In the huge project of road construction, asphalt mixing plant is an indispensable key role. It is like a magical “magician”, which cleverly combines aggregates and asphalt to produce asphalt mixtures for paving highways, municipal roads, parking lots and even airport runways. In some special cases, mineral fillers and additives are added to further improve the performance of asphalt mixtures. Understanding the different types of asphalt mixing plants is an important prerequisite for ensuring the efficient and high-quality completion of road construction projects.
Main types of asphalt mixing plants
Stationary asphalt mixing plants
Stationary asphalt mixing plants, also known as intermittent asphalt mixing plants, stand out in many large-scale and high-standard construction projects with their powerful mixing capacity and excellent performance. It uses a forced mixer to mix the asphalt mixture. This mixing method can ensure that various raw materials are fully mixed to produce high-quality asphalt mixtures. Therefore, it has become the preferred equipment for municipal roads, grade highways, airport runways and other projects with extremely high requirements for engineering quality and output.
Stationary asphalt mixing plants have many significant advantages. Its modular design is a highlight, which makes the equipment layout more reasonable and scientific, and it is faster and more convenient whether it is disassembly, transportation or installation. In the selection of core components, a large number of internationally renowned brands such as Siemens motors are used, which greatly reduces the equipment failure rate and effectively extends the service life of the equipment. In addition, it has a strong production capacity and a wide range of output, which can meet the needs of projects of different sizes. In addition, the two-stage dust collector equipped has excellent dust removal effect and meets the standards of areas with high environmental protection requirements.
Drum asphalt mixing plant
The drum asphalt mixing plant takes a different approach and uses a drying drum to complete the mixing process of asphalt mixture. Due to its relatively low equipment cost and the quality of the finished products produced can meet some projects with low requirements, it is highly favored in the construction of township roads, rural roads and road maintenance projects.
The advantages of the drum asphalt mixing plant are also very obvious. It has a compact structure and a small footprint, and can operate flexibly even in construction sites with limited space. The transportation and transfer of the equipment are very convenient. Some drum mixing plants are equipped with a movable chassis, which can be directly towed by a trailer and easily transferred to different construction sites. The optimized internal structure of the drying drum greatly increases the heating speed and the mixing effect is also excellent. Moreover, its price is relatively affordable and the investment cost is low, which is a very cost-effective choice for projects with limited budgets. In addition, its production process is simple and smooth, which can achieve continuous production and is very easy to operate.
Mobile Asphalt Mixing Plant
With the increasing diversification of road construction project needs, mobile asphalt mixing plants have quickly emerged in the market with their unique mobility and flexibility. Compared with Stationary asphalt mixing plants, the biggest feature of mobile mixing plants is that they are easy to move and flexible to transfer, which makes them a “powerful assistant” for projects with short construction periods and frequent changes of construction sites.
The main components of mobile asphalt mixing plants are installed on trailers and chassis, which enables the equipment to be relocated quickly. During the installation process, there is no need to lay the foundation in advance like fixed mixing plants, which greatly saves time and cost. Its core components are made of wear-resistant materials, which effectively extends the service life of the equipment. At the same time, the main equipment is centrally installed on the mobile frame, which occupies a small area and has high space utilization. In addition, this type of mixing plant adopts a PLC control system to achieve automatic control and higher production accuracy.
Differences between intermittent mixing plants and drum-mixed mixing plants
Differences in components
Although both intermittent mixing plants and drum-mixed mixing plants contain cold aggregate batching machines, drying drums, belt conveyors, asphalt tanks, burners, finished asphalt storage silos, control rooms, dust collectors, and finished product elevators, the composition of intermittent mixing plants is more complex. In addition to the above common components, they are also equipped with forced mixers, two different types of dust collectors, vibrating screens, electronic control systems, and hot aggregate elevators. These unique components also determine the different work processes of the two.
