Henan Ruichi (Ruichi AAC factory), a leading AAC block machinery manufacturer in China, has been deeply involved in the field of autoclaved aerated concrete for over 20 years. Based on the diversified market demand for green building materials, it has launched the Automatic 6.0m AAC Panel & Block Production Line—an intelligent equipment line integrating the dual production functions of AAC Slabs and Panels (AAC slabs) and AAC blocks (aerated concrete blocks). Its annual output can flexibly cover 50,000-1,000,000 cubic meters, perfectly adapting to different scale needs from small and medium-sized workshops to large industrial bases.
I. Dual-Product Core: Application Scenarios and Product Advantages of AAC Slabs and Blocks
(I) AAC Slabs and Panels: Core Building Components for High-Efficiency Assembly
AAC slabs are construction components. As a key material for modern prefabricated buildings, Henan Ruichi's 6.0m ultra-long AAC Slabs and Panels can be widely used in residential buildings, commercial complexes, and industrial plants for interior partitions, exterior wall panels, floor slabs, and roof panels. Its core advantages are reflected in:
Strong structural adaptability: The 6.0m large-span design meets the needs of large-space buildings and can be directly combined with AAC block walls to form a complete enclosure system, reducing the number of component splicing operations;
Superior construction efficiency: Compared with traditional concrete slabs, AAC slabs weigh only 1/3 of ordinary concrete. Combined with standardized installation procedures, on-site construction speed is increased by more than 40%;
Outstanding green performance: Using industrial waste such as fly ash and limestone as raw materials, it aligns with environmental protection policies and possesses excellent thermal insulation and sound insulation effects (thermal conductivity ≤0.12W/(m・K)), helping buildings achieve green building level two or higher standards.
(II) AAC Blocks: A Preferred Building Material for Multifunctional Enclosures
AAC blocks (including aerated and pressurized blocks and autoclaved aerated concrete) are a core material for building wall construction. Henan Ruichi's production line can customize AAC blocks of different sizes according to customer needs, suitable for various scenarios such as load-bearing walls, infill walls, and partition walls. Their advantages are significant:
Balanced Performance: Combining lightweight, high strength, fire resistance, and moisture resistance, AAC block density is controlled at 500-700 kg/m³, and compressive strength can reach 3.5-7.5 MPa, fully complying with AAC block IS Code standards;
Convenient Construction: The blocks are regular in shape, and when used with AAC block adhesive, the mortar joint thickness is only 3-5 mm, reducing mortar usage and lowering the risk of wall cracking. Construction efficiency is 60% higher than traditional clay bricks;
Economical and Environmentally Friendly: Compared to concrete blocks, AAC blocks can reduce the building's self-weight by 30%. The above reduces basic engineering costs, and the production process generates no waste gas or wastewater emissions, meeting the environmental protection requirements for aerated concrete plants.
II. Core Production Line Configuration: Intelligent Adaptation to Dual Production and Scale Demand
Henan Ruichi's Automatic 6.0m AAC Panel & Block Production Line is designed with "intelligentization, high stability, switchability, and scalability" as its core principles. It integrates a self-developed AAC block making machine and a complete set of supporting equipment. Core configurations include:
Raw Material Handling System: Utilizes multiple slurry tanks for precise raw material storage and proportioning, coupled with high-efficiency dust removal equipment to ensure a compliant production environment, adaptable to raw material handling needs of 50,000-1,000,000 cubic meters per year;
Mixing and Pouring System: The fully automatic pouring mixer features adaptive raw material proportioning, adjusting slurry concentration according to panel/block production needs to ensure product homogeneity under large-scale production;
Conveying and Curing System: A heavy-duty belt conveyor enables seamless transfer of raw materials and semi-finished products. The core equipment, the autoclave, employs precise temperature control technology (180℃±5℃) and modular design, allowing for adjustments to the number of chambers based on production capacity requirements, ensuring the aerated and pressurized concrete of AAC. The strength and performance are stable.
