Foam Concrete Block Production Line

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Foam Concrete Block Production Line – 100–300 m³/day

High-efficiency, automated production line for high-quality foam blocks

Reliable and Scalable Solution for Foam Concrete Block Production

Designed for medium-scale production, the non-autoclaved foam concrete block production line delivers a capacity of 100–300 m³ per day, making it an ideal choice for growing construction companies.

Equipped with advanced technology, the line ensures consistent quality and density of foam blocks while maintaining energy efficiency and reducing overall production costs.

Thanks to its intuitive interface and high level of automation, the system allows operators to manage production with ease, optimizing workflow and increasing productivity.

The modular design of the equipment makes upgrades and expansions simple, enabling manufacturers to scale production as market demand grows.

This robust and reliable production line is built from high-quality materials and engineered for intensive daily operation, ensuring long-term performance while minimizing maintenance requirements.

In addition, its cost-efficient operation and adaptability to different project needs provide companies with a strong competitive advantage, supporting market expansion and sustainable business growth.

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Plant Overview

Parameter	Value
Daily production capacity	100 – 300 m³/day	The output depends on the configuration of the line and the number of installed cutting units: Key considerations include: 1 cutting unit → 100 m³/day 2 cutting units → 200 m³/day 3 cutting units → 300 m³/day
Automation level	Up to 90%	The degree of automation depends on the selected configuration: the line can operate in a semi-automatic mode or as a fully automated system with a high level of automation. At the same time, all key elements of the line are fully automated by default, which reduces manual labor and minimizes errors, ensuring stable quality and efficiency regardless of the chosen package.
Required installation area	1000 – 3000 m²	Required Area for Installation and Operation of the Block Production Line is approximately 1,000 to 3,000 m². The final size depends on the specifics of the project and is determined during the design and planning stage. Key factors influencing space requirements include: Compliance with local construction standards and safety regulations (sanitary, fire safety, occupational health). Building configuration, which depends on target capacity, level of automation, and methods of material handling (forklifts, roller conveyors, automated transport systems). Important aspects include internal height, column spacing, floor strength, lighting, ventilation, and technological openings (industrial gates, ducts, service passages). Integration of auxiliary and staff areas, such as changing rooms, showers, restrooms, break rooms, canteens, offices, workshops for mechanics and electricians, and spare parts storage. These facilities may be integrated into the production hall or located in adjacent buildings Raw material storage Storage of cement, additives, and aggregates is planned individually — either in a separate warehouse or in integrated unloading areas. The required space depends on storage volumes, delivery intervals, supply chain reliability, and local transport accessibility. If deliveries are irregular, a larger buffer stock may be needed; with stable and frequent supplies, more compact storage is possible. Finished block storage A dedicated area is required for temporary storage of finished blocks before shipping. The size depends on the chosen logistics model: direct dispatch after production or intermediate warehousing. Key factors include shipment frequency, availability of transport, delivery scheduling, and efficiency of loading/unloading operations. Staff and auxiliary facilities Employee comfort is ensured by providing changing rooms, restrooms, break areas, and canteens. Requirements are determined by workforce size, number of shifts, and labor regulations.
Installation time	20 – 30 days
Number of operators	6 – 10 persons
Installed power	100 – 400 kW	The required power depends on the selected configuration and level of automation. If a ball mill for sand grinding is included (optional), energy consumption will be higher. When alternative raw materials or different mix designs are used, the installed power is adjusted accordingly to the chosen technology.
Voltage	380 V / 50 Hz 400 V / 60 Hz
Block size	600 х Adjustable х Adjustable	The maximum block height is up to 600 mm, determined by the casting mold height. Block length and width can be freely adjusted within the mold matrix to meet specific project requirements.

Please keep in mind that key parameters — such as staffing levels, required floor space with auxiliary areas, and power supply capacity — depend on the selected line configuration and overall project requirements.

All values are determined on a case-by-case basis, taking into account the layout, degree of automation, and site-specific conditions.