Differences in weighing systems
In the weighing process, intermittent mixing plants and drum-mixed mixing plants use completely different methods. In order to ensure the accuracy of the raw material ratio, intermittent mixing plants need to be weighed twice. The first time is after the cold aggregate enters the aggregate batching machine, and the second time is before the hot aggregate enters the mixer from the temporary storage silo. The weighing process of the drum-mixed mixing plant is relatively simple, and only a rough weighing is performed after the cold aggregate enters the batching machine.
Differences in mixing systems
In terms of mixing systems, the design concepts of the two mixing plants are significantly different. The drying drum of the intermittent mixing plant is only used to dry and heat materials, and the mixing work is completed by a special forced agitator; the drying drum of the drum mixing plant integrates drying, heating and mixing functions, and multiple operations can be completed in one device.
Differences in dust removal systems
At a time when environmental protection requirements are becoming increasingly stringent, the performance of the dust removal system is crucial. Intermittent mixing plants are usually equipped with a two-stage dust removal system, which is commonly a combination of gravity dust removal and bag dust removal. The dust removal effect is significant and can effectively reduce environmental pollution. Drum mixing plants are generally only equipped with a first-stage dust removal system, and water dust removal is mostly used. Although the cost is low, the dust removal effect is relatively general.
Differences in the quality of finished asphalt mixtures
Due to accurate weighing and high-performance agitators, the quality of finished asphalt mixtures produced by intermittent mixing plants is significantly better than that of drum mixing plants. In projects with strict quality requirements, the advantages of intermittent mixing plants are fully reflected.
Different production capacity
In terms of production capacity, the production range of intermittent mixing plants is between 40 tons/hour and 400 tons/hour, while the production range of mixed mixing plants is between 20 tons/hour and 120 tons/hour. Intermittent mixing plants have more advantages in terms of output.
Price difference
Taking all factors into consideration, the price of intermittent mixing plants is usually slightly higher than that of drum-mixed mixing plants. When choosing, users need to weigh the project budget and actual needs.
Key differences between the production processes of intermittent and drum-mixed mixing plants
Working method
The production process of intermittent mixing plants has obvious periodicity. Each production cycle has a clear start and end node. Only one batch of asphalt concrete is produced at a time. After completion, it is necessary to wait for the next batch of raw materials to be ready before continuing production. The drum-mixed mixing plant belongs to continuous production, and the raw materials can be put in uninterruptedly, and the mixing process continues.
Production efficiency
Due to the continuous production characteristics of drum-mixed mixing plants, their production efficiency is usually high, which is very suitable for large-scale production projects; intermittent mixing plants are limited by the production cycle, and their production efficiency is relatively low, which is more suitable for small-scale production or situations where the production speed is not high.
Raw material input
In terms of raw material input, drum-mixed mixing plants can add raw materials continuously without pausing and waiting; intermittent mixing plants need to put in enough raw materials at the beginning of each production cycle, and add them again after each batch of production.
Flexibility and adjustability
In contrast, intermittent mixing plants are more difficult to adjust production parameters and are more suitable for long-term production under stable conditions; drum-mixed mixing plants are relatively flexible in adjusting production parameters and can better adapt to different production needs.
Maintenance requirements for different types of asphalt mixing plants
Stationary asphalt mixing plants
The focus of maintenance for Stationary asphalt mixing plants is on the forced agitator. The wear of the mixing blades needs to be checked regularly. Once severe wear is found, they should be replaced in time. At the same time, the two-stage dust collector also needs regular maintenance, and the filter elements of the bag dust collector should be cleaned or replaced according to the manufacturer’s guidelines. In addition, for core components such as Siemens motors and Ibio burners, preventive maintenance should be carried out strictly in accordance with the recommended maintenance plan.
Drum-mixed asphalt mixing plant
The drying drum of the drum-mixed asphalt mixing plant is the key to maintenance. Regularly check whether there is damage or deformation on the inner surface of the drum, and maintain the heating system including the burner to ensure heating efficiency. Since its dust removal system is relatively simple, the water dust removal equipment should be regularly checked and cleaned to ensure its normal operation.
