Asphalt production made easy

Training session: An operator sits at the control system screen while a trainer stands behind, pointing something out on the display.

August 2026 | Reading time: 3 min.

BLS 4 control system proves its worth in practice

Thanks to modern control technology, Bayerische Asphaltmischwerke (bam) is taking its asphalt production to a whole new level. The BLS 4 plant control system features an intuitive operating concept, intelligent lifecycle management and a high level of IT security.

A first for the Upper Palatinate: With its new RPP 3000 Plus from Benninghoven at its Luhe-Wildenau site, bam is prioritising innovation and efficiency. Alongside technologies such as the hot gas generator and foam bitumen module, the BLS 4 plant control system with the recipe generator option is now also in use at Luhe-Wildenau. This enables comprehensive monitoring of all system components: ensuring stability, performance and reliable processes. A single graphical visualisation provides an overview of all relevant plant information, and the system is user-friendly and intuitive to operate. The control system offers a wide range of parameters and settings to ensure a high degree of flexibility and is easy to use for both seasoned professionals and new plant operators alike. To help users understand and utilise all the features, Benninghoven offers operator training – either on-site or online.

bam - one of Germany's leading asphalt producers

Founded in Munich in 1969, bam is one of Germany’s leading asphalt producers. It has 5 branches and around 40 production sites, and manufactures high-quality asphalt products to meet a wide range of customer requirements. The existing asphalt mixing plant in the Upper Palatinate has been replaced with a state-of-the-art RPP 3000 Plus from Benninghoven.

The Benninghoven asphalt mixing plant in Luhe-Wildenau features integrated hot gas generator technology and enables maximum RAP utilisation while maintaining compliance with emission limits.

Find out how Bayerische Asphaltmischwerke is preparing its Luhe-Wildenau site for the challenges ahead with the commissioning of an RPP 3000 Plus.

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BLS 4 features at a glance

  • Here, the focus is on a stable, powerful and secure system
  • Both software and hardware are now covered by lifecycle management
  • Aligned with the software's product lifecycle – the system is always up to date

  • Curved monitor – two screens merged into one – for exceptional clarity
  • Pre-configured trends for analysis and process optimisation

  • Easy on the eyes – even during long shifts or at night
  • Enables fast, straightforward handling of small batch orders

  • Extensive parameter and configuration options for maximum flexibility and optimal fine-tuning
  • The mixing plant can be operated manually or run fully automatically

  • Overpressure interlock protects critical weighers via a pressure sensor in the mixer
    • Protection against accidents and contamination
  • Adherence to the discharge sequence
    • Important when using additives

The quality of the final product depends significantly on the precise composition of the raw materials in line with the recipe specification. Even small deviations in dosing can negatively affect the properties of the asphalt – such as its strength, skid resistance or resistance to deformation and cold. In special applications such as racetrack surfacing, recipe accuracy and dosing precision are crucial. 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: This adaptive system responds in real time to changes in materials and irregular material flows, adjusting the dosing as required. The mixing foreman no longer needs to make continuous optimisations – the system can handle these tasks automatically. The result is an asphalt mix that is produced with high recipe accuracy and quality for long-lasting asphalt roads.

  • Intelligent, adaptive dosing
  • Real-time response for maximum precision
  • Precise dosing, even at very low feed rates
  • Precise recipe management with very tight recipe tolerances

  • Two separate, clearly structured alarm lists for improved clarity: Production and process alarms. All messages are displayed in a clearly structured list – this simplifies operation and reduces distractions compared to pop-ups.
  • Detailed alerts with date and time stamps enable fast root-cause identification
  • A comprehensive alarm report enables historical diagnostics

  • Comprehensive system monitoring of all control components, including the emergency stop chain and key transfer system
  • A single graphical visualisation provides an overview of all relevant plant information
  • Display and status monitoring of all modules down to the I/O level
  • Wiring diagrams are stored digitally
  • Graphical display of control cabinets for easy orientation and rapid fault finding (faulty components are highlighted within the cabinet view)

Efficiency and cost control at a glance: Energy and mix reports enable targeted measures to reduce energy consumption and optimise costs. The result: better planning, less downtime and higher profitability.

  • Energy and carbon reporting can be used to analyse energy consumption and calculate CO₂ emissions
  • Production overview (asphalt types and RAP content)
  • Performance indicators

  • State-of-the-art – Protection against cyberattacks and strong password security
  • Proven in practice

  • The retrofit mainly takes place within the control cabinets and can also be carried out on third-party plants.
  • Standard data interface

Screen view of the BLS 4 control system
Screen view of the BLS 4 control system

The Benninghoven recipe generator

The recipe generator, an optional software module for the Benninghoven plant control system, ensures optimum recycling management in the asphalt mixing plant and enables maximum RAP addition rates. The RAP content can be adjusted dynamically in 1% increments without interrupting production or changing the mix recipe. All other components are adjusted automatically in line with the recipe specifications – exceptions for additives can be defined and selected as needed.

Additional benefits:

  • Reclaimed asphalt data can be stored in the system and assigned to different asphalt mix recipes
  • Intelligent binder management when incorporating reclaimed asphalt
  • Suitable for use in both cold and hot/warm feed systems, as well as in combination

Fit for Benninghoven RPP 3000 Plus:
Top-level support through training

A new plant – no matter how operator-friendly its design – must be fully understood and practically mastered from the ground up to achieve the best possible results. For this reason, Benninghoven has provided bam with comprehensive support from day one, covering the commissioning of new plants as well as ongoing services to fine-tune processes and boost operational efficiency. Additional in-depth training was offered for the BLS 4 plant control system and the recipe generator - available either at Benninghoven‘s facility or virtually.

Everyone benefits from this “driver’s licence” for the asphalt mixing plant. The Wittlich team ensures that all plant functions are fully understood and can be used to their full potential. Plant operators gain greater confidence in their day-to-day work, enabling them to optimise product quality. Last but not least, Bayerische Asphaltwerke can deliver the best quality to its customers for every application.

RPP 3000 Plus lit up at dusk
RPP 3000 Plus lit up at night
RPP 3000 Plus at dusk