Parameter	Value
Water consumption D400 / D500 / D600	200/200/230 L/m³	The values provided are indicative.The final water consumption will be determined during the recipe adjustment stage by our technologist, based on the quality and characteristics of raw materials available in the customer’s region. The mix design and raw material properties have a direct impact on the final figures.
Cement consumption D400 / D500 / D600	250/270/280 kg/m³	The values provided are indicative. The exact cement consumption will be determined during the mix design stage by our technologist and depends primarily on the quality of cement available in the region, as well as on the additives used and raw material characteristics. Cement quality plays a crucial role in ensuring the strength and consistency of the blocks.
Sand consumption D400 / D500 / D600	120/200/290 kg/m³	Sand consumption is directly related to the quality of cement. The higher the cement quality, the more sand can be used, which reduces the required amount of cement. If alternative raw materials are selected, the same principle applies: the final consumption depends on the quality of the cement used and will be adjusted by the technologist during the mix design process.
Adaptability to raw material	Works in hot/cold/humid regions
Minimum indoor temperature	Not below +5 °C (41 °F)
Compressive strength	1.1 – 13.5 MPa (11.2 – 137.7 kgf/cm²)
Block density	300 – 1200kg/m³
Casting volume per mold	1,2m³

Our engineering team develops a customized production concept based on the client’s target capacity and long-term objectives.

The configuration is adjusted to match the enterprise’s specific features and business priorities, ensuring reliability, flexibility, and the potential for scalable growth.

Key Features

Intelligent control system (optional) — remote monitoring, diagnostics, and real-time alerts.
Full customization — block dimensions, output capacity, and line configuration are tailored to client needs.
Fast commissioning — production can be launched within 20–30 days after site preparation.

Accurate and consistent block geometry — the cutting system ensures high precision and minimal waste.
Energy-efficient production — no autoclave required, reducing energy costs and simplifying installation.
Reliable performance in all climates — proven operation in hot, cold, and humid regions.

Adaptation to local raw materials — recipes are optimized by technologists based on regional resources.
Low operating costs — reduced energy consumption and minimal staffing requirements.
Scalability — the modular design allows expansion of production capacity as demand grows.

Blocora FC 300-A — Complete Scheme of the Foam Concrete Block Production Line (300 m³/day)

To give you a clearer understanding of how a foam concrete block production line with a capacity of 300 m³/day is organized and how individual units work together, we have prepared a detailed scheme with numbered components.

Below you will find a description of each section, explaining its function and role in the overall production process.

This section provides a comprehensive view of the plant layout and helps you evaluate how the line can be integrated into your facility, ensuring alignment with your business goals and project requirements.

1Sand Milling Section (optional) 2Additives and Foam Agent Solution Preparation Unit 3Foam Concrete Mix Preparation Section 4Pre-Cutting Curing Section 5Cutting Section 6Final Curing Section 7Packaging Section (optional) 8Waste Collection and Recycling Section

Sand Milling Section (optional)

1.1Sand Storage Hopper 1.2Sand Feeding System to the Mill 1.3Dry Grinding Ball Mill 1.4Pneumatic Transfer Pump

Sand is the most common and cost-effective filler used in the production of foam concrete blocks. It is available in almost every region and serves as the foundation for achieving durable and economical material. However, when producing blocks with densities of D400–D600, proper sand preparation becomes critical. Using unground sand may result in higher cement consumption, reduced strength, and an uneven block structure.

On the Blocora FC 300-A line, as well as on other configurations of the FC series, quartz sand can undergo dry grinding to optimize particle size distribution. The ideal moisture level for efficient grinding is 0.5–1.5%. If the sand moisture exceeds these values, a drum dryer can be integrated into the line.

Properly prepared sand ensures a uniform block structure, improved compressive strength, and reduced cement consumption, making production more stable and cost-efficient.

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1.1. Sand Storage Hopper

The sand storage hopper is designed to accumulate and evenly feed sand into the production process. Its main purpose is to maintain a stable reserve of sand before dosing and mixing with cement slurry and foam.

Loading is performed by a wheel loader. The hopper is equipped with a vibrating feeder and a controlled discharge system, which ensures even material feeding and prevents process interruptions. This configuration supports stable line operation and consistent block quality.

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1.2. Sand Feeding System to the Mill

The sand feeding system transfers material from the storage hopper to the dosing and mixing zone. The specific solution is selected according to plant layout and technical requirements:

Belt conveyor — used for inclined transportation with minimal material loss;
Bucket elevator — suitable for lifting sand to greater heights within compact plant layouts.

Both systems provide even and reliable feeding, reduce downtime risks, and help maintain the stability of the production cycle. The choice depends on the facility design, production volumes, and requirements of the subsequent processes.

