process is compliant, to avoid stopping rectification due to incomplete procedures.

Scientific site selection and rational planning

Site selection should give priority to the selection of flat, away from the residential areas of the site, if the site ground is not flat, can be rectified by laying a solid foundation, to avoid the site is not flat resulting in unstable operation of the equipment, material transportation is blocked and other issues. At the same time, it is necessary to rationally plan the functional areas of the site, such as raw material storage area, production area, finished product storage area, equipment maintenance area, etc., to ensure smooth production process and efficient material transportation.

Accurate selection, matching demand

Select the asphalt mixing plant manufacturer with mature technology, quality service and reasonable price to ensure equipment quality and after-sales protection. At the same time, we need to strictly match the equipment with our own project needs, focusing on production capacity, site area, customer demand and other core factors, to avoid improper selection to affect the construction progress.

Daily inspection to prevent abnormalities

Daily inspection of equipment, focusing on temperature abnormalities, abnormal noise, alarm signals and other anomalies, once the problem is found, you need to immediately shut down to investigate, to avoid small problems evolve into equipment failure, affecting the continuity of production.

Lubrication and maintenance to ensure operation

Before each use, the equipment needs to be lubricated on all parts of the connection to reduce wear and tear of components, to avoid the lack of lubrication leads to equipment stalling, operating faults, to extend the service life of the components, to protect the production efficiency.

One of the core advantages of small-scale asphalt mixing plant is convenient installation and migration flexibility, is the ideal choice for site constraints or the need for frequent transfer projects, the specific advantages and applicable scenarios are as follows:

(I) Core advantages of installation and relocation

1. modular design:adopting modular structure, each component can be disassembled into standard transportation unit, no need for large-scale transportation equipment, ordinary vehicles can complete the transfer, low transportation cost and strong flexibility.
2. No need for complex foundation:the installation process is simple, only need to level the site to complete the assembly and debugging, a small number of personnel can operate, without heavy foundation construction, significantly shorten the installation cycle.
3. Integral trailer/chassis movement: equipped with the whole machine trailer structure, with tires and hydraulic support legs, can be transported to the new site, quickly leveled and put into use, high migration efficiency.
4. High transfer efficiency: the module design is in line with the national highway transportation standards, not ultra-wide, not ultra-high, the demolition and re-installation cycle is short, and part of the equipment can be completed from disassembly to commissioning in just a few days.

(ii) Core application scenarios

The relocation and installation characteristics of small asphalt mixing plant make it perfectly suited to the following scenarios: county and township highway, low-grade highway construction; road maintenance, municipal small-scale projects; remote areas or space-constrained construction sites, is the first choice of equipment for frequently relocated projects.

Operation of a small asphalt mixing plant with a capacity of 80 tons per hour or less, usually requires 4-6 core operators, the specific configuration can be appropriately streamlined according to the degree of automation of the equipment, the following is the detailed staffing and responsibilities:

Central control operator (1-2 persons/shift)

Responsible for the overall operation and control of the mixing plant, including the adjustment of production ratios, equipment start and stop, production parameter monitoring, etc., need to master the automated operating system to ensure that the production process is stable and product quality is up to standard.

Loader driver (1-2 persons)

Responsible for aggregate, sand and gravel and other raw materials yard management and loading work, need to skillfully operate the loader, to ensure sufficient supply of raw materials, to avoid the silo empty material phenomenon, to protect the production continuity.

Mechanic/Electrician (1 person)

Responsible for daily inspection, troubleshooting and regular maintenance of the equipment, covering the belt transmission system, mixing machine, electrical system and other core components, timely investigation and resolution of equipment operation abnormalities, to ensure the normal operation of the systems.

Site maintenance/cleaning personnel (1 person)

Responsible for construction site sanitation and cleaning, daily cleaning of equipment, assisting mechanic/electrician to carry out maintenance work, and at the same time monitoring the transportation of finished materials to ensure timely transfer of finished materials to avoid backlog.

Manpower streamlining techniques

Small asphalt mixing plant equipped with fully automated control system can reduce the manpower requirements by 30% -50%; at the same time, professionals can perform a number of duties, such as quality inspectors and maintenance workers can be merged into one person, effectively reducing labor costs.

The core raw material requirements

Small asphalt mixing plant production of raw materials required are mainly divided into three categories, and need to be strictly in accordance with the project design requirements of the precise proportion:

1. Bitumen: as the core binder, usually using No. 70, No. 90 and other road petroleum asphalt, need to ensure that the quality of asphalt in line with industry standards.
2. Stone: including coarse aggregate (such as crushed stone, rolled gravel) and fine aggregate (such as stone chips, natural sand, mechanism of sand), according to the grading requirements of classification and storage, precise placement.
3. Mineral powder: usually limestone or basalt finely ground filler, used to fill the gaps in the mixture to enhance the stability of the mixture, need to ensure that the purity and fineness of mineral powder in line with the standard.

Typical storage space requirements

The storage space should be reasonably planned according to the capacity of the equipment and the type of raw materials, the following is a typical storage space configuration of small asphalt mixing plant:

1. Bitumenstorage tanks:generally equipped with 1-3 asphalt tanks, a single tank capacity of about 10-30 tons (8-25 cubic meters), the total asphalt storage space of small stations is usually between 30-80 cubic meters, need to do a good job of heat preservation and leakage prevention.
2. Stone yard:need to distinguish between coarse and fine aggregates classified piles, 40-60 type small mixing plant, for example, the daily production of 40-60 tons of mix, need to set aside 200-400 square meters of the pile area, pile height control in 1.5-2 meters, to avoid the accumulation of materials or moisture.
3. Mineral powder storage: usually use silo storage, capacity of 10-30 tons (6-18 cubic meters), occupies an area of about 10-20 square meters, need to do a good job of moisture-proof, dust-proof treatment to ensure the quality of mineral powder.

