What is AAC Block Manufacturing Process?
In recent years, Autoclaved Aerated Concrete (AAC) blocks have revolutionized the construction industry. These lightweight, precast foam concrete blocks offer excellent thermal insulation, soundproofing, and fire-resistant properties, making them a preferred choice for modern construction. At Essarcon, we take pride in manufacturing high-quality AAC block Machines that adhere to the highest standards. Here’s an in-depth look at our AAC block manufacturing process.
1. Raw Material Preparation
The foundation of any great product lies in the quality of its raw materials. For AAC blocks, the essential ingredients are:
- Cement:
Acts as a binder and gives the blocks their structural integrity. - Lime:
Works as a major constituent that reacts with the aluminum powder to create the desired aeration. - Sand or Fly Ash:
Provides the siliceous component, contributing to the strength of the blocks - Gypsum:
Enhances the properties of the mixture and helps in the setting process. - Aluminum Powder:
This is the key to creating the aeration process, forming tiny bubbles within the mix
All raw materials are thoroughly inspected for quality before they enter the manufacturing process.
The Competitive Advantage:
By incorporating these elements, AAC/ALC block machinery can become a strategic tool for businesses. It can deliver:
- Increased production capacity and reduced costs.
- Enhanced product quality and consistency.
- Greater flexibility and responsiveness to market needs.
- Improved sustainability through resource optimization.
Remember:
The most competitive AAC/ALC block machinery solution will be one that is tailored to address your company's specific challenges and growth goals.
Click here for more on AAC Block Manufacturing Plant Setup Cost in India
Minimizing Downtime for Maximum AAC/ALC Block Production
Downtime is the enemy of production. Here's how redesigned AAC/ALC block machinery can be engineered to specifically target downtime reduction:
Improved Equipment Reliability:
- Heavy-duty and wear-resistant components:
Invest in machinery built with durable materials to minimize repairs and replacements. - Simplified and accessible design:
Ensure easy access to machine components for maintenance and cleaning tasks. - Standardized spare parts:
Facilitate quick replacement of parts when necessary, reducing downtime for sourcing components.
Enhanced Operator Training and Support:
- Advanced operator training programs:
Train operators on proper equipment use, basic troubleshooting, and preventive maintenance procedures. - Dedicated technical support:
Provide access to qualified technicians for prompt assistance in case of complex issues. - Improved maintenance efficiency.
By incorporating these features, AAC/ALC block machinery can significantly reduce downtime through:
- Reduced number of unexpected equipment failures.
- Faster identification and resolution of potential problems.
- Improved maintenance efficiency.
This product is for the new start ups and who are new to this industry. Or say someone wants to produce blocks in a brand new market with minimum risk of investment.
Small plants are for small production with low investment.
It starts from 3.3M³ and reaches a maximum of 26M³ per Day.
These lines are compatible with natural curing
An ideal production line with a perfect combination of Performance and Budget
It starts from 8.6M³ and reaches a maximum of 80M³ per Day.
These are categories in two types :
- Stationary type Mold system - ACB Pro - FX ( called Stationary line ) the molds do not move, for pouring, and cutting, the mixer and cutting machines move along the rails.
Advantages :
- Easy to install
- Can be upgrade to conveyor line
- Movable type Mold system - ACB Pro - TT ( called Conveyor line ) In conveyor lines, molds move along the rails, and the mixer and cutting machines stand still.
Advantages :
- Easy to automate
- The area of the room is saved due to the proximity of the forms High productivity
These lines are compatible with natural curing (ALC) as well as steam curing (AAC).
AAC Block Machinery Series:
-
AAC Value Series:
Ideal for beginners, offering a minimum investment to start your AAC block production. - AAC Eco Series:
Budget-friendly option with essential equipment, allowing for future upgrades as your business grows. - AAC Pro Series:
Designed for high performance with advanced automation, maximizing efficiency for established businesses.
These lines are designed for steam curing (AAC).
