iAsphalt: asphalt plant automation

What you gain

The mix design's bitumen content, in the mixer

The bitumen scale doses with high-accuracy load cells and in-flight correction, batch by batch. Deviation per material is logged, so the lab sample holds no surprises.
Live control in your hand

One live picture of the plant on web, tablet and desktop. The operator commands from wherever they stand, the owner sees the same screen from the office. One system from the controller code to the cloud.
Aggregate and bitumen temperature under control

Thermocouples at the dryer outlet, in the hot bins, in the bitumen tanks and in the oil circuit. The burner is regulated so the mix leaves at the temperature the recipe asks for, not 20 degrees higher just to be safe.
Dryer and burner with less fuel

Automatic ignition, control of fuel-oil or diesel injection and circulation, fuel temperature monitoring. The flame follows the material flow instead of burning at maximum all day.
Hot bins and screen without overflow

Levels per fraction, overflow discharge, current monitoring of screen and elevator. The operator sees where each fraction goes before the wrong bin fills up.
Installed in 1 day

Panel and software are prepared in our workshop. On site we do the changeover, test batches and operator training. The same applies to mobile plants that move from project to project.
Switch cold-feed bins without stopping

When a cold-feed bin runs empty the operator pulls the same fraction from another with one tap, inside automatic production.
Filters and dust working together

Control of baghouse or hydrocyclone, dust screws and filler. Reclaimed dust returns to the recipe as a dosed material, not as an unpredictable addition.
Compliant with international asphalt production standards

Theoretical and actual quantities per fraction, bitumen content, temperatures and mixing time recorded per batch, ready for quality control and for the project owner.
Tonnes and bitumen content on your phone

Every production uploads automatically to the iOLABS Automations Cloud: tonnes per day, recipe and customer, real versus theoretical bitumen content, consumption, batch duration, alerts.
Delivery notes and accounting, connected

Productions feed iAsphalt DMS for delivery notes with myDATA and any accounting package or ERP.

How it works

01
The panel

An iOLABS IP54 panel with main switch, power relays, dosing inverters, motor cabling and a modern Ethernet controller. It replaces the old panel or is fitted onto it, with plug & play wiring on mobile plants.
02
The signals

Load cells of the aggregate, bitumen and filler scales, PT100 thermocouples, level sensors, safety limit switches and ammeters reach the PLC. iAsphalt reads them hundreds of times per second.
03
Cold feed and dryer

Cold feeders dose the recipe's fraction ratios through inverters. The drum dries and heats, the burner is regulated by the outlet temperature, the elevator lifts the material to the screen.
04
Screen, hot bins, weighing

The screen separates fractions into the hot bins. The aggregate scale weighs cumulatively per fraction, the filler scale and the heated bitumen scale dose in parallel, with free-fall correction on every scale.
05
The mixer

Dry mixing, bitumen spray from the nozzles, wet mixing with times per recipe, discharge to the truck or to the storage silo. Mixer current monitoring protects against overload.
06
The record and the cloud

Every batch is stored with theoretical and actual weights, temperatures, time and operator, and uploads automatically to the iOLABS Automations Cloud within seconds.

Modules

Cold-feed dosing

Inverter-driven feeders, ratios per recipe, vibrators, automatic bin switching, collecting belt control.
Dryer and burner

Automatic ignition, fuel injection and circulation, pre-heater, aggregate outlet temperature, safety limit switches, flame regulation.
Screen and hot bins

Levels per fraction, overflow discharge, current monitoring of screen, elevator and screws.
Aggregate, filler and bitumen weighing

Cumulative weighing per fraction, filler scale, heated double-wall bitumen scale discharging to nozzles or pump.
Bitumen tanks and oil heater

Tank and oil-circuit temperatures, tank burners, safety limit switches, tank selection per recipe.
Mixer and discharge

Dry and wet mixing, bitumen spray, times per recipe, discharge to truck or silo, current monitoring.
Filters and dust

Baghouse or hydrocyclone, dust screws, dust return to the recipe, filter motor monitoring.
Productions and reports

Batch printout, consumption of aggregates, bitumen, filler and fuel, deviations, export to accounting and to iAsphalt DMS.
iOLABS Automation Core

Recipes, four operating modes, two-step calibration, self-tuning, maintenance, tablet, users, backups, multilingual.
Learn more