The forming and cutting system is equipped with CNC cutting equipment and a mesh welding machine, allowing for rapid switching between sheet and block forming molds. Cutting accuracy is ≤±2mm, adaptable to different sizes of AAC blocks and sheet specifications, meeting the needs of large-scale customized production.
The intelligent control system utilizes full-process PLC automated control and an industrial internet platform, enabling real-time monitoring, data traceability, and remote operation and maintenance from raw material input to finished product output, effectively improving production efficiency and product qualification rate, and reducing the management difficulty of large-scale production.
This production line not only encompasses the core technology of the Autoclaved Aerated Concrete AAC Plant but also conforms to the production standards of Autoclaved sand lime brick production lines and Autoclaved aerated concrete brick production lines, enabling flexible production of diverse products such as AAC aerated concrete and Autoclaved aerated concrete brick, fully meeting the differentiated needs of the market.
III. Comprehensive Production Process Analysis: Intelligent Closed-Loop from Raw Materials to Finished Products
Henan Ruichi's Automatic 6.0m AAC Panel & Block Production Line adopts a fully automated production process with six interconnected core links. This ensures stable product quality and allows for flexible switching between panels and blocks, adapting to the needs of large-scale production:
(I) Raw Material Processing: Precise Pre-treatment of Green Substrates
The production line uses industrial waste such as fly ash and sand as core raw materials, combined with cement, aluminum powder, gypsum, and other cementing materials. Pre-treatment is completed through the following steps:
Raw Material Screening and Crushing: Impurities and large particles are removed from the raw materials using crushing and screening equipment to ensure uniform particle size (≤5mm), meeting the production requirements of AAC aerated concrete;
Wet Grinding: Dry raw materials are fed into a ball mill for wet grinding, forming a fine slurry which is then stored in slurry tanks. Intelligent sensors monitor the slurry concentration in real time to ensure accurate subsequent mixing ratios;
Environmental Protection: The entire raw material processing process is equipped with pulse dust removal equipment and a wastewater recycling system, eliminating dust leakage and wastewater discharge, fully complying with aerated concrete plant standards. Environmental standards help enterprises obtain green production qualifications.
(II) Automated Wire Mesh Manufacturing and Circulation Section: The Core Guarantee for Panel Reinforcement
Addressing the structural strength requirements of AAC Slabs and Panels, the production line integrates a fully automated mesh welding machine and a closed-loop circulation system:
Customized Wire Mesh Production: Based on the specifications of AAC slabs (6.0m length and different thicknesses), the system automatically completes wire cutting, precise welding, and rust prevention treatment to form a high-strength reinforced wire mesh with a weld tensile strength ≥300MPa;
Intelligent Conveying and Circulation: The wire mesh is precisely fed into the forming mold via a dedicated belt conveyor. Unused wire scraps are recycled through a recycling device, increasing raw material utilization to over 98% and effectively reducing production costs;
Compatible with Block Production: When switching to AAC blocks production mode, the wire mesh manufacturing system automatically stops, and the mold is quickly replaced with a block forming template, achieving "one-click switching and seamless connection." (III) Batching and Pre-curing: Precise Proportioning and Initial Molding
This stage is crucial for product performance, relying on an intelligent control system to achieve full automation:
Precise Batching: Based on the production plan (sheets/blocks), the PLC system automatically retrieves formula parameters, extracts slurry from slurry tanks, mixes it with aluminum powder paste (gas generator), additives, and other raw materials, and then stirs it at high speed (speed ≥1200r/min) using a pouring mixer to achieve uniform mixing;
Mold Casting: The mixed slurry is injected into the molding mold (sheet molds include a wire mesh positioning device) through a quantitative casting device. The material level is monitored in real time during the casting process, with an error ≤±10mm;
Pre-curing: After casting, the mold is conveyed to the pre-curing chamber via a belt conveyor and cured for 4-6 hours at 25-35℃ and humidity ≥85% to allow the slurry to complete initial solidification and gas generation, forming a green body with a certain strength, preparing for subsequent cutting.
