Polymer Modified Bitumen Plant (PMB)

What Is Polymer Modified Bitumen (PMB)?

Polymer modified bitumen (PMB) is a binder made by adding a polymer such as SBS to bitumen and dispersing it homogeneously in a high-shear mill. The polymer gives the bitumen elasticity: the pavement becomes far more resistant to rutting at high summer temperatures, to cracking at low winter temperatures and to fatigue under heavy traffic.

The most widely used polymer is SBS (styrene-butadiene-styrene). Polymers such as SBR, EVA and APP are also used; when crumb rubber is used instead of a polymer, the product is called crumb rubber modified bitumen (CRMB). Depending on the recipe, additives such as aromatic oils and softeners, sulphur as a crosslinker and PPA are added.

PMB is not used only in road surfacing: waterproofing membranes, crack and joint sealants, modified emulsions and industrial bituminous products are also made with polymer modified bitumen.

What Is a Polymer Modified Bitumen Plant?

A polymer modified bitumen plant (PMB plant) is the production unit that weighs hot bitumen and polymer to the recipe ratio, mixes them and passes them through a high-shear mill so that the polymer is dispersed finely and homogeneously in the bitumen. The plant combines bitumen and polymer feeding, the mixing tank, the mill, heating, automation and dispatch of the PMB to the storage tank.

Vimpo VPM Polymer Modified Bitumen Plant

The Vimpo VPM series is offered with a maximum capacity of 5 – 50 t/h in two production types: batch (VPM-B) and continuous (VPM-C). The batch type passes the mix through the mill by circulation, for the number of passes set in the recipe; it suits small and mid-size PMB producers and asphalt plant owners. The continuous type produces in a single pass through the mill with metered feeding; it is designed for large refineries, terminals and operations running large, uninterrupted production. Both types are built with thermal oil jacketed or electric heating with PT100 temperature control.

Batch plants use our own Vimpo VCM-P MultiShear™ high-shear colloid mill and load-cell weighed mixing tanks; continuous plants use a Buckau-Wolf Supraton® mill, a Coriolis mass flowmeter and gravimetric SBS dosing. All plants are recipe-controlled by PLC and SCADA, and are built and tested on a skid with an air-conditioned control cabin at our Ankara factory.

Why Vimpo PMB Plants?

• Milling technology: our own design and manufacture Vimpo VCM-P MultiShear™ high-shear colloid mill in the batch type, Buckau-Wolf Supraton® mill in the continuous type
• Dosing precision: a repeatable, recipe-bound polymer content with load-cell weighed tanks, Coriolis mass flowmeter and gravimetric SBS dosing
• Reliable, proven design: a process proven by plants in operation — our PMB references include Colas, Lukoil, Puma Energy and İstanbul Teknik
• Experience in asphalt and bitumen processing since 1997; Vimpo equipment operating in more than 40 countries
• Our own design office in Ankara — engineering with SolidWorks and ANSYS
• Mills, bitumen pumps and mixing tanks are made in our own factory — 10,000 m² of covered production area
• Batch or continuous, thermal oil or electric heating, optional additive lines — one series for every need
• CE marked; ISO 9001 · ISO 14001 · ISO 45001
• Commissioning, operator training and spare parts support from Ankara, Herford (Germany) and Pune (India)

How Does a Polymer Modified Bitumen Plant Work?

Batch Type (VPM-B) — Circulation, Multi-Pass

Bitumen is pumped from the storage tank into the load-cell mixing tank and the recipe quantity is weighed. SBS is fed into the tank by screw conveyor; two 7.5 kW agitators disperse the polymer in the bitumen. The mix passes through the Vimpo VCM-P MultiShear™ mill and returns to the tank — this circulation is repeated for the number of passes defined in the recipe. Mixing time and temperature are controlled automatically; when the recipe is complete, the PMB is sent automatically to the storage tank.

VPM-T-B-5, VPM-T-B-10 and VPM-E-B-10 have a single mixing tank. VPM-T-B-20 and VPM-E-B-20 have two mixing tanks: one tank is filled and weighed while the other is being milled, so the mill never stands idle.

Continuous Type (VPM-C) — Single Pass

Bitumen is fed by a VFD-controlled Vimpo VN pump and metered by a Coriolis mass flowmeter. SBS is dosed gravimetrically to the recipe ratio from a 1,800 kg weighed bunker by rotary valve and screw conveyor. Bitumen and SBS combine in a 1,000 kg load-cell premix tank with a 5.5 kW agitator and pass to the storage tank in a single pass through the Buckau-Wolf Supraton® mill. Production is uninterrupted; recipes and dosing are managed from the operator panel. If required, premix bitumen can be sent directly to the tanks through the by-pass line.