Note: The actual storage space should be combined with the local climate, construction cycle, transportation conditions and other factors to adjust flexibly.

Small asphalt mixing plant is fully capable of producing high-quality asphalt mixture in line with industry standards, the core of the equipment needs to have a precision measurement system, stable heating and temperature control system, efficient mixing system, while strictly enforcing the production specifications, the specific points of the guarantee are as follows:

The core configuration guarantee

1. Accurate measurement:equipped with high-precision hot aggregate measurement system, asphalt measurement system and mineral powder measurement system, can accurately control the ratio of raw materials to ensure accurate mix gradation and asphalt dosage. 2. temperature control: equipped with high-quality combustion and temperature control system, stable heating and temperature control system, efficient mixing system, while strictly enforcing the production specifications.
2. Temperature control:Equipped with high-quality burner and reasonable design of drying drum, the heating temperature of aggregate and asphalt can be stably controlled to avoid asphalt aging and guarantee the performance of the mixture.
3. High-efficiency mixing: the paddle of mixing pot is reasonably designed, which can ensure the mixing uniformity of high demand materials such as asphalt horseshoe grease crushed stone mix (SMA), and avoid problems such as segregation of the mixture and uneven coating.

Production management guarantee

Strictly in accordance with the technical specifications for highway asphalt pavement construction and other industry standards to carry out production, precise control of aggregate gradation, asphalt dosage and mixing time, and strengthen the quality of raw materials testing to ensure that each batch of mixes meet the standard requirements.

In summary, small asphalt mixing plant as long as the core configuration of qualified, standardized operation, fully capable of producing high-quality asphalt for highway maintenance or rural road construction, without worrying about product quality.

Small asphalt mixing plant maintenance should follow the “prevention-oriented, mandatory maintenance” principle, the implementation of daily cleaning, weekly inspection, monthly maintenance system, focusing on cleaning, lubrication, dust removal, metering system maintenance and other work to extend the service life of the equipment, improve productivity and ensure construction safety, the specific maintenance process is as follows:

Daily maintenance (after each operation)

1. clean up the lumps: after the operation, make sure to thoroughly clean up the asphalt lumps left on the inner wall of mixing cylinder, aggregate bin and conveyor belt, so as to avoid the hardening of the material and causing the equipment to be stuck.
2. Cleaning and dust removal: Use high pressure air gun to reverse blow the dust removal system filter, clean the dust and impurities on the surface of the filter to ensure the normal operation of the dust removal system.
3. Abnormality checking: check the electric motor/diesel engine for abnormal vibration and rattling, check the hydraulic system for leakage, and promptly troubleshoot and deal with potential problems.

Weekly/monthly maintenance

1. system lubrication: establish lubrication ledger, lubricate all moving parts and bearings regularly, focus on lubricating the mixing spindle bearings to reduce the wear and tear of parts and prolong the service life.
2. dust removal maintenance: clean up the dust collector filters every week, dredge the holes in the filter element, check the operating status of the fan to ensure that the fan suction is normal, to ensure the effect of dust removal.
3. Measurement calibration: regularly check the measurement sensor signal, using standard weights to calibrate the weighing accuracy, to ensure the accuracy of the mixture ratio, to avoid product quality due to measurement errors.
4. Replacement of wearing parts: when the wear and tear of mixing blades and scraper exceeds 15% of the original size, they must be replaced in time to prevent the blades from breaking and damaging the equipment and to ensure production safety.

Seasonal and safety maintenance

1. anti-rust treatment: clean the exposed metal parts of the equipment and apply anti-rust coating to avoid rust and corrosion of the parts, especially in the humid or rainy season to strengthen the protection.
2. Electrical inspection: Regularly check the insulation of the electrical system and tighten the loose wires to prevent safety accidents caused by electrical faults.
3. safe operation: maintenance must wear protective equipment, dealing with asphalt adhesion problems, the need to use gasoline or special cleaning agents, to avoid personal injury caused by illegal operation.

Selection of small asphalt mixing plant, combined with the actual needs of their own projects, comprehensive consideration of the following three core factors to avoid improper selection of construction progress and cost:

Accurate matching of production capacity

According to the construction scale of their own projects, the duration of the requirements, select the corresponding capacity of small asphalt mixing plant models to ensure that the equipment capacity to meet the project schedule, to avoid delays caused by undercapacity, or overcapacity resulting in a waste of resources.

Strictly control product quality and brand reputation

Priority is given to manufacturers with good reputation and high brand credibility in the industry, focusing on checking the quality certification of the equipment, test reports, confirming the quality of the core components (such as metering systems, mixing drums, dust collectors), to ensure that the equipment has a stable production capacity and qualified product quality.

Emphasize on after-sales service

Choose a manufacturer that can provide timely and efficient after-sales service to ensure that when the equipment fails in the course of use, it can respond quickly and solve the problem in time to minimize the loss of downtime; at the same time, understand the manufacturer’s scope of maintenance services, the ability to supply spare parts, etc., so as to provide a guarantee for the long-term and stable operation of the equipment.

Comprehensive consideration of the site and working conditions

Combining the area of the construction site, terrain conditions, transportation convenience, and the climate of the region where the project is located, construction cycle and other factors, consider the flexibility of the equipment migration, ease of installation, fuel consumption and other characteristics, and choose the most suitable for their own project equipment models.