For road construction businesses aiming to streamline asphalt production and aggregate supply, one common question is whether a 100tph asphalt mixing plant can work efficiently with a 200tph stone crushing plant. This article explores the feasibility, advantages, and practical points of combining these two capacities—and how such a setup can actually help reduce costs, improve efficiency, and ensure consistent quality in road and bridge projects.
Understanding the Capacity Difference Between Asphalt and Aggregate Plants
At first glance, the numbers might seem mismatched. Why pair a 100tph asphalt mixing plant with a 200tph aggregate crushing line? To answer this, we must look at how much aggregate is actually needed to produce asphalt.
How Much Aggregate Does a 100tph Asphalt Plant Use?
Typically, hot mix asphalt consists of about 95% aggregates by weight and only around 5% bitumen. This means a 100tph asphalt plant requires about 95 tons of aggregates per hour. So, to maintain stable production, the crushing plant must deliver slightly more than 100tph of usable aggregates, accounting for gradation losses and stockpiling.
This is where a 200tph aggregate plant offers a strategic advantage. Even if you run it at half its maximum output, it still delivers the required volume. More importantly, it provides flexibility, stockpile options, and backup supply if you need to ramp up asphalt production temporarily.
Benefits of Pairing a 100tph Asphalt Plant with a 200tph Crusher
Though the asphalt plant’s production rate is lower, combining it with a higher-capacity crusher makes a lot of sense from an operational and business point of view.
1. More Reliable Aggregate Supply
Inconsistent aggregate supply can lead to asphalt plant downtime. A 200tph aggregate crushing plant can easily build up stockpiles ahead of time, ensuring that the asphalt plant always has the right mix of material. This improves overall stability and reduces production delays.
2. Flexibility to Handle Multiple Projects
With extra crushing capacity, you can produce different sizes of aggregates at the same time—such as 0-5mm for asphalt, and 10-20mm or 20-40mm for concrete or road base. This setup helps you serve multiple construction needs without additional investments in new crushing lines.
3. Efficient Use of Equipment and Manpower
Crushing at 200tph doesn’t mean you must run at full capacity all day. You can run the crusher intermittently to build buffer stock while minimizing fuel, labor, and wear. This gives you greater control over plant operations and helps reduce cost per ton of aggregate produced.
4. Easier Expansion for Future Demand
If your project expands or you win new contracts, the existing 200tph crushing plant gives you the ability to upgrade your asphalt plant—say, to 120tph or 160tph—without needing to invest in a new crusher.
What to Consider for a Well-Matched Setup
While the 100tph and 200tph capacities can work together well, certain aspects need careful planning to ensure compatibility and optimal performance.
Material Handling and Stockpiling
You’ll need enough space for storing various aggregate sizes. Conveyor systems, hoppers, and bins must be designed to accommodate larger aggregate production without causing overflow or delays in feeding the asphalt plant.
Aggregate Gradation Control
A high-capacity crusher can help maintain consistent grading for the asphalt mix, but only if the screening and crushing configuration is properly set up. Pay attention to screening efficiency and adjust settings to meet asphalt mix design requirements.
Fuel and Energy Management
Running two plants at different capacities requires smart energy planning. Choose crushers with fuel-efficient engines or electrical drives if possible, and consider automation systems that help regulate production levels based on demand.
Real-World Use Case: Supporting Road Projects Across Regions
Many road contractors in Southeast Asia and Africa already use this setup. One customer in Indonesia operates a 100tph drum mix asphalt plant supported by a 200tph stationary stone crushing plant. The crushing plant produces 0-5mm, 5-10mm, and 10-20mm aggregates, all stored in separate stockpiles. This allows them to supply consistent materials to the asphalt plant while also selling extra aggregates to nearby batching plant operators, generating additional revenue.
Is This Setup Right for Your Project?
If you operate several road construction projects simultaneously or plan to expand asphalt production in the future, this setup offers both stability and flexibility. It also helps reduce risk—by always keeping your asphalt plant supplied with properly sized, high-quality aggregates.
Why Choose Us to Provide a Complete Solution?
We don’t just sell equipment—we help you design the right solution. From planning to commissioning, we support clients with complete crushing and asphalt mixing systems tailored to your production goals, site layout, and material characteristics.
Our experienced engineers in Indonesia and other regions offer localized service, fast installation, and professional after-sales support. Whether you need mobile crushing units, stationary batch asphalt plants, or custom-designed conveying systems, we’ve got you covered.
Let’s Build a Stable and Profitable Asphalt Supply Chain
If you’re considering combining asphalt and aggregate production, now is the time to make a smart investment. A well-matched setup improves reliability, reduces costs, and positions your business for long-term growth.
Contact us today to get a tailored solution for your road construction projects. We’re here to help you plan smarter, build faster, and grow stronger.
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