Asphalt Mixing · AVL-MAP

Mobile Asphalt Plant

Site-Ready Mobile Asphalt Plants Built for Demanding Road Programs

20–120 TPH continuous (up to 160 TPH peak at low inlet moisture)

Output capacity

Model variants

Spare parts

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Overview

The Avelta AVL-MAP is a road-transportable hot-mix asphalt (HMA) plant engineered for civil contractors, road authorities, and construction companies that need production-grade output capacity at multiple project locations without committing to a permanent stationary installation. Available across a model range from 20 TPH to 120 TPH nominal output — with peak rates approaching 160 TPH on dry, well-graded aggregate — the AVL-MAP series addresses the full spread of road-construction programmes: rural feeder roads and district maintenance contracts, urban arterial upgrades, national highway rehabilitation, and airfield pavement works. Every assembly is designed to fit within road-legal trailer dimensions and permissible axle loads, enabling a plant to be stripped, transported to a new site, and restored to production in as little as eight to twenty-four hours on a prepared pad, subject to local haul distances and crew experience.

The plant operates on a continuous drum-mix principle, with an option for an external twin-shaft pugmill for mix designs that demand tighter residence-time control. Cold aggregate fractions are metered from variable-speed belt-feeder bins onto a collecting conveyor and fed into a rotating drying drum, where a multi-fuel burner heats the material to the target discharge temperature of 150–180 °C (302–356 °F) while evaporating inlet moisture. Liquid bitumen is held at controlled temperature in an insulated storage tank and metered by a calibrated pump directly into the aggregate curtain. Mineral filler — drawn from the bag-house recovery system or an independent silo — is added at the same stage. The finished mix discharges into an insulated surge silo or is loaded directly into haulage trucks, depending on site logistics.

What distinguishes a well-engineered Avelta unit is the insistence on conservative design margins, heavy-plate structural fabrication, and a fully integrated pollution-control system treated as standard equipment rather than a cost option. The reverse-pulse jet bag-house filter processes all process exhaust before atmospheric release, routinely achieving stack dust concentrations well below 50 mg/Nm³. The PLC-based control cabin delivers automated recipe management, real-time production data logging, and the ability to integrate remote-monitoring connectivity, reducing dependence on highly skilled operators in remote or infrastructure-limited environments. Avelta supports each AVL-MAP with a structured spare-parts programme and site-commissioning assistance, ensuring the plant reaches design throughput quickly and remains in productive service for the duration of the road contract.

Typical applications

National highway and expressway construction, rehabilitation, and overlay programmes
Airport runway, taxiway, and apron pavement construction and resurfacing
Urban arterial roads, ring roads, and city-bypass construction
Rural and district feeder road construction and periodic maintenance
Bridge approach slabs and structural deck overlay works
Industrial estate, logistics park, and warehouse complex access roads
Port terminal, container yard, and heavy-vehicle apron paving
Mining site haul roads and heavy-axle-load access corridors

Technical DataAVL-MAP

Nominal Output Capacity	20–120 TPH continuous; up to 160 TPH peak (aggregate inlet moisture ≤ 2%)
Drying Drum Dimensions	1.0 m dia. × 4.5 m L (MAP-20) to 2.0 m dia. × 9.0 m L (MAP-120)
Burner Type and Fuels	Multi-fuel rotary swirl-stabilised drum burner; diesel, LDO, or heavy furnace oil (HFO); gas-adaptable on request
Burner Thermal Capacity	0.8–6.5 million kcal/h (model-dependent)
Bitumen / Binder Tank Capacity	15,000–50,000 litres; double-skin insulated; thermic-oil or electric-element heated with circulating pump
Cold-Feed Bins	2–4 bins, 5–12 m³ capacity each; variable-speed belt feeders with individual load-cell calibration
Installed Electrical Power	90–380 kW; 415 V, 3-phase, 50 Hz standard (60 Hz adaptable for export markets)
Dust Collection System	Reverse-pulse jet bag-house filter; 200–600 m² filtration cloth area; typical stack outlet ≤ 50 mg/Nm³
Aggregate Inlet Moisture Tolerance	Up to 5% by weight; automatic burner-trim compensation via PLC signal
Aggregate Discharge Temperature	150–180 °C (302–356 °F), operator-adjustable per mix specification
Hot Mix Surge Silo	Optional 15–60 tonne insulated surge silo with motorised discharge gate and truck-loading chute
Control System	PLC-based SCADA with colour touchscreen HMI; automated recipe management; production logging; alarm history; remote-monitoring-ready
Transport Configuration	2–5 road-legal trailer loads per model; maximum 40 t GVW per move (local regulations apply)
Site Setup Time	8–24 hours on a prepared level pad with power, aggregate supply, and bitumen utilities in place

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Working Principle

How the Mobile Asphalt works

Cold Aggregate Feed and Proportioning

Aggregate stockpiles are loaded into two to four variable-capacity cold-feed bins. Variable-speed belt feeders beneath each bin meter individual size fractions at ratios defined in the active mix recipe, combining them on a single collecting conveyor in the correct proportions before the drum inlet.

Moisture Assessment and Conveying

The blended aggregate stream is carried to the drum by the collecting conveyor. A load-cell system or inline moisture sensor feeds live data to the PLC, which adjusts burner firing rate in real time to compensate for variations in inlet moisture content and maintain consistent aggregate discharge temperature.

