High Quality Asphalt Batch Mix Plant Manufacturer, Exporter in India
At Vinayak Equipment, we are a prominent asphalt Batch Mix Plant Manufacturer, Supplier, and Exporter offering a highly efficient system, technologically advanced, and capable of producing high-quality and consistent asphalt mixtures used in road construction and various infrastructure projects. Designed to accommodate the needs of present-day paving, this plant guarantees the precision of every batch, providing full control over the proportion of materials, mixing time, and temperature. The modular design also makes it easy to lug around and makes the plant flexible to meet project requirements. Having a drying drum, vibrating screen, hot bins, weighing systems, and a twin-shaft mixer, the plant ensures uniformity and reliable mix. In addition, the excellent burner system guarantees the most efficient transfer of heat with minimum consumption of fuel and serves as a cost-effective solution. Low-maintenance and user-friendly control systems with high build quality provide a smooth operation and zero downtime to contractors.
The plant will have a fully automated PLC or SCADA control panel with easy decision-making while leveraging operations with supreme ability for regulation and changing important values in real-time, and maintaining immense performance and reliability. Primary cyclones and bag filters are installed to limit the release of emission products and guarantee adherence to environmental criteria. Efficient heating and insulation systems are offered in storage silos and bitumen tanks, ensuring the integrity of the material during the production process. The structure is specifically developed to provide optimal safety, serviceability, convenient platforms, and easy-to-maintain layouts. The Asphalt Batch Mix Plants can either be installed in small-scale or large projects, and the standard capacity of such plants varies between 80 TPH to 160 TPH or even higher. These plants have achieved the success of providing proven performance at low operation costs as well as adaptation to the environment, which has made them the backbone of high-road development programs all over the world. It doesn’t matter whether you are on a backcountry highway or a city expressway. This plant provides dependable production of asphalt regardless of time and place. Choose us as your reliable and trusted partner for an Asphalt Batch Mix Plant manufacturer in India.
- Compact, modular design for quick setup
- Automated control with PLC/SCADA system
- High-efficiency mixing unit
- Accurate weighing for aggregates and bitumen
- Effective dust and pollution control
- Energy-saving burner and drying drum
- Optional storage silo
- Customizable output capacity
- Highways and expressways
- Urban and municipal roads
- Airport runways
- Industrial roads and SEZs
- Rural road projects
- Bridge decks and bypasses
| Output Capacity | 80–160 TPH |
|---|---|
| Cold Feed Bins | 4–5 bins |
| Dryer Drum | Thermally insulated, counterflow type |
| Burner Type | Diesel / Furnace Oil / Natural Gas |
| Mixing Time | 45–60 seconds |
| Control System | Fully automatic PLC / SCADA |
| Hot Bin Storage | 4 compartments |
| Bitumen Tank Capacity | 15,000 to 30,000 litters |
| Filler Storage | Separate silo with screw conveyor |
| Dust Collector | Primary cyclone + bag house filter |
Process of Asphalt Batch Mix Plant
1) Cold Aggregate Feeding
A mixture of varying sizes is premised in cold feed bins.
They are fed into a vibrating screen by conveyor belts.
The screen weeds out excessively bulky materials and provides correct gradation.
2) Drying &Heating
Screened aggregates are fed into a rotary evaporator that uses a burner.
The burner is a diesel, LDO, or gas-fired one, which produces abundant heat.
The aggregates are heated to the necessary temperature (150-190 C) and stirred within the drum in the form of tumbling.
3) Hot Screening & Storage Aggregates
The hot aggregates are then taken directly to the vibrating hot screen using a bucket elevator after heating.
They are segregated into various sizes and are kept in hot bins above the mixing unit.
4) Weighing System
The weighing is important.
The recipe is followed, and each component (aggregates, bitumen, filler) is weighed in individual weigh hoppers.
5) Strategies to Mix in Twin-Shaft Mixer
All measured ingredients are introduced in a pugmill or twin-shaft mixer.
Firstly, there is a dry mix and then bitumen and filler are added.
Mixing of the batch is done at a stipulated time (normally 30-40 seconds).
6) Convection and storage
The hot mix asphalt is then pushed into a silo or straight into loading trucks.
Optional: Eco-friendly operation is guaranteed by a pollution control unit (such as a bag house filter or wet scrubber).
Components of an Asphalt Batch Mix Plant
Function: It stores and dispenses various sizes of aggregates in proportional measure.
Feature: Heterogeneous bins with motor variable speeds to maintain a constant flow of material.
Automation: Is fitted with load cells or frequency drives to feed accurately.
Collecting Conveyor: This conveyor takes aggregates from the feeder bins and puts them into the loading conveyor.
Charging Conveyor: Transfers the mix of cold aggregates to the drying drum.
Advantage: It guarantees the continued and smooth flow of aggregates.
Purpose: Drives out the water contained in aggregates and warms them evenly.
Burner Type- Oil, gas, or dual-fuel burners that are temperature-controlled.
Efficiency: Flight design and proper insulation to save heat and fuel.
Role: Separates hot aggregates of various sizes prior to batching.
Positioning: The tower positioning is on the mixing tower.
Advantage: The Aggregate gradation of the high-quality mix is correct.
Function: It elevates hot aggregates off the dryer to the vibrating screen.
Mechanism: a bucket-type elevator made out of heat-resistant material.
Description: Takes the separated hot aggregates temporarily after screening.
Segregation: Normally partitioned into 4-5 sections.
Significance: Acts as a cushion prior to accurate weighing and blending.
Aggregate Weigh Hopper: This is able to measure each fraction before being mixed.
Bitumen Weighing Tank: Checks correct asphalt binder dosing.
Filler Weigh Hopper: Putts in mineral fillers in the right proportion.
Main Function: Final mixing of weighed aggregates, bituminous, and fillers.
Feature: Twin-shaft to provide speedy and uniform mixing.
Control: The timing of the batches and sequence is fully automated.
Function: It traps the dust and fine particles formed in the process of drying.
Type: Bag filters or wet scrubbers of high efficiency.
Compliance: The standards achieved are suitable locally and internationally.
Function: The storage of bitumen at the necessary temperature.
System: Contains heating coils, temperature controls, and circulation pumps.
Use: Stocks and feeds mineral fillers such as stone dust, lime, or fly ash.
Delivery: By screw conveyor to the weigh hopper.
Core Role: The Control system at the center controls everything in the plant.
Technology: PLC or SCADA-based automation to monitor in real-time, have diagnostics, and remote access.
Operator Comfort: Air conditioned, ergonomically made.
Use: Station the hot prepared mix before loading into trucks.
Features: Hot and insulated to help maintain the temperature.