Stationary hot mix asphalt plants are fixed installations, designed for non-portable operation, and are typically deployed for large-scale, long-term asphalt production projects. These plants are indispensable for producing high-quality asphalt mixes, which are critical materials for the construction of vital infrastructure such as roads, highways, airport runways, parking lots, and various building applications.
Batch mix plants, specifically, offer exceptional precision and flexibility in controlling the composition of the asphalt mixture. This allows for the production of asphalt with consistent quality and the adaptability to meet diverse project specifications, which is paramount for modern infrastructure demands. The inherent nature of stationary plants, requiring substantial upfront investment and a stable production site, indicates Polygonmachine’s strategic focus on clients involved in major, enduring infrastructure development rather than temporary or smaller-scale projects. The product features, such as high capacity, robust durability, and comprehensive support services, are meticulously tailored to meet the rigorous demands and extended operational lifecycles characteristic of such large-scale endeavors. This strategic alignment ensures that Polygonmachine’s product development is concentrated on delivering reliability and long-term performance, qualities that are of utmost importance to these clients.
Core Components and Functional Architecture
1. Aggregate Storage and Handling Systems
The initial stage of asphalt production involves the precise handling of aggregates. Polygonmachine’s plants are equipped with robust storage bins or silos designed to hold various sizes of aggregates, including sand, gravel, and crushed stone. These materials are systematically sorted and fed into the plant for subsequent processing. The cold aggregate bunkers are typically constructed from 5mm St 37 sheet, each with an approximate capacity of 20m³, and feature 800mm high upper additions to effectively prevent material overflow.
2. High-Efficiency Drying and Heating Units (Rotary Dryer, Burner Group)
Following aggregate handling, the materials undergo a crucial drying and heating process within a rotary drum or dryer. This step is vital for removing moisture and elevating the aggregates to the precise temperature required for optimal asphalt mixing. Polygonmachine’s dryers are engineered with specialized wing designs that maximize the heat transfer surface, enabling efficient humidity removal with minimal fuel consumption.
3. Bitumen Storage and Dosing Systems (Bitumen Tanks, Pumps)
The plant incorporates dedicated storage tanks for the asphalt binder (bitumen), which are heated to a specified temperature prior to mixing with the aggregates. These bitumen tanks are specialized, insulated containers meticulously designed to heat and maintain bitumen at a workable temperature, thereby ensuring a steady supply for continuous production. The capacity and number of bitumen tanks can be customized based on the overall size of the asphalt plant and specific production requirements, with examples including 30-ton capacity tanks.
4. Precision Mixing Unit (Asphalt Mixer, Hot Aggregate Elevator)
The mixing unit represents the central component of the asphalt plant, where the heated aggregates and asphalt binder are precisely combined to produce the hot mix asphalt. Polygonmachine offers flexibility in mixing technology, providing both drum mixers, which are suitable for higher production rates, and batch mixers, which offer precise control and adaptability, depending on specific project needs.
5. Advanced Dust Collection and Filtration Systems
Environmental protection is a critical consideration in asphalt plant design, and Polygonmachine addresses this with advanced dust collection and filtration systems. These systems are essential for collecting and eliminating dust and particulate matter generated during the drying and mixing processes. The systems typically incorporate cyclones or baghouse filters, such as the Jet-Pulse filter body , which efficiently capture particles before exhaust air is released into the atmosphere.
6. Integrated Automation and Control Systems (SCADA, User Interface)
The control system acts as the central “brain” of the plant, meticulously supervising and directing the entire asphalt production process. This state-of-the-art computer-based system ensures accurate measurement and mixing of aggregates and asphalt binder, precise control of drying and heating processes, and efficient management of the overall production flow. User-friendly interfaces are integrated to allow plant managers to monitor operations in real-time and adjust parameters as needed, ensuring consistent high-quality asphalt production.
Polygonmachine actively embraces Industry 4.0 principles, integrating advanced sensors, PLC/SCADA control systems, and connectivity features for real-time process data collection and remote operation. Their mobile and stationary units can be equipped with GPS tracking, remote telemetry, and diagnostic SCADA systems, which are instrumental in optimizing output consistency. This deep integration of Industry 4.0 technologies transforms Polygonmachine’s plants into intelligent, self-optimizing production units. Beyond basic automation, the application of SCADA and remote telemetry facilitates predictive maintenance, real-time diagnostics, and data-driven operational adjustments. This proactive approach minimizes unexpected breakdowns, optimizes resource utilization (e.g., fuel, aggregates), and ensures consistent product quality by continuously adapting to changing conditions. For clients, this translates to maximum uptime, reduced operational costs, and higher confidence in meeting stringent project specifications, solidifying Polygonmachine’s position as a provider of advanced, future-ready solutions. Studies indicate that such automated control systems can significantly boost productivity, increasing plant capacity by up to 16% and improving product quality while cutting shutdowns by more than half.