Production Lines
ALC Mini
LineALC Pro TT
Conveyor LineALC Pro FX
Stationary LineALC & AAC
Hybrid LineAAC Block
Production Line
ACB Mini Eco - 3
ACB Mini - 6
Description
Stationary line for the production of aerated concrete - ACB Mini series with a capacity of up to 26M³ per day. The line consists of a mobile mini mixer-activator suitable for a batch volume of 0.33 M³, Lower height of feeding hopper for easy material feeding in the mixer. Semi automatic cutting machine capable of Six surface cutting, stationary mold base frames interconnected with rail track, mold boxes. transfer trolley with its track
Key features
- Mobile mini mixer activator equipped with Load cell based material weighing system
- L shape openable mold boxes equipped with toggle clamps for easy de-molding
- Semi automatic mobile cutting system with Six surface finish
- Mobile semi automatic cutting system with Six surface finish
- Easy to operate machines
Mold dimensions : 600W x 230H x 2400L
No. of Bricks per Mold
100W x 230(or 200)H x 600L = 24Pcs
150W x 230(or 200)H x 600L = 16Pcs
200W x 230(or 200)H x 600L = 12Pcs
Layout of Plant
ACB Pro TT - 42
ACB Pro TT - 17
ACB Pro TT Eco - 9
Description
Conveyor line for the production of aerated concrete - ACB Pro TT series with a capacity of up to 80M³ per day. The standard line consists of a fixed mixer-activator suitable for a batch volume of 0.86 M³, automatic material feeding system includes screw conveyor for cement and belt conveyor for fly ash (optional in Eco Model), Automated cutting system includes Horizontal cutting machine and Vertical cutting machine, mobile mold base trolleys, mold boxes, rail tracks, transfer trolleys with its track. Optionally, the line can be equipped with a cement and fly ash silo.
Key features
- Stationary mixer activator with Load cell based automatic batching control
- Screw conveyor for cement feeding (optional in Eco Model)
- Belt conveyor for fly ash feeding (optional in Eco Model)
- Four side openable mold boxes equipped with toggle clamps for easy de-molding
- Heavy mold base trolleys fitted with specially designed wheels for easy movement
- Automatic cutting system with Six surface finish
- Easy to increase productivity
Can be converted to AAC/ALC by adding an autoclave and boiler.
Mold dimensions : 600W x 600H x 2400L
No. of Bricks per Mold :
100W x 200H x 600L = 72Pcs
150W x 200H x 600L = 48Pcs
200W x 200H x 600L = 36Pcs
Layout of Plant
ACB Pro FX - 17
ACB Pro FX Eco - 9
Description
Stationary line for the production of aerated concrete - ACB Pro FX series with a capacity of up to 43M³ per day. The line consists of a mobile mixer-activator suitable for a batch volume of 0.86 M³, Raw material feeding belt conveyor (Optional with Eco Model) , Automated cutting system includes mobile Horizontal cutting machine and mobile Vertical cutting machine, stationary mold base frames interconnected with rail track, mold boxes.
Key features
- Mobile mixer activator equipped with Load cell based material weighing system
- Optional belt conveyor for raw materials feeding
- Four side openable mold boxes equipped with toggle clamps for easy de-molding
- Stationary mold base frames interconnected with rail track
- Mobile automatic cutting system with Six surface finish
Can be converted to AAC/ALC by adding an autoclave and boiler along with mobile mold base trolleys.
Mold dimensions : 600W x 600H x 2400L
No. of Bricks per Mold :
100W x 200H x 600L = 72Pcs
150W x 200H x 600L = 48Pcs
200W x 200H x 600L = 36Pcs
Layout of Plant
AAC-ALC Hybrid 17
Description
This system is designed to produce AAC as well ALC blocks in same plant. Machines are similar to ALC Line - ACB Pro TT. Mold volume is 0.86M³. 3 Layers of blocks in each mold. One can use autoclave and boiler to produce AAC blocks to cater the clients demanding AAC only. Simultaneously ALC Blocks are produced for other clients. This enables the optimum use of system and produces more blocks to reduce the payback period.
Simplest system for AAC & ALC production made ever. The line consists of a mixer-activator suitable for a batch volume of 0.86M³, raw material feeding belt conveyor, automated cutting system includes Horizontal cutting machine and Vertical cutting machine, mobile mold base trolleys, mold boxes, rail tracks, transfer trolleys with its track, curing autoclave and a boiler.
Key features
- Stationary mixer activator with Load cell based automatic batching control Screw conveyor and Belt conveyor for raw materials feeding.
- Four side open able mold boxes equipped with toggle clamps for easy de-molding,
- Heavy mold base trolleys fitted with specially designed wheels for easy movement
- Automatic cutting system with Six surface finish
- Curing autoclave included
- Productivity of AAC/ALC can be expanded by adding more autoclave and molds
- Productivity of ALC can be expanded by more molds.
- Modular system for quick add-ons of many accessories to ease the operations and increase the productivity.
Mold dimensions (Finished cake): 600W x 600H x 2400L
No. of Bricks per Mold :
100W x 200H x 600L = 72Pcs
150W x 200H x 600L = 48Pcs
Production capacity: AAC/ALC up to 8.6M³ /Day + ALC up to 8.6M³ /Day can be expand up to 80M³ /Day in total
Layout of Plant
From Startup to Success: Your AAC Block Production Partner
Essarcon doesn't just provide AAC block plants – we empower your business. Regardless of your plant size, we offer comprehensive support at every stage:
- Equipment assembly & commissioning
- Raw material selection & cost analysis
- Production formula optimization
- Finished product marketing guidance
Our expertise ensures you produce high-quality AAC blocks and navigate the production process with confidence.