Vimpo VPM PMB Plant Features

Two Production Types

The batch type (VPM-B) circulates the mix between the mill and the tank and produces different recipes and high polymer contents flexibly, with the required number of passes. The continuous type (VPM-C) works in a single pass through the mill with metered feeding for high, uninterrupted production. Both types are offered with thermal oil or electric heating.

MultiShear™ High-Shear Mill

Batch plants use the Vimpo VCM-P MultiShear™ mill, our own design and manufacture: VCM-P-10 is direct coupled with 90 kW; VCM-P-20 runs at a mill speed of 1,950 rpm with a 160 kW motor and belt-and-pulley drive. The mills are rated for 13 bar working pressure and have a thermal oil or electrically heated jacket. Continuous plants use Buckau-Wolf Supraton® 349-5.03 (90 kW),449-5.03 (132 kW) and 549-5.03 (250 kW) mills.

Precise Dosing

In batch plants each mixing tank is weighed by 4 load cells. In continuous plants the bitumen flow is measured by a Coriolis mass flowmeter, SBS is dosed gravimetrically from the weighed bunker and the premix tank is monitored by 3 load cells. The polymer content therefore stays bound to the recipe and repeatable.

Recipe-Controlled Automation

The plant is managed by PLC and SCADA through an industrial operator panel and computer. Mixing time and temperature are controlled automatically; transfer from the mill to the tank and dispatch of the PMB to the storage tank are automatic. All process valves are pneumatically actuated and operated from the operator panel. The control cabin is air-conditioned; panel protection is IP54 indoors and IP55 outdoors.

Heating Options

In thermal oil heated (T) plants the tank, mill, pump and all lines are jacketed; a Vimpo VTH thermal oil heater can be used as the heat source. In electric (E) plants the tank, pump, mill and all process lines are electrically heated and the temperature is controlled by PT100; no thermal oil system is needed on site.

Quality Components

The bitumen and mill feed pumps are our own Vimpo VN helical gear pumps. Continuous plants use Siemens PLC and SCADA, and the 20 and 30 t/h models use a KROHNE Coriolis flowmeter (Endress+Hauser on the 50 t/h model) and ABB drives; Schneider Electric or Eaton switchgear, Weidmüller terminals and VEGA level safety are used. Cabling is UV resistant and EMC compliant.

Certified Manufacturing

VPM plants are CE marked and built to the 2006/42/EC Machinery Directive and 2014/30/EU EMC Directive, with electrical equipment to EN IEC 60204-1 and EN IEC 61439. The bitumen and heating lines of continuous plants are made of drawn P235GH steel pipe, TIG welded to EN ISO 3834, for 16 bar / 230 °C design conditions.

Optional Additive Lines

Both plant types can be fitted, depending on the recipe, with aromatic oil and softener (flux oil) dosing, sulphur dosing as a crosslinker, PPA dosing and a thermal oil heat exchanger that heats the bitumen before the mill. Liquid additives are dosed by Coriolis flowmeter and VFD-controlled additive pump, solid additives by weighed bunker and screw conveyor. In batch plants the SBS feeding can be automated with the Vimpo VPM-DOS-2000 gravimetric dosing unit.

Polymers and Additives That Can Be Used

VPM plants can produce with the polymers and additives commonly used on the market: SBS polymers such as Kraton™, Calprene®, Globalprene® and Kumho KTR, APP (atactic polypropylene) for membrane production, EVA, Elvaloy™ RET reactive polymer and PPA. The recipe is set together during commissioning according to the polymer type and content.

Crumb Rubber Modified Bitumen (CRMB)

VPM plants can also produce crumb rubber modified bitumen (CRMB) with crumb rubber from end-of-life tyres. CRMB brings waste tyres back into road construction and gives the pavement elasticity, fatigue and rutting resistance. The rubber content and feeding system are sized per project.

Brand names mentioned are trademarks of their respective owners.

Polymer Modified Bitumen Plant Models

In the VPM series the model code shows the heating type (T: thermal oil, E: electric), the production type (B: batch, C: continuous) and the maximum capacity.

