Kian Industry Bitumen Jumbo Filler
Kian Industry’s bitumen jumbo filler is designed and manufactured inspired by the technology of leading European brands such as HAVER & BOECKER and BEUMER. This machine is available in two models: automatic (with PLC system and touch controller, capable of storing 100 weighing formulas, SCADA connectivity) and semi-automatic (operator-based operation, simple digital display, suitable for lines with limited budgets). In terms of the number of filling stations, it is available in three versions: single-spout (capacity of 30 to 40 jumbo bags per hour, suitable for small and medium-sized factories), twin-spout (capacity of 60 to 80 jumbo bags per hour, ideal for semi-industrial and industrial production lines), and four-spout (capacity of 120 to 160 jumbo bags per hour, suitable for mass production lines and large factories). Standard technical features of this machine include a C3 class load cell weighing system with 0.1 to 0.2% accuracy, heating flanges to maintain bitumen temperature in the range of 150 to 180°C, body and hopper made of stainless steel 304 with rock wool insulation, a telescopic chute filling system with automatic bag locking, an aspiration and bitumen vapor extraction system, an electrical panel with temperature controller, and data output to a central computer.Bitumen Jumbo Filler Jumbo Bitumen Filling Machine
The only bitumen filling system manufactured in Iran with the ability to fill at high temperatures, integrated heating system, and ±0.3% weighing accuracy — competitive with Bühler, Haver & Boecker, and Concetti in international markets
Why fill bitumen in jumbo bags? What is the real challenge?
Critical Temperature Management
Bitumen is pumped at 140–180°C. Any temperature drop means pipe blockage, nozzle damage, and line stoppage. The system must keep the entire path heated.
Weighing Molten Material
Molten bitumen has high viscosity and density changes with temperature. Accurate weighing requires dynamic tare and thermal compensation.
Complete Sealing
Even the slightest bitumen leak in the work environment creates fire risks, product contamination, and operator hazards. The nozzle must be 100% sealed.
Controlled Cooling
After filling, the bag must cool quickly to form and be transportable — without bitumen sticking to the bag's inner walls.
Integrated Heating System
The beating heart of the Kian Industry Bitumen Jumbo Filler
Models & Configurations
From semi-automatic to fully automatic with production line integration
KS-BJF-S
- Single-stage weighing system
- Jacketed nozzle with thermal oil
- Digital display
- Manual bag placement and removal
- 7.5 kW gear pump
- 500-liter buffer tank
KS-BJF-A
- Two-stage weighing (Coarse + Fine)
- Drip-free nozzle with electromagnetic shut-off
- 10" HMI touch + Siemens PLC
- Automatic bag handling with rail
- Pre-load weight detection system
- 5-zone independent temperature control
- Multi-level alarm system
- Label printer connectivity
KS-BJF-PRO
- Three-stage weighing with ±0.1% accuracy
- Robot for bag cap opening/closing
- Controlled cooling system after filling
- Roller conveyor + automatic palletizing
- SCADA + cloud logging of all parameters
- In-line check weighing after filling
- Machine vision camera for quality control
- Integration with factory ERP/MES
- Batch Tracking and Traceability support
Technical Specifications
| Parameter | KS-BJF-S | KS-BJF-A | KS-BJF-PRO |
|---|---|---|---|
| Bag Capacity | 500–1000 kg | 500–1500 kg | 500–2000 kg |
| Loading Speed | 4–6 bags/hour | 8–10 bags/hour | 10–12 bags/hour |
| Weighing Accuracy | ±0.5% | ±0.3% | ±0.1% |
| Max Material Temperature | 180°C | 180°C | 200°C |
| Heating System | Thermal oil | Thermal oil / Steam | Thermal oil / Steam / Electric |
| Pump Type | Gear 7.5 kW | Gear 15 kW | VFD Gear 22 kW |
| Controller | PLC Delta | PLC Siemens S7-1200 | PLC Siemens S7-1500 |
| HMI | 7" Display | 10" Weintek Touch | 15" Touch + SCADA |
| Construction Material | SS304 | SS304 / SS316 | SS316L (Food/Pharma Grade) |
| Power Consumption | 15 kW | 30 kW | 55 kW |
| Dimensions (L×W×H) | 2.5×1.5×3.5 m | 3.5×2×4.5 m | 6×3×5 m |
| Machine Weight | ~800 kg | ~1800 kg | ~3500 kg |
Key Technologies
Thermal Drip-Free Nozzle
Trap-type nozzle with thermal oil jacket, solenoid valve, and return suction system — not a single drop leaks after flow cutoff.
Two / Three-Stage Weighing
In the first stage, 95% of the weight is filled at high flow rate. In the second/third stage, the remaining 5% is completed with low flow and high accuracy. Automatic in-flight correction for falling material weight.
Multi-Zone Temperature Control
Independent PID system for the tank, transfer pipes, pump jacket, and nozzle. Each zone is independently controlled and logged. Temperature drop alarms activate before any issues occur.
Post-Filling Cooling System
Forced air channel or water cooling tunnel to speed up bitumen solidification in the bag — without the bitumen sticking to the inner liner and maintaining bag shape for transport.
SCADA & Data Logging
Real-time logging of temperature, pressure, flow rate, weight, and operator ID for each bag. Production reports, OEE, and preventive alerts. Connectable to factory MES/ERP systems.
ATEX / SIL Safety
Bitumen vapors are flammable. All electric motors, sensors, and panels in export models are available with ATEX Zone 1/2 certification. SIL 2 emergency stop system is standard.
Industries & Applications
Road Construction Bitumen
Pure 60/70 and 80/100 bitumen for export and infrastructure projects
Modified Bitumen (PMB)
SBS/SBR polymer bitumen with higher viscosity and higher operating temperature requirements
Refineries
The final refinery line for packaging export bitumen in jumbo bags
Export
Jumbo bags are the most suitable format for export to Arab countries, Africa, and Asia
Building Insulation
Oxidized bitumen for waterproofing insulation manufacturers
Cable & Power
High-purity bitumen for underground cable insulation
Comparison with Global Competitors
Kian Industry vs. the world's leading brands
| Feature | Kian Industry Iran |
Haver & Boecker Germany |
Concetti Italy |
Bühler Switzerland |
|---|---|---|---|---|
| Weighing Accuracy | ±0.1–0.3% | ±0.1% | ±0.2% | ±0.1% |
| Max Material Temperature | 200°C | 220°C | 200°C | 230°C |
| Customization | ✅ Full | ⚠️ Limited | ✅ High | ⚠️ Limited |
| Delivery Time | ✅ 3–5 months | ❌ 8–12 months | ❌ 6–10 months | ❌ 10–14 months |
| Relative Price | ✅ Competitive | ❌ Very High | ❌ High | ❌ Very High |
| Support in Iran | ✅ 24/7 | ❌ Not available | ❌ Not available | ❌ Not available |
| Spare Parts | ✅ Local stock | ❌ Import 2–6 months | ❌ Import 2–4 months | ❌ Import 3–6 months |
| Training & Commissioning | ✅ On-site | ⚠️ Online | ⚠️ Limited | ⚠️ Online |
| SCADA/ERP Connectivity | ✅ Full | ✅ Full | ✅ Full | ✅ Full |
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