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1.3. Dry Grinding Ball Mill

The dry ball mill is applied for grinding quartz sand to a fine, homogeneous state required for producing high-quality foam concrete blocks. The fineness of grinding plays a key role in recipe stability and the durability of finished products.

The system allows operators to adjust the degree of grinding through controlled material feeding. Proper steel ball loading and optimized drum rotation ensure consistent milling results with minimal deviations.

Designed for 24/7 operation, the equipment is highly reliable and requires little maintenance. Output can be adapted to meet the demands of different line configurations.

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1.4. Pneumatic Transfer Pump

The pneumatic chamber pump is applied for conveying dry ground sand through pipelines using compressed air. The system guarantees an even material flow, prevents segregation, and contributes to consistent mix quality.

An intermediate hopper is integrated as a buffer between the ball mill and the pump. This feature allows milling to continue without interruption during silo loading, ensuring greater efficiency and reliability of the production line.

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Additives and Foam Agent Solution Preparation Unit

The preparation unit for chemical additives and foam agent solution is an essential stage in the production of non-autoclaved foam concrete (FC). It ensures the stability, homogeneity, and performance of the mix, directly affecting the strength, density, and thermal insulation properties of the final blocks.

The unit includes two separate mixing tanks: one for preparing chemical additives and the other for preparing the foam agent solution. Unlike NAAC technology, there is no aluminum slurry preparation here — foam generation is carried out by a dedicated foam generator at a later stage.

Chemical Additives Preparation Tank

This tank is used for mixing and dissolving chemical additives according to the recipe. The additives are manually loaded into the tank and mixed with water using a mechanical agitator.

The tank is equipped with a weighing system for accurate dosing of water and additives, as well as temperature sensors for process control. Dosing pumps ensure precise and stable delivery of the prepared solution to the main mixing unit.

Foam Agent Solution Preparation Tank

The second tank is designed for preparing the foam agent solution. Protein-based or synthetic foaming agents are dissolved and mixed with water until a homogeneous solution is obtained.

The tank is also equipped with a weighing system and dosing pumps, ensuring precise concentration of the solution and reliable delivery to the foam generator.

This approach guarantees consistent foam quality, stable density, and reproducible results in the production of foam concrete blocks.

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Foam Concrete Mix Preparation Section

3.1Foam Concrete Mixing Unit 3.2Cover Handling Device 3.3Cement Silo (optional) 3.4Finished Sand Storage Silo (optional) 3.5Casting Mold for Foam Concrete

The foam concrete mix preparation section is the central element of the entire production line, as it is here that the base composition of the future blocks is formed. The quality of component mixing directly determines the strength, density, thermal insulation properties, and overall stability of the finished products.

The process includes the precise dosing of cement, sand (or other aggregates), water, and chemical additives into the main mixing unit. The foaming agent solution is not fed directly into the mixer but first enters a specially designed foam generator, where stable foam is produced. The ready foam is then delivered to the mixing unit and evenly distributed throughout the mixture.

The mixing unit is equipped with a high-quality cycloid mixer that ensures thorough blending of components without destroying the foam structure, guaranteeing consistent mix properties and high quality of the finished blocks.

Modern automation systems allow full control over every stage of the process — from dosing to mixing time — ensuring repeatability of results and consistently high block quality.

The section is designed with scalability in mind: it can be adapted to various mix recipes, production capacities, and levels of automation depending on the specific requirements of the project.

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3.1.

Foam Concrete Mixing Unit

The foam concrete mixing unit is a central element of the production line, where the homogeneous composition of the future blocks is formed. At this stage, cement, sand (or other mineral fillers), water, and chemical additives are mixed in precise proportions.

A key role is played by the foam generator, specifically developed for this technology. The foaming agent solution does not go directly into the mixer but first enters the foam generator, where a stable fine-pored foam is created. The prepared foam is then introduced into the mix, ensuring a uniform structure and reduced block density.

At the heart of the unit is the cycloidal mixer, which provides intensive and even blending without destroying the foam structure. This guarantees strength, thermal insulation performance, and consistency of the final products.

The process is supported by a modern automation system. Integrated weighing dispensers for cement, sand, water, and additives, along with automated control of mixing time and parameters, ensure precision and reliability. The operator panel (HMI) allows recipe management, real-time monitoring, and error diagnostics. This approach delivers stable, repeatable quality and minimizes human error.