Batch Type Models

• VPM-T-B-5: max. 5 t/h · VCM-P-10 mill (90 kW) · 1 × 5 m³ mixing tank · VN636 pump · thermal oil
• VPM-T-B-10: max. 10 t/h · VCM-P-10 mill (90 kW) · 1 × 10 m³ mixing tank · VN636 pump · thermal oil
• VPM-E-B-10: max. 10 t/h · VCM-P-10 mill (90 kW) · 1 × 10 m³ mixing tank · VN636 pump · electric, PT100
• VPM-T-B-20: max. 20 t/h · VCM-P-20 mill (160 kW) · 2 × 10 m³ mixing tanks · VN863 pump · thermal oil
• VPM-E-B-20: max. 20 t/h · VCM-P-20 mill (160 kW) · 2 × 10 m³ mixing tanks · VN863 pump · electric, PT100

Get a quote for VPM-B on WhatsApp

Continuous Type Models

• VPM-T-C-20: max. 20 t/h · Supraton® 349-5.03 mill (90 kW) · 1,000 kg premix tank · thermal oil
• VPM-E-C-20: max. 20 t/h · Supraton® 349-5.03 mill (90 kW) · 1,000 kg premix tank · electric, PT100
• VPM-T-C-30: max. 30 t/h · Supraton® 449-5.03 mill (132 kW) · 1,000 kg premix tank · thermal oil
• VPM-E-C-30: max. 30 t/h · Supraton® 449-5.03 mill (132 kW) · 1,000 kg premix tank · electric, PT100
• VPM-T-C-50: max. 50 t/h · Supraton® 549-5.03 mill (250 kW) · 2,000 kg premix tank · thermal oil

The 20 and 30 t/h continuous plants are delivered on an 8,900 × 2,300 × 2,200 mm chassis.

Get a quote for VPM-C on WhatsApp

Elvaloy™ RET PMB Tank: PMB Without a Mill

1 Feed hoppers · 2 Agitators 15 kW · 3 Rock wool insulation · 4 Thermal oil coil — Illustration, not to scale.

Elvaloy™ RET is a reactive elastomeric terpolymer. It melts into hot bitumen and bonds chemically with it, so a high-shear mill is not necessary. The Vimpo Elvaloy™ RET PMB tank is a heated, insulated VBT bitumen tank with agitators and feed hoppers. It is a lower-cost PMB option next to the VPM plants with mills, for asphalt plant owners, contractors and terminals that make PMB from their own bitumen.

How Does It Work?

1. Fill the tank with hot bitumen. Thermal oil heating keeps the bitumen at process temperature.
2. Add Elvaloy™ RET through the feed hoppers. Load cells on the hoppers can weigh each dose.
3. Mix with the agitators: one 15 kW agitator for each hopper. A frequency converter can set the agitator speed.
4. Add PPA as the catalyst and continue to mix. Then send the PMB to storage or to the asphalt plant.

Elvaloy™ RET Tank Models

• VBT-T-H-50-50-AG-RET: 50 m³ gross volume · 40 t batch · 6 mm shell plate · 50 mm rock wool, galvanized cladding · 3 × 15 kW agitators, 127 rpm · 3 manual feed hoppers · thermal oil
• VBT-T-H-100-100-AG-RET: 100 m³ gross volume · batch per project · 8 mm shell plate · 100 mm rock wool, galvanized cladding · 4 × 15 kW agitators, 127 rpm · 4 manual feed hoppers · thermal oil
• Options: speed control with frequency converter · load cells on the hoppers · pneumatic valves

Typical Process Values (Published Data)

• Elvaloy™ RET content: 0.7 – 2 % of the bitumen mass. Do not go above 2.5 %: the bitumen can gel.
• PPA (catalyst): 0.2 – 0.3 %, after Elvaloy™ RET. Do not add Elvaloy™ RET after PPA.
• Mixing time: 2 – 3 h (Dow); typically 4 h from Elvaloy™ RET addition to ready binder.
• Temperature: set to the recipe (laboratory studies: 185 °C).

™ Elvaloy is a trademark of Dow or an affiliated company of Dow. Process values are typical published values (Dow, DuPont / AMAP, academic studies),not a guarantee. The recipe is set for the base bitumen and the target grade by laboratory test at commissioning.

Which PMB Plant Is Right for You?

The right model is chosen by your production scale, capacity need, the heating infrastructure on site and the product you will make.

• Batch (VPM-B) — small and mid-size producers, asphalt plant owners: for contractors and plants producing their own PMB, frequent recipe changes, high polymer contents and different PMB grades. The mix circulates through the mill; the number of passes is set by the recipe.
• Continuous (VPM-C) — large refineries and large-scale producers: for operations with high, uninterrupted output such as refineries, bitumen terminals and producers selling PMB. Bitumen and SBS are metered and production runs in a single pass through the mill.
• Capacity: daily PMB demand and operating hours set the maximum capacity — 5, 10 or 20 t/h in the batch type; 20, 30 or 50 t/h in the continuous type.
• Heating: T if a thermal oil system is on site; otherwise, or if the power supply allows, E (electric, PT100 controlled).
• Product and additives: the recipe follows the product — road PMB, membrane or sealant; aromatic oil, softener, sulphur and PPA dosing lines and the heat exchanger are optional on both types.

Tell us your production target and we will size the right VPM model together.