(IV) Cutting Section: Precise Control of Customized Molding
The pre-cured blanks are conveyed into the cutting workshop and precisely shaped using cutting equipment:
* Blank Positioning: The blanks are fixed on the cutting platform with a positioning accuracy of ≤±2mm to ensure accurate cutting dimensions;
* Multi-Dimensional Cutting: The cutting mode is automatically switched according to the product type (boards/blocks)—when producing AAC Slabs and Panels, longitudinal and transverse combined cutting is used to form 6.0m ultra-long boards; when producing AAC blocks, different sizes of AAC blocks (such as 600×200×240mm, 600×200×300mm, etc.) are quickly cut through mold partitioning and cutting parameter adjustment;
* Scrap Recycling: Scrap materials generated during cutting are crushed and recycled back into slurry tanks, achieving zero waste of raw materials and further reducing AAC block making machine costs and production costs. (V) High-Pressure Sterilization: Core Enhancement of Strength and Performance
The cut semi-finished products are conveyed into an autoclave via a belt conveyor, where performance is solidified through high-temperature and high-pressure curing:
Step-by-Step Pressure and Temperature Increase: A "step-by-step" curing process is adopted, first increasing the pressure inside the autoclave to 1.2-1.5 MPa and the temperature to 180-190℃, maintaining this temperature for 8-12 hours to ensure sufficient hydration reaction within the green body;
Constant Temperature and Pressure Curing: Continuous curing is performed under set parameters to ensure the uniform and dense internal structure of the AAC aerated and pressurized concrete, achieving key indicators such as compressive strength and thermal insulation performance meeting AAC Block IS Code standards;
Safe Pressure Relief and Cooling: After curing, the pressure and temperature are slowly released through an intelligent control system to prevent product cracking due to sudden temperature and pressure changes, ensuring a finished product qualification rate of ≥98%. This step is the core process that distinguishes autoclaved aerated concrete from ordinary concrete and is also the technological advantage of Henan Ruichi AAC production line.
(VI) Finished Product Packaging: Standardized Output and Warehousing Adaptation
After autoclaving, the finished products (AAC slabs/AAC blocks) are packaged and shipped out through the following steps:
Automated Packaging: Different packaging methods are used according to product type—AAC blocks are packaged with stretch film and pallets for easy stacking and storage; AAC slabs and panels are fixed with special brackets to prevent damage during transportation;
IV. Profound Advantages of Dual Production Line + Large-Scale Capacity: Cost Reduction and Efficiency Improvement, Empowering Industrial Upgrading
For AAC block factory investors, choosing Henan Ruichi's dual-function large-scale production line offers core value far exceeding "one line for two uses," focusing on comprehensive optimization of production costs and market competitiveness:
(I) Significantly Reduced Investment and Operating Costs
Optimized Fixed Asset Investment: There is no need to purchase separate AAC block production lines and panel production lines; only one set of equipment is needed to achieve dual output. Combined with a flexible capacity design of 50,000-1,000,000 cubic meters, equipment specifications can be precisely matched according to the investment budget, directly saving more than 50% of equipment procurement costs (including...) (AAC block making machine cost) significantly reduces AAC block factory cost; Operational cost consolidation: sharing core resources such as slurry tanks, autoclaves, and raw material supply reduces equipment idle time and floor space occupation. Under large-scale production, the unit price of raw material procurement can be reduced by 10%-15%.The combined reduction of logistics, warehousing, and labor costs by 30%-40% makes AAC block prices more competitive in the market.
Accelerated return on investment: For clients intending to establish an AAC factory for sale, dual production capacity + economies of scale can increase the project's return on investment by more than 25%, shortening the investment recovery period by 1-2 years, which is especially suitable for the long-term profit planning of large-scale AAC block manufacturing plants.