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3.2.

Cover Handling Device

The cover handling device is an automated system used in the production of foam concrete blocks, performing a dual function: removing the mold cover after the initial setting stage and precisely placing it back before the next casting cycle.

Once the mixture has undergone its initial setting, the mechanism lifts the cover, allowing the mold to move to the next stage of the production line. When the pallet without the block array returns to the casting zone, the device accurately repositions the cover, preparing the mold for a new batch of foam concrete mix.

This automated process eliminates manual labor, protects the mixture during curing, and ensures process stability, thereby improving overall production efficiency and reliability.

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3.3.

Cement Silo (optional)

The cement silo plays a key role in foam concrete block production, providing safe storage and consistent cement supply. The system is designed with dust filtration and pneumatic loading to ensure environmental compliance.

Cement is fed into the mixing unit via a screw conveyor with adjustable speed, which enables accurate dosing and adaptability for different mix designs.

For uninterrupted operation, the silo can be fitted with level sensors, cleaning systems, and safety valves, ensuring smooth production and extended equipment durability.

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3.4.

Finished Sand Storage Silo (optional)

The sand storage silo acts as a buffer unit after the grinding and pneumatic conveying stages. Its role is to maintain uninterrupted sand supply to the mixing section during foam concrete preparation.

It features a controlled discharge system with a screw conveyor for accurate feeding, along with a dust filter, level sensors, and a safety valve — ensuring environmental safety, operational reliability, and protection during production.

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3.5.

Casting Mold for Foam Concrete

The mold is used for pouring foam concrete mix and initial setting before transfer to the cutting unit.

It is composed of:

Base with wheels – a sturdy mobile platform for convenient movement between casting and cutting sections.
Removable top cover (hood) – ensures dimensional accuracy during casting and is removed before cutting.

The construction ensures consistency, prevents leaks with sealing systems, and supports a streamlined, reliable production workflow.

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Pre-Cutting Curing Section

4.1Pre-Curing Chamber 4.2Automated Loading Shuttle Cart 4.3Positioning Conveyors 4.4Automated Unloading Trolley

Before foam concrete blocks are cut, the cast mixture must partially harden to form a stable mass. This pre-curing step is critical for achieving structural stability and precise block dimensions during cutting.

The pre-curing chamber maintains constant temperature and humidity, allowing even pore distribution and optimal mechanical properties of the material.

The setup includes insulation and automated transfer mechanisms that coordinate the movement of molds, preparing each batch for accurate and efficient cutting.

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4.1.

Pre-Curing Chamber

The pre-curing chamber plays a key role in foam concrete production, allowing the mass to stabilize and gain strength before cutting. After pouring, the molds are moved into the chamber, where the material gradually hardens and forms a uniform structure.

The holding time is typically 2 to 4 hours, depending on the mix design and raw material properties, including cement quality and chemical additives. This regime ensures dimensional stability and reliable product quality.

The chamber is fitted with electric air curtains at the inlet and outlet to maintain constant conditions. The system automatically opens and closes as molds move, preserving temperature and humidity inside.

This solution guarantees even pre-curing, resulting in precise, clean cutting and durable, high-quality foam concrete blocks.

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4.2.

Automated Loading Shuttle Cart

This automated cart transports molds filled with foam concrete to the pre-curing chamber, ensuring uninterrupted and accurate operation of the production line. It eliminates the need for manual handling and streamlines material flow.

Its friction-driven roller system provides smooth and careful movement of molds, while the integrated PLC cabinet guarantees synchronization with the production schedule. Full automation ensures accuracy, efficiency, and reliability throughout the process.

The system is equipped with safety sensors, emergency stop functions, and manual control mode. By reducing human intervention, the cart increases workplace safety, lowers labor costs, and supports continuous and stable production.

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4.3.

Positioning Conveyors

This conveyor system is designed to accurately position molds filled with foam concrete inside the pre-curing chamber. Each mold is automatically guided to its designated location and securely held until it reaches the necessary strength for cutting.

The conveyors are synchronized with automated transfer carts and fully integrated into the plant’s central control logic, ensuring smooth coordination across the line. The number of curing lanes within the chamber depends on the chosen configuration and target production volume.

Its modular setup allows flexible adaptation to different site layouts, providing efficiency, safety, and stable quality for every batch of blocks.

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4.4.

Automated Unloading Trolley

This trