Who would have thought that asphalt production could be this easy?
August 2026 | Reading time: 3 min.
The BLS 4 control system impresses in practice
Bayerische Asphaltmischwerke (bam) is using cutting-edge control technology to take its asphalt production to the next level. The BLS 4 plant control system impresses with an intuitive operating concept, smart lifecycle management and highly-effective cybersecurity.
A first in the Upper Palatinate region: with the new RPP 3000 Plus from Benninghoven at its Luhe-Wildenau site, bam is prioritising innovation and efficiency. Alongside the hot gas generator and foam bitumen module, a BLS 4 plant control system with the recipe generator option has now also been installed at the site in Luhe-Wildenau. It enables comprehensive monitoring of all system components to ensure stability, performance and process reliability. An overview of all relevant plant information is presented in a single graphic visualisation, and its operating concept operation is user-friendly and intuitive. With a wide range of parameters and settings, the control system offers outstanding flexibility, and is easy to use for both seasoned professionals and newcomers to plant operating. To ensure that all functions have been understood and can be used to the full, Benninghoven offers operator training courses – both on-site and online.
bam – one of Germany’s biggest asphalt producers
Founded in Munich in 1969, bam is one of Germany’s largest producers of asphalt. Operating from 5 subsidiaries and around 40 production facilities, bam produces high-quality asphalt products capable of meeting a wide range of customer requirements. The company’s existing asphalt mixing plant in the Upper Palatinate region of Bavaria has been replaced by an ultra-modern RPP 3000 Plus plant from Benninghoven.
With its integrated hot gas generator system, the Benninghoven asphalt mixing plant in Luhe-Wildenau enables high RAP feed rates while complying with all applicable emission limits.
Learn more about how Bayerische Asphaltmischwerke is making its site in Luhe-Wildenau ready to face the latest challenges by commissioning an RPP 3000 Plus.
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Overview of the key features of the BLS 4 system
The quality of the final product essentially depends on the precise composition of the raw materials according to the recipe. Even small variations in dosing can have a negative effect on asphalt properties – from resilience and grip to resistance against deformation or low-temperature environments, for example. Recipe precision and dosing accuracy are decisive in special cases such as mixes for racetrack surfacing. Asphalt mixing plants must ensure precise and reliable dosing of all components, even in variable conditions such as fluctuating temperatures or varying quantities of virgin mineral filler or RAP being dosed. This is where the Benninghoven Smart Weighing System comes in: the adaptive system responds in real time to material changes and irregular material flows and adjusts the dosing as required. Continuous optimisation by the mixing supervisor is also no longer required – the system can handle these tasks automatically. The end result is an asphalt mix that is true to the recipe and provides a high-quality, durable asphalt pavement.
Efficiency and cost control at a glance: reports on energy usage and asphalt mixes enable targeted action for energy saving and cost optimisation. This results in improved planning, less downtime and greater profitability.
The Benninghoven recipe generator
The Benninghoven recipe generator, available as an optional software add-on for the Benninghoven plant control system, ensures efficient recycling management in the mixing plant and creates ideal preconditions for maximising RAP feed rates. The proportion of RAP can be adjusted dynamically in 1% steps without having to interrupt ongoing production or switching the recipe. All other components are adjusted automatically while complying with recipe specifications – exceptions for additives can be defined and selected as required.
Additional benefits:
Fit for Benninghoven RPP 3000 Plus:
First-class support with training courses
No matter how user-friendly its design, a new plant needs to be understood and experienced from A to Z if the best-possible results are to be achieved. This is why Benninghoven offered bam a comprehensive support package from the outset – not only during the commissioning of new plants but also as an aftersales service that aims to optimise process flows and maximise operational efficiency. Additional, intensive training for the BLS 4 plant control system and recipe generator were also offered – either at the Benninghoven factory or in the form of online training sessions.
Everyone benefits from this ‘pilot’s licence’ for the asphalt mixing plant. The specialists from Wittlich made sure that all participants were familiar with the plant functions and how they can best be used, The plant operators gain greater confidence in their day-to-day work and can optimise the quality of products produced. Last but not least, this approach ensures that Bayerische Asphaltmischwerke can supply customers with a top-quality product that is ideal for their specific applications.
