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Asphalt Batch Mix Plant
ASPHALT BATCH MIX

Asphalt Batch Mix Plant

A heavy-duty industrial facility used to manufacture high-quality asphalt concrete (hot mix asphalt) in precise batches. Unlike continuous drum plants, a batch plant measures, heats, and mixes aggregates, bitumen, and filler materials in distinct, separate cycles (batches). This provides the highest level of flexibility and accuracy, making it the preferred choice for major highway construction and airports. Capacities from 80 to 400+ TPH.

verified ISO 9001:2015 batch Batch Precision history 20+ Year Lifespan public Exported to 35 Countries

CAPACITY

80–240 TPH

BATCH TYPE

Discontinuous Batch

POWER

180–650 kW

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Overview
Technical Specifications
Features & Benefits
Applications
FAQs

Precision Batch Production for Superior Mix Quality

An Asphalt Batch Mix Plant is a heavy-duty industrial facility used to manufacture high-quality asphalt concrete (hot mix asphalt) in precise batches. Unlike continuous drum plants, a batch plant measures, heats, and mixes aggregates, bitumen, and filler materials in distinct, separate cycles (batches). This provides the highest level of flexibility and accuracy, making it the preferred choice for major highway construction and airports.

settings Core Technical Specifications

Parameter Standard Industrial Specifications
Plant Capacity Range 80 TPH to 400 TPH+
Batch Cycle Time 45 to 60 seconds per batch
Batch Capacity 1,000 kg to 5,000 kg per batch
Operating Temperature 140°C to 180°C (Up to 200°C for modified bitumen)
Fuel Options for Burner Diesel, Heavy Oil, Natural Gas, LPG, or Coal
Control System Fully Automatic PLC with SCADA control interface

flowchart Key Modules and System Flow

An asphalt batch plant operates through a series of interconnected stations. The system layout follows this structural sequence:

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    Cold Aggregate Feeder Bins: Multiple hoppers feed different sizes of raw aggregate (sand, stone chips) onto a collecting conveyor belt using variable-speed drives.
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    Drying Drum with Burner: A tilted, rotating drum removes all moisture from the aggregates and heats them to the required processing temperature using a high-efficiency burner.
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    Baghouse Filter (Pollution Control): A heavy-duty pulse-jet dust collector traps fine airborne particles from the drying drum to meet strict environmental emission standards.
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    Vertical Bucket Elevator: Lifts the hot, dry aggregates to the top of the mixing tower structure.
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    Vibrating Screen Unit: Separates the hot aggregates by size through multi-deck screens, dropping them into isolated "hot bins" below.
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    Weighing Section: Independent, high-precision load cell hoppers weigh the hot aggregates, liquid bitumen (supplied from a thermic fluid-heated tank), and filler material according to the recipe.
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    Pugmill Mixer: A twin-shaft jacketed mixer blends the ingredients thoroughly for 15–20 seconds before opening a pneumatic bottom gate to discharge the finished hot mix asphalt into trucks.

check_circle Primary Applications

  • National Highways & Expressways: Where strict government specifications demand absolute material consistency.
  • Airport Runway Construction: Demanding precise aggregate grading and uniform binder distribution.
  • Urban Municipal Supply: Ideal for commercial suppliers who serve multiple contractors with different mix designs on the same day.

inventory_2 Quick Facts

BrandAtlas Engineering
OriginAhmedabad, India
Warranty18 Months
Delivery10–14 Weeks
Batch Cycle45–60 sec
ControlPLC + SCADA
SpecificationDetails
Capacity80 TPH / 120 TPH / 160 TPH / 200 TPH / 240 TPH (custom up to 400 TPH)
Batch TypeDiscontinuous batch (pugmill mixing)
Batch Cycle Time45–60 seconds
Batch Capacity1,000–5,000 kg per batch
Cold Feed Bins4 bins (customizable), each 10–20 m³ capacity
Drying DrumDiameter 1.8–3.2 m, Length 8–14 m
Screening SystemMulti-deck vibrating screen (4–6 decks)
Mixer (Pugmill)Twin-shaft, capacity 1,500–4,000 kg per batch
Weighing AccuracyAggregates: ±0.2%, Bitumen: ±0.1%, Filler: ±0.3%
Burner SystemForced draught, fully automatic, multi-fuel (LDO/HSD/Gas/Coal)
Fuel EfficiencyUp to 95% (thermic fluid heated)
Control SystemPLC + HMI Touchscreen with full SCADA integration
Power Requirement180–650 kW (model dependent)
ComplianceIS 8887, ASTM D977, MoRTH specifications
FootprintApprox. 70 ft x 45 ft (model dependent)
Net Weight35,000–85,000 kg (model dependent)
precision_manufacturing

Precision Weighing & Batching

Electronic load cells with ±0.2% accuracy for aggregates and ±0.1% for bitumen ensure consistent mix quality across every batch.

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Advanced Burner & Drying

Multi-fuel burner with precise air-fuel ratio control and high-efficiency drying drum ensures optimal fuel consumption and low emissions.

memory

Atlas Direct IoT Ready

Optional remote monitoring for production, fuel consumption, batch data, and plant performance.

build

Low Maintenance Design

Heavy-duty construction with wear-resistant materials ensures long life and minimal downtime.

settings

Flexible Recipe Management

Store and recall up to 100 mix recipes with individual aggregate proportions, bitumen content, and additive dosages.

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24/7 Technical Support

On-site commissioning, training, and spare parts support across 35 countries.

route

National Highways & Expressways

Strict government specifications demand absolute material consistency, met by the precision batch production of this plant.

flight_takeoff

Airport Runway Construction

Demanding precise aggregate grading and uniform binder distribution for critical aviation pavements.

apartment

Urban Municipal Supply

Ideal for commercial suppliers who serve multiple contractors with different mix designs on the same day.

bridges

Bridge & Overpass Decks

Specialized asphalt mixes for bridge decks and overpasses requiring high rut resistance and waterproofing.

What is the key advantage of a batch mix plant over a drum mix plant?expand_more

Batch mix plants offer superior mix quality control because each batch is independently weighed and mixed. This allows for frequent changes in mix design, making them ideal for projects with multiple asphalt grades and stringent quality requirements.

What is the typical batch cycle time?expand_more

Batch cycle time typically ranges from 45 to 60 seconds per batch, depending on the mix design and plant configuration, resulting in production rates of 80–240 TPH (up to 400 TPH).

Can the plant produce different mix grades without stopping production?expand_more

Yes, the plant's recipe management system allows operators to switch between different mix designs seamlessly between batches, without interrupting production.

What fuel options are available for the burner?expand_more

The burner is compatible with Diesel, Heavy Oil, Natural Gas, LPG, and Coal, offering flexibility based on fuel availability and cost.

What is the expected lifespan of the plant?expand_more

With proper maintenance, the plant can operate for 20–25 years. The heavy-duty construction and wear-resistant components ensure long-term reliability.

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