Drying and Aggregate Heating

Inside the rotating drum, a multi-fuel swirl-stabilised burner heats the aggregate to the target mix temperature — typically 160–175 °C (320–347 °F) — while fully evaporating residual moisture. Counter-flow drum geometry, in which aggregate travels toward the flame, maximises thermal efficiency and reduces fuel consumption per tonne of output compared with co-current arrangements.

Binder Metering and Introduction

Hot bitumen is circulated continuously from the insulated storage tank through a dedicated heating circuit and metered by a positive-displacement or gear pump calibrated against the aggregate mass-flow signal from the PLC. The binder is introduced into the aggregate curtain at the mixing zone, ensuring uniform coating of all aggregate particles at the correct binder-to-aggregate ratio.

Mixing and Homogenisation

In standard drum-mix configuration, mixing is completed within the rear section of the drying drum before discharge. Where an external twin-shaft pugmill is specified, preheated aggregate and metered binder enter the mixer separately for a defined residence-time blend cycle, offering tighter control of mix homogeneity for polymer-modified or gap-graded mix designs.

Discharge to Surge Silo or Haulage Truck

Finished hot-mix asphalt exits through a drag conveyor or direct discharge chute into an insulated surge silo — available in 15 to 60 tonne capacity — or directly into waiting trucks. The surge silo decouples plant output from variable truck dispatch cycles, preventing production interruptions and temperature loss.

Dust Collection and Emission Control

Exhaust gases and entrained fines are drawn by an induced-draft fan through ductwork into the reverse-pulse jet bag-house filter. Collected mineral filler is mechanically conveyed back to the mixing zone, recovering material value and reducing waste, while the cleaned exhaust gas is discharged to atmosphere at particulate concentrations well within the applicable regulatory limits.

Engineered Advantages

Why buyers specify the Avelta MAP.

Modular Road-Legal Transport Architecture

Every sub-assembly — drum module, control cabin, binder tank, bag-house, and silo — is dimensioned to fit within the road-legal envelope for standard low-bed or flatbed trailers, eliminating the need for special-permit loads on most national road networks and dramatically reducing relocation cost and downtime between contracts.

Counter-Flow Drum Technology for Fuel Efficiency

The counter-flow drum arrangement, in which aggregate travels toward the burner flame rather than away from it, extracts maximum heat from the combustion gases before exhaust. This configuration consistently reduces fuel consumption by 10–15% per tonne of output compared with co-current designs at equivalent moisture conditions, directly lowering operating cost over the life of a contract.

Integrated Reverse-Pulse Bag-House Filtration

A reverse-pulse jet bag-house filter is engineered as an integral part of every AVL-MAP, not a supplementary add-on. Automatic pulse cleaning maintains filter-bag permeability throughout continuous operation, and recovered fines are returned to the mix as mineral filler — reducing material waste and contributing to consistent mix gradation without operator intervention.

PLC/SCADA Automation and Recipe Management

The plant control system stores multiple mix recipes with individual aggregate proportions, binder percentages, and temperature set-points. Production quantities, batch weights, and alarm events are logged automatically for quality-assurance reporting, reducing the scope for operator error and providing auditable data for client or regulatory inspections.

Multi-Fuel Burner Flexibility

The burner is designed from the outset to handle diesel, light diesel oil, and heavy furnace oil without a change of burner body, allowing the contractor to select the most economical or readily available fuel at each project location. Gas-conversion kits are available for sites with pipeline or LPG supply.

Heavy-Plate Structural Fabrication

Primary structural members, drum shells, and feed-bin bodies are fabricated from heavy structural and abrasion-resistant steel plate, with key wear zones protected by replaceable bolt-in liner plates. This conservative approach to material selection extends service intervals and protects residual value when the plant is redeployed or sold.

Factory Pre-Wired and Pre-Plumbed Modules

All electrical wiring, conduit runs, and bitumen piping are completed and tested in the Avelta factory before dispatch, reducing site-assembly time to mechanical bolting and connection of inter-module coupling points. This pre-integration approach also simplifies fault-finding during commissioning and reduces the risk of field wiring errors.

Avelta Global Commissioning and Spare-Parts Support

Avelta dispatches trained commissioning engineers to verify alignment, calibrate feed-belt and binder-pump systems, and conduct mix-design trial runs before handover. A structured spare-parts programme — covering fast-wear items including filter bags, mixing tips, liner plates, and burner components — is maintained for dispatch to any destination, with documentation in major international languages.

Model Range

Choose the capacity for your output.

Model	Capacity	Notes
AVL-MAP-20	20 TPH	Ultra-compact single-trailer unit suited to rural feeder roads, island projects, and small maintenance contracts where site access limits transport	Enquire →
AVL-MAP-40	40 TPH	Standard compact twin-trailer plant; the most widely deployed model for district-level road maintenance programmes and medium-length rural corridors	Enquire →
AVL-MAP-60	60 TPH	Mid-range three-module configuration balancing transport economy with sustained production capacity; suited to state-road rehabilitation contracts	Enquire →
AVL-MAP-80	80 TPH	High-output mobile plant for national-highway resurfacing and new-build works; counter-flow drum option standard at this rating	Enquire →
AVL-MAP-100	100 TPH	Heavy-duty semi-mobile configuration intended for large-scale road programmes with extended on-site duration; twin-shaft pugmill and 40 t surge silo standard	Enquire →
AVL-MAP-120	120 TPH	Maximum-output mobile class for major arterial and expressway projects; near-stationary deployment with full bag-house, surge silo, and filler-recovery system	Enquire →

Spare Parts