Benefits:
- Reduced risks & smoother operations
- Optimized production costs
- Expert guidance for long-term success
We manufacture AAC block plants catering to various production scales and budgets.
- Starter-Friendly: Our Value Series targets beginners by providing a cost-effective entry point into AAC block production.
- Budget-Conscious: The Eco Series focuses on affordability with essential equipment, keeping initial investment low. It also allows for future upgrades as your business grows.
- High-Performance: The Pro Series caters to established businesses, featuring advanced automation for maximum efficiency and high-volume AAC block production.
AAC Value Series
Description
Production capacity - up to 92M³ /Day
Mold volume is 1.15M³ and offers 4 Layers of blocks in each mold.
This VALUE series is the most affordable AAC Plant system. This system is designed for beginners who want to start the AAC/ALC block production with minimal investment with Mandatory only equipment. Though it comes with less automation, its block quality will be similar to other high end systems.
Simplest system for AAC/ALC production made ever. The line consists of a mixer-activator capable for a batch volume of 1.3M³, raw material feeding belt conveyor, Automated cutting system includes Horizontal cutting machine and Vertical cutting machine, mobile mold base trolleys, mold boxes, transfer trolley &, curing autoclave. buyers can purchase a boiler on their own locally, otherwise we can supply from our ventured manufacturers.
Key features
- Mold volume (Finished cake) approximate 1.15M³
- Stationary mixer activator with Load cell based automatic batching control
- Fly ash Slurry preparation mixer
- Belt conveyor for raw materials feeding to mixer
- Four side openable mold boxes equipped with toggle clamps for easy de-molding
- Heavy mold base trolleys fitted with specially designed wheels for easy movement
- Automatic cutting system with Six surface finish
- Curing autoclave included
Mold dimensions : 600W x 800H x 2400L
No. of Bricks per Mold :
100W x 200H x 600L = 96Pcs.
150W x 200H x 600L = 64Pcs.
200W x 200H x 600L = 48Pcs.
Adding more autoclaves and molds will increase the production.
AAC Eco Series
Production capacity - up to 105M³ /Day
Mold volume is 1.3M³ and offers 6 Layers of blocks in each mold.
This is an Ideal startup AAC/ALC plant designed to cater the requirements of today’s competition world. This includes a Hi speed mixer equipped with load cell based material weighing system. PLC based easy to operate control panel for batching and mixing. Raw material feeding belt conveyor, Unique Automated cutting systems include tilting - demolding machine, horizontal cutting machine and vertical cutting machine & autoclave. Buyers can purchase a boiler on their own locally, otherwise we can supply from our ventured manufacturers.
Key features
- Mold volume (Finished cake) approximate 1.3M³
- Mixer activator with Load cell based batching control
- Fly ash Slurry preparation mixer
- Belt conveyor for raw materials feeding
- Tilting mold boxes - Tilting provides consistent density
- Heavy mold base trolleys fitted with specially designed wheels for easy movement
- Automatic 2 stage cutting system with Six surface finish
- Curing autoclave included which is capable to cure molds with 6 layers of block on dual track - This save up to 20% of steam cost than conventional method
Mold dimensions : 600W x 1200H x 1800L
No. of Bricks per Mold :
100W x 200H x 600L = 108Pcs.
150W x 200H x 600L = 72Pcs.
200W x 200H x 600L = 54Pcs
AAC Pro Series
Production capacity - up to 125M³ /Day
Mold volume is 1.3M³ and offers 6 Layers of blocks in each mold.
Performance is a key to productivity. High speed mixer fitted with automatic batching hopper system with dedicated cement and lime feeding screw conveyors, Integrated aluminum powder mixer-dispenser. PLC based control panel is included for easy operations. Includes dedicated underground slurry mixers each one for fresh and recycled slurry preparation. Unique tilting - demolding system for faster operations. Optional Silos for raw material storage This is a high performance automated line.
Key features
- Mold volume (Finished cake) approximate 1.3M³
- Mixer activator is equipped with additional batching hoppers for speedy raw material weighing.
- Two screw conveyors, each one is for cement and lime feeding
- Two slurry preparation mixers. Each one is for Fresh and recycled slurry
- Tilting mold boxes - Tilting provides consistent density and faster production
- Heavy mold base trolleys fitted with specially designed wheels for easy movement
- Automatic 2 stage cutting system with Six surface finish
- Curing autoclave included which is capable to cure molds with 6 layers of block on dual track - This save up to 20% of steam cost than conventional method.
Mold dimensions : 600W x 1200H x 1800L
No. of Bricks per Mold :
100W x 200H x 600L = 108Pcs.
150W x 200H x 600L = 72Pcs.
200W x 200H x 600L = 54Pcs
Adding more autoclaves and molds will increase the production.