Mobile asphalt mixing plant
In addition to the maintenance of components similar to the above two mixing plants, the mobile asphalt mixing plant also needs to pay special attention to the mobile chassis and trailer parts. Regularly check the tires, brakes and suspension systems to ensure safe and smooth movement of the equipment. At the same time, ensure that the electrical connections associated with the mobile unit are stable and good.
Asphalt mixing plant price and project budget considerations
Production capacity of hot mix plant
The production capacity of asphalt mixing plant is one of the important factors affecting the price. Generally speaking, the smaller the production capacity, the lower the price of the mixing plant, while the price of large mixing plants is relatively high. When planning a project, it is necessary to accurately assess the required production scale. For small projects, choosing small or medium-sized equipment can reduce costs, while large projects require investment in large mixing plants to ensure production progress.
Types of asphalt mixing plants
As mentioned above, asphalt mixing plants are mainly divided into two types: continuous (drum mixing) and intermittent. Intermittent mixing plants are rich in functions and complex in structure, with high purchase and operation costs, but they have high production accuracy and good product quality; drum mixing plants are relatively cheap and are a good choice for projects that allow a certain weight error (2-3%).
Detailed configuration of asphalt mixing plant
The detailed configuration of the mixing plant also has an important impact on the price. The more parts and functions the equipment has, the higher the price. For example, increasing the number of asphalt tanks and equipping hot storage silos will increase the price of the equipment, but in the long run, it can bring many conveniences to the project. In addition, factors such as the size of the burner, whether to add recycled asphalt pavement (RAP) material, the specifications of the dust collector, the number of aggregate silos, filler storage and additives will ultimately affect the price of the mixing plant.
Mobility of hot mix plants
Mobile asphalt mixing plants are generally more expensive than fixed mixing plants due to their mobility. However, for projects that require frequent transfers, the convenience and flexibility they bring are enough to make up for the price difference.
Accessories of asphalt mixing plants
The choice of accessories will also affect the price of the mixing plant. Adding more silos, adding RAP functions or additional asphalt tanks will increase the total price of the equipment. Therefore, when choosing accessories, make careful decisions based on the actual needs of the project to avoid unnecessary cost increases.
After-sales service provided by asphalt mixing plant suppliers
Technical support
A reliable asphalt mixing plant supplier should provide comprehensive technical support, including equipment installation guidance, operator training, and continuous technical consulting services to ensure that customers can use the equipment proficiently and effectively.
Spare parts supply
Timely supply of spare parts is the key to ensuring the normal operation of equipment. Suppliers must be able to quickly provide the required spare parts, reduce downtime during equipment maintenance, and maintain stable production of asphalt mixture.
Maintenance service
Efficient maintenance service is indispensable. Suppliers should have the ability to respond quickly to equipment failures and provide professional maintenance services to restore the equipment to its optimal operating state as soon as possible.
Remote monitoring
The remote monitoring service provided by some suppliers enables customers to grasp the operating status of the equipment anytime and anywhere, discover and solve potential problems in a timely manner, and further improve the reliability of the equipment.
Training service
The training service provided by the supplier helps customers master the operation and maintenance skills of the equipment and improve the efficiency and production benefits of the equipment.
Regular inspection
The supplier regularly maintains and inspects the equipment, which can effectively extend the service life of the equipment, discover and deal with potential problems in a timely manner, and prevent problems before they occur.
Conclusion: Accurate matching for the best results
When choosing an asphalt mixing plant, whether it is a choice between intermittent and drum mixing, or a consideration between fixed and mobile, there is no absolute “optimal solution”, only the choice that best suits a specific project.
Only by comprehensively and carefully evaluating the project scale, quality standards, mobile requirements and budget, and accurately matching them with the characteristics and advantages of various asphalt mixing plants, can we make wise investment decisions. This will not only ensure the stable production of high-quality asphalt mixtures, ensure that road construction or maintenance projects are carried out on time, but also effectively guarantee the return on investment.
Working with experienced asphalt machinery manufacturing experts can help you determine and purchase the most ideal asphalt mixing plant equipment. Contact us now to get customized solutions to help your project succeed!
