Solution for 50,000 Cubic Meters/Year AAC Block Production Line
1. Site Area Requirements
A production line with an annual output of 50,000 cubic meters requires a total site area of approximately 15,000-20,000 square meters. This includes:
- Raw material storage area (3,000-4,000 sq.m) for sand, cement, and additives.
- Production workshop (5,000-6,000 sq.m) housing mixing, casting, and cutting equipment.
- Autoclave and curing zone (2,000-3,000 sq.m) with high-pressure steam facilities.
- Finished product storage yard (4,000-5,000 sq.m) for stacking and loading.
- Auxiliary areas (1,000-2,000 sq.m) including offices, maintenance rooms, and power supply stations.
The site should be flat with convenient transportation access and stable water/electricity supply.
2. Raw Material Composition
The primary raw materials for AAC blocks include:
- Siliceous materials: Sand (60-70% of total weight) or fly ash, with particle size ≤2mm.
- Calcareous materials: Cement (15-20%) and lime (10-15%), ensuring sufficient CaO content.
- Aluminum powder (0.05-0.1%): As a foaming agent to generate hydrogen gas.
- Additives: Gypsum (2-3%) to adjust setting time, and water (appropriate ratio based on mixture consistency).
Raw material sources in Central Asia are abundant—local sand deposits and cement plants can meet production needs, reducing transportation costs.
3. Equipment List:
| Equipment Category | Specific Equipment | Quantity | Function |
| Raw Material Processing | Sand crusher, ball mill | 1 set each | Crush and grind raw materials to required fineness. |
| Mixing System | Continuous mixer, slurry tank | 1 set each | Blend materials into homogeneous slurry. |
| Casting & Foaming | Casting machine, mold carts | 1 machine, 10-15 carts | Pour slurry into molds and facilitate foaming. |
| Cutting Equipment | Automatic cutting machine | 1 set | Cut green bodies into standard block sizes. |
| Curing System | Autoclave (Φ2.5m×31.5m) | 2 units | Cure blocks under high temperature (180-200℃) and pressure (1.2-1.5MPa). |
| Handling Equipment | Forklifts, conveyor belts | 3-4 forklifts, 5-6 belts | Transport raw materials and finished products. |
| Auxiliary Equipment | Boiler, air compressor, control system | 1 each | Provide steam, power, and automated control. |
4. Production Process
- Raw Material Preparation: Sand is crushed and ground; lime and cement are stored in silos with metering devices.
- Mixing & Foaming: Materials are weighed and mixed with water to form slurry; aluminum powder is added to initiate foaming.
- Casting & Setting: Slurry is poured into molds, where it expands and sets for 2-3 hours to form green bodies.
- Cutting: Green bodies are demolded and cut into blocks of specified dimensions (e.g., 600×200×100mm) using wire cutters.
- Autoclaving: Blocks are loaded into autoclaves for 8-10 hours of curing under high pressure and temperature, enhancing strength.
- Storage & Packaging: Finished blocks are stacked in yards, ready for shipment.
5. Staff Allocation
A total of 30-35 employees are required, working in 3 shifts (8 hours/shift):
- Management: 2 (production manager, quality supervisor).
- Technical staff: 3 (equipment maintenance, process control).
- Production workers: 20-22 (raw material handling, mixing, casting, cutting, curing).
- Logistics & administration: 5-6 (warehousing, transportation, office staff).
Training focuses on equipment operation, safety protocols, and quality control to ensure efficient production.
6. Profit Direction in Central Asian Markets
Central Asian countries (Kazakhstan, Uzbekistan, etc.) offer significant opportunities due to:
- Growing Construction Demand: Urbanization and infrastructure projects (residential buildings, roads) drive demand for cost-effective building materials. AAC blocks, with advantages of lightweight, insulation, and fire resistance, are preferred over traditional bricks.
- Cost Advantage: Local raw material availability reduces production costs. Export prices (≈$80-100/cubic meter) are competitive compared to imported alternatives.
- Policy Support: Governments promote energy-efficient construction, providing subsidies for eco-friendly materials like AAC blocks.
- Distribution Strategy: Partner with local distributors to cover major cities; establish after-sales services (technical guidance) to build brand loyalty.
Profit Margin: With production cost at
- 40−50/cubicmeter,annualprofitcanreach1.5-2.5 million, considering 50,000 cubic meters of sales.
