Bitumen block forming system

Bitumen processing system for efficient bitumen solidification and packaging.

IPCO’s oxidized bitumen packaging system is a highly-efficient, automated solution for bitumen solidification, forming and packaging. Designed for minimal operator input, this system ensures consistent, high-quality solid bitumen blocks for easy handling and transport.

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IPCO’s oxidized bitumen packaging system is a highly-efficient, automated solution for bitumen solidification, forming and packaging. Designed for minimal operator input, this system ensures consistent, high-quality solid bitumen blocks for easy handling and transport.

Bitumen block forming

The solution

End-to-end process from liquid feed to block

This fully automated, self-contained system streamlines the bitumen production process by forming consistently sized solidified bitumen packs in little more than 15 minutes. Molten bitumen is fed onto an IPCO single belt cooler in the form of bands or strips. The steel belt-based system then applies cooling water to the underside and applies cooling air from above, rapidly solidifying the bitumen. This controlled process ensures uniform bitumen solidification and high throughput.

Efficient downstream block forming

Once solidified, bitumen bands are cut into uniform slabs and stacked to form 25 kg blocks. These are shrink-wrapped in polyethylene foil, which can be remelted with the bitumen, eliminating the need for unwrapping. Finally, the wrapped blocks are palletized for transport.

With rapid throughput and minimal labor input, the system delivers a highly efficient bitumen manufacturing process with low operational costs.

Versatile forming

Standard pack sizes are 710 x 345 x 100 mm, weighing 25 kg, but this can be adjusted to individual needs.

End-to-end process from liquid feed to block

This fully automated, self-contained system streamlines the bitumen production process by forming consistently sized solidified bitumen packs in little more than 15 minutes. Molten bitumen is fed onto an IPCO single belt cooler in the form of bands or strips. The steel belt-based system then applies cooling water to the underside and applies cooling air from above, rapidly solidifying the bitumen. This controlled process ensures uniform bitumen solidification and high throughput.

Efficient downstream block forming

Once solidified, bitumen bands are cut into uniform slabs and stacked to form 25 kg blocks. These are shrink-wrapped in polyethylene foil, which can be remelted with the bitumen, eliminating the need for unwrapping. Finally, the wrapped blocks are palletized for transport.

With rapid throughput and minimal labor input, the system delivers a highly efficient bitumen manufacturing process with low operational costs.

Versatile forming

Standard pack sizes are 710 x 345 x 100 mm, weighing 25 kg, but this can be adjusted to individual needs.

Bitumen block forming system credentials

Highly automated

10,000 tons

Annual throughput with just two operators

High productivity

c.15 mins

From liquid bitumen to palletized packages

Steel belt coolers

1935

World’s first steel belt cooler installed by IPCO

How it works

Hot molten bitumen is fed onto the IPCO steel belt cooler in the form of bands created by dividers running the full length of the cooling line.

Chilled water is sprayed on the underside of the belt, and air is blown from above. The smooth, durable surface of the steel belt provides an ideal surface for the temperatures and loadings involved.

As the melt travels along the system, the heat is transferred to the air above and – via the steel belt – to the water below, resulting in quick, controlled solidification.

Cutting to size and shrink-wrapped

At the end of the belt, the solidified asphalt bands are cut into consistently sized slabs that are then stacked to form blocks. These in turn are automatically shrink-wrapped in polyethylene foil, and transferred to pallets.

The whole process takes little over 15 minutes, and the packed end product is easily handled, and can be thrown straight into melting vessels on site.

Hot molten bitumen is fed onto the IPCO steel belt cooler in the form of bands created by dividers running the full length of the cooling line.

Chilled water is sprayed on the underside of the belt, and air is blown from above. The smooth, durable surface of the steel belt provides an ideal surface for the temperatures and loadings involved.

As the melt travels along the system, the heat is transferred to the air above and – via the steel belt – to the water below, resulting in quick, controlled solidification.

Cutting to size and shrink-wrapped

At the end of the belt, the solidified asphalt bands are cut into consistently sized slabs that are then stacked to form blocks. These in turn are automatically shrink-wrapped in polyethylene foil, and transferred to pallets.

The whole process takes little over 15 minutes, and the packed end product is easily handled, and can be thrown straight into melting vessels on site.

Benefits

Why choose an IPCO bitumen block forming system?

The IPCO oxidized bitumen packaging line provides rapid, environmentally friendly production, plus a number of other important user benefits:

Fully automated production – Minimal labor costs – a plant producing 10,000 tonnes per annum can be operated by just two workers
High system productivity – Total process time from liquid bitumen to palletized blocks is little over 15 minutes
Cost-effective packaging – Polyethylene shrink-wrapping is more economical than traditional packaging materials
Flexible production – Customizable pack sizes for diverse industrial needs · Convenient handling – Wrapped packs can be directly added to melting vessels without unpacking
Optimized storage and logistics – Standardized pack sizes allow for efficient palletizing and space utilization

Use this solution for

Processes supported

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Film casting

IPCO’s film casting systems deliver precise, high‑quality thin films for advanced industrial applications.

Forming

IPCO’s custom forming systems deliver efficient, precise solutions for diverse industries, from food and pharmaceuticals to energy and automotive.

Freezing

IPCO’s advanced freezing systems with stainless steel belts ensure faster cooling, product quality, and exceptional energy efficiency.

Portfolio showcase

Our ScatterPro portfolio

Double belt coolers

High capacity solidification of chemical melts into flake form.

Single belt coolers

Steel belt-based cooling/solidification in pastille or flake form.

Supercooling systems

Rotoform-based pastillation and flaking solution for subcooling melts

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