Specifications

Controllers
Controllers	Siemens, Beckhoff and any modern PLC or controller, over standard industrial protocols (Modbus, Profinet, OPC UA). Controller code written by iOLABS.
Control interface	iOLABS Live Control: live screens on web, tablet and desktop; SCADA/HMI functions built in
Communication	Wired network, Wi-Fi for tablet, secure remote support
Architecture	iOLABS Live Control with a secure production database; LEMS (Less Electronics More Stability), ATS (Auto Tuning System), SCS (Self Care System)

Weighing and temperature
Scales	Hot aggregates (cumulative per fraction), filler, bitumen (heated, double wall), optionally reclaimed material
Sampling	Thousands of samples per second, digital filtering, automatic free-fall correction
Temperatures	iOLABS PT100 / thermocouples at dryer outlet, hot bins, bitumen tanks, oil circuit, fuel
Calibration	2 steps by the operator, values logged

Plant
Plant types	Mobile and stationary batch asphalt plants, any capacity
Cold feeders	Inverter control, unlimited bins
Panel	Metal IP54, main switch, power relays, inverters, cabling, controller with wired and wireless communication

Software
Operation	Automatic, semi-automatic, manual, maintenance
Users	Roles and permissions, action log, automatic and manual backups
Languages	Greek, English, extensible
Integrations	iAsphalt DMS, iBridge, any accounting package/ERP, iOLABS Automations Cloud
Compliance	International asphalt production standards

Media

Integrations

References

Greece, GR · 2020

Full reconstruction of a mobile asphalt plant and iAsphalt for TEVAR S.A.

Mechanical and electrical reconstruction of a TEVAR S.A. mobile asphalt plant with new iAsphalt automation. Set up and producing in 1–2 days.
Learn more Full reconstruction of a mobile asphalt plant and iAsphalt for TEVAR S.A.

FAQ

Will iAsphalt fit my asphalt plant?

Yes. iAsphalt is configured for any asphalt plant, from a small mobile unit to a large stationary one, regardless of manufacturer. If the machine has motors, scales, thermocouples and valves, iAsphalt controls them.

How long will the plant be out of production?

One day, including the electrical panel work, test batches and training. We schedule the changeover between projects or on days without deliveries.

Does it control the dryer and the burner as well?

Yes. Automatic ignition, control of fuel injection and circulation, flame regulation from the aggregate outlet temperature and safety limit switches. Where the burner has its own controller, iAsphalt works with it.

How is the bitumen content guaranteed?

Bitumen is weighed on a heated scale with high-accuracy load cells and free-fall correction. The real content per batch is logged and compared with the theoretical value in the report and in the cloud.

Can the operator calibrate the scales alone?

Yes, in two guided steps: zero and known weight. No technician needed. The calibration is logged with date and user.

What happens if a thermocouple or sensor fails mid-production?

The interlock stops only the affected element and alerts the operator. From maintenance mode the operator isolates it and continues semi-automatically, while our engineers connect remotely if needed.

Can I see production on my phone?

Yes, with the iOLABS Automations Cloud. You see tonnes per day, recipe and customer, real versus theoretical bitumen content, consumption and batch duration, with e-mail alerts.

Is there a demo?

Yes. Ask us for a live presentation, in person or online, and see iAsphalt running with your own data. The presentation videos are on iasphalt.eu.

Help

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iAsphalt DMS

Online delivery notes for asphalt and recycled materials, with QR and MARK on myDATA, daily schedule, return notes and accounting integration.
Learn more iAsphalt DMS
iBridge

Weighbridge management: unattended weighing with RFID, first/second weighing tickets, traffic lights and barriers, digital delivery notes with myDATA.
Learn more iBridge
iLoading

Automatic pre-loading of aggregate bins: the operator picks a bin, the system opens belts, diverters and gates in the right order and stops when it is full.
Learn more iLoading
iFleet

Live fleet view, routes, consumption and driver sheets. With a GPS tracker in the vehicle or a tablet running the iFleet Tracker app, no extra hardware.
Learn more iFleet
Service
Bitumen scales

iOLABS-built bitumen scales: double-wall vessel with hot-oil circulation, optional built-in electric oil heater, high-precision load cells.
Learn more Bitumen scales
Service
Thermocouples & temperature sensors

Thermocouples, PT100 resistance thermometers and temperature sensors made by iOLABS, in any diameter, length and thread, for any industrial application.
Learn more Thermocouples & temperature sensors