Standard Scope

• High-shear mill and bitumen / mill feed pumps
• Batch type: load-cell mixing tank or tanks and agitators; continuous type: load-cell premix tank
• SBS feeding: screw conveyor in the batch type, weighed bunker and gravimetric dosing in the continuous type
• Thermal oil jacketed or electric heating with PT100 control; rock wool insulation
• Pneumatically actuated process valves
• Air-conditioned control cabin, switchgear and control panel, PLC and SCADA
• Factory tests, technical data sheet, CE declaration of conformity and operating manual

The thermal oil heater, bitumen and PMB storage tanks and civil works are outside the scope unless expressly quoted.

Where Is Polymer Modified Bitumen Used?

Besides road surfacing exposed to heavy traffic and a wide temperature range, PMB is also used in waterproofing and sealing products that require elasticity and adhesion:

• Motorways and heavy traffic: wearing courses resistant to rutting and fatigue
• Airports and bridges: runway, apron, taxiway and bridge deck surfacing
• SMA and porous asphalt: stone mastic and porous asphalt mixes
• Waterproofing membranes: bituminous membranes for roofs, foundations and bridges
• Crack and joint sealing: crack sealants and joint sealants for asphalt and concrete pavements
• Modified emulsions: chip seal and micro-surfacing binders — with bitumen emulsion plants
• Refineries and terminals: PMB production, storage and tanker loading
• Asphalt plants: PMB production next to the plant

Why Use Polymer Modified Bitumen?

• Rutting resistance: a pavement more resistant to permanent deformation at high temperatures
• Cracking resistance: a more flexible binder at low temperatures
• Fatigue life: longer service life under heavy, repeated loads
• Elastic recovery: a binder that regains its shape after the load is removed
• Less maintenance: longer-lasting pavements with fewer repairs and traffic closures

Frequently Asked Questions About Polymer Modified Bitumen Plants

How Is a Polymer Modified Bitumen Plant Operated?

The plant and lines are brought to operating temperature by the heating system. The operator selects the recipe on the SCADA screen — polymer content, mixing time, temperature and, in the batch type, the number of passes — and starts production. Weighing, dosing, mixing, milling and dispatch to the storage tank run automatically while the operator monitors the values on screen. At the end of production the lines and the mill are emptied. Vimpo carries out commissioning and operator training on site.

Do You Need a Mill to Make PMB With Elvaloy™ RET?

No. Elvaloy™ RET melts into hot bitumen and disperses by agitation. A heated tank with agitators, the Elvaloy™ RET PMB tank, is sufficient. To make PMB with SBS, the polymer must be milled; for this, use a VPM plant with a VCM-P MultiShear™ mill.

What Determines the Price of a Polymer Modified Bitumen Plant?

PMB plant prices depend on capacity, production type (batch or continuous), heating type, mill model, options such as automatic dosing and additive lines, and whether storage tanks and a thermal oil heater are in the scope. For a fair comparison, look not only at the initial investment but also at product quality, energy consumption and after-sales support. Contact us for a price by model and scope.

How Is a Polymer Modified Bitumen Plant Maintained?

• Daily: temperatures, pump and mill pressures, agitators, and leak checks on flanges, valves and seals.
• Periodic: wear check of the mill rotor and stator, bitumen filter cleaning, pump and mill seals, lubrication.
• Calibration: regular checks of load cells and flowmeters — the accuracy of the polymer content depends on them.
• Heating: leak checks on thermal oil lines; heater and PT100 checks in electric plants.

Vimpo provides spare parts and after-sales service for the VPM series.

What Safety Precautions Are Needed in a PMB Plant?

• Hot bitumen and surfaces: heat-resistant gloves, face shield and work clothing must be used; lines must be insulated.
• Contact with water: water entering hot bitumen causes sudden foaming and overflow; water must be kept out of tanks and lines.
• Mill maintenance: power must be isolated and locked out before working on the mill and agitators.
• Polymer dust: the SBS feeding area must be kept clean and dust build-up prevented.
• Safety interlocks: level, temperature and pressure interlocks must never be bypassed.

Common Problems in PMB Plants

• Polymer not dispersing homogeneously: the temperature may be low, the number of passes insufficient or the mill worn.
• Polymer content drifting: load cell or flowmeter calibration, bridging in the SBS feed.
• High mill current: polymer content or feed rate above the mill capacity.
• Separation in storage: insufficient agitation and temperature in the PMB storage tank.
• Fluctuating pump pressure: clogged filter, low temperature or insufficient suction.

Polymer Modified Bitumen Plant Quotation

Tell us your production capacity, polymer type, heating preference and site conditions; we will recommend the right VPM model and send the technical data sheet and quotation. Contact us, write to info@vimpo.com or call +90 312 354 85 09.