(II) Flexible response to market demand fluctuations and large-scale orders: The demand for AAC slabs and AAC blocks in the construction market often changes dynamically with project type and policy guidance. Henan Ruichi's production line can achieve a "one-click switching" production mode—when demand for commercial complex projects is strong, it focuses on the production of AAC slabs and panels; when residential projects are concentrated, it switches to the production of AAC blocks, avoiding inventory backlog of a single product. At the same time, the annual production capacity of 50,000-1,000,000 cubic meters can flexibly undertake orders ranging from small regional projects to large-scale national building material supply orders, enhancing the company's risk resistance and market coverage. (III) Enhancing Product Quality and Brand Competitiveness
As a benchmark enterprise among AAC block manufacturers, Henan Ruichi's production line adopts unified raw material standards, production processes, and quality testing systems to ensure the performance consistency of AAC slabs and AAC blocks. All products pass national building material testing standards, with key indicators such as AAC block density and AAC block weight consistently meeting standards. Furthermore, when used with AAC block adhesive, construction quality can be further improved. In addition, the production line is compatible with various raw materials such as beton, fly ash, and sand-lime, and the produced autoclaved aerated concrete products meet green building material certification requirements, helping the company seize the high-end market.
V. Core of Turnkey Project: Henan Ruichi Provides Full Lifecycle Support for Projects
Henan Ruichi has been deeply involved in the AAC production line field for over 20 years. Leveraging its full-chain capabilities of "equipment R&D + project planning + implementation and operation," it provides clients with true AAC Blocks Manufacturing Plant Turnkey Project Solutions. From project preparation to stable profitability, we participate in and precisely empower the entire process, specifically including:
(I) Preliminary Preparation: Precise Planning to Mitigate Investment Risks
Project Feasibility Analysis: Combining the building materials market demand, raw material supply (fly ash, lime, etc.), and policy guidance (green building materials subsidies, environmental protection requirements) in the client's region, we provide customized feasibility reports, clarifying the optimal configuration scheme for an annual output of 50,000-1,000,000 cubic meters;
Site Planning and Design: Based on capacity requirements, we provide an overall layout design for the AAC block factory, including the rational planning of production workshops, raw material warehouses, finished product storage yards, and office areas, ensuring smooth logistics and compliance with environmental and safety regulations;
(II) Mid-Term Implementation: Efficient Construction to Ensure Rapid Production
Equipment Customization and Production: Based on project requirements, we produce customized equipment... The Automatic 6.0m AAC Panel & Block Production Line utilizes core equipment such as the pouring mixer, autoclave, and mesh welding machine, all independently developed and manufactured by Henan Ruichi, ensuring equipment compatibility and stability.
On-site Installation and Commissioning: A professional technical team is dispatched to the site to handle equipment installation, wiring, and commissioning, ensuring the production line operates according to design standards and enabling smooth switching between panel and block production.
Personnel Training: Comprehensive training is provided for all positions, including raw material proportioning, equipment operation, quality inspection, safety regulations, and daily maintenance, ensuring the customer's team can independently manage production operations.
Trial Production Support: During the trial production phase, the technical team provides full-process monitoring, optimizing production process parameters, resolving practical problems, and ensuring a rapid increase in product qualification rate to over 98%.
(III) Post-Production Operation: Continuous Empowerment to Ensure Stable Profitability
Technical Support: Establishing a 24-hour response mechanism, resolving equipment malfunctions and process challenges during production through remote operation and maintenance platforms or on-site services, ensuring an annual production line uptime of ≥95%;
VI. Diverse Product Line Adaptation: Meeting Differentiated Needs
In addition to the core Automatic 6.0m AAC Panel & Block Production Line, Henan Ruichi also offers a rich product line, including Autoclave Curing Brick Production Line, Autoclaved Sand Lime Brick Production Line, Aac Brick Production Line, Autoclaved Aerated Concrete, and Autoclaved Aerated Concrete (AAC) Production Line, etc. These can be combined to form diversified production solutions according to customer needs, such as simultaneously producing AAC blocks and autoclaved sand lime bricks, further enhancing market competitiveness.