Technical Specifications and Capacities
Polygonmachine offers a comprehensive series of stationary batch asphalt plants, designated under the “PBA” series, which are engineered to meet a wide spectrum of production needs across various project scales. This series encompasses a broad range of models, including the PBA 40-60 Tph, PBA 60-80 Tph, PBA 80-100 Tph, PBA 100-120 Tph, PBA 120-140 Tph, PBA 140-160 Tph, PBA 160-200 Tph, PBA 200-240 Tph, PBA 240-320 Tph, and PBA 320-400 Tph. The precise naming convention (PBA XX-YY Tph) directly reflects the production capacity range, simplifying client selection and demonstrating a clear product segmentation strategy. By clearly labeling models with their TPH range, Polygonmachine makes it straightforward for potential clients to identify the plant that precisely matches their project scale. This transparency in product naming facilitates efficient decision-making and underscores the company’s commitment to meeting specific market demands across various project sizes, from medium to very large infrastructure developments.
For instance, a 160 TPH plant is specifically designed for production under standard conditions, including an initial moisture content of 4% in aggregates, a finished product temperature of 160°C, an aggregate inlet temperature of 10°C, operation at sea level altitude, an average feed aggregate density of 1.650 kg/m³, and specific calorific values for various fuel types. These detailed operational conditions provided for the 160 TPH plant serve as a crucial benchmark for performance expectations across the entire PBA series.
Energy Efficiency and Optimized Fuel Consumption
Polygonmachine’s asphalt plants are inherently designed for energy efficiency, aiming to achieve minimal waste throughout the production process. They incorporate high-efficiency rotary dryers and burners, specifically engineered for minimum fuel consumption. Furthermore, energy-efficient electric motors are integrated with Variable Frequency Drives (VFDs) to precisely match crusher speed to demand, thereby reducing overall energy consumption. As an optional enhancement, hybrid powerpacks (diesel-electric) can be utilized to further reduce fuel use and associated emissions. Polygonmachine’s strong focus on energy efficiency offers direct economic benefits to clients through significantly reduced operating costs. Fuel and energy represent major operational expenses for asphalt plants. By designing high-efficiency dryers, burners, and integrating VFDs, Polygonmachine directly assists clients in lowering their asphalt production costs. This cost-effectiveness enhances the competitiveness of their clients in project bidding and improves their profit margins, making Polygonmachine plants a more financially attractive investment in the long term.
Versatility for Diverse Asphalt Mix Production (Mastic, Colored, Recycled)
Polygonmachine plants demonstrate considerable versatility, being suitable for the production of various asphalt types, including specialized mixes such as mastic asphalt, colored asphalt, and recycled asphalt. The plant design also allows for the seamless integration of various additives, such as fiber additives, modified bitumen, and foam asphalt, as well as recycling asphalt units. The versatility to produce various asphalt types, including recycled asphalt, positions Polygonmachine as a responsive and future-oriented supplier. Modern infrastructure projects increasingly demand specialized asphalt mixes for specific climate conditions, aesthetic purposes, or sustainability goals. Polygonmachine’s plants’ ability to produce mastic, colored, and recycled asphalt enables clients to cater to a broader range of project requirements and market demands. The inclusion of recycled asphalt production capability is particularly significant, aligning with global sustainability trends and offering clients cost savings through material reuse, thereby enhancing their competitive edge in the market.
Comprehensive After-Sales Support and Spare Parts Availability
Polygonmachine provides extensive after-sales support, including 7/24 service availability. A key advantage highlighted is the possibility of obtaining asphalt mixing plant spare parts at reasonable prices. The company maintains critical parts in stock and offers a 2-year plant warranty. This robust after-sales support system, encompassing 24/7 support, readily available spare parts, and comprehensive maintenance services, is a critical component of Polygonmachine’s value proposition, extending significantly beyond the initial sale. For heavy machinery, uptime is paramount. The availability of continuous support and accessible, affordable spare parts directly minimizes costly downtime due to unexpected breakdowns or routine maintenance. This comprehensive support system ensures operational continuity for clients, reduces their long-term operational risks, and fosters strong, trusting relationships, which are vital in the capital-intensive construction equipment market. It contributes significantly to a favorable total cost of ownership (TCO) for the client. Polygonmach machinery is also capable of meeting the needs for transportation, revision, maintenance, and spare parts for various brands and types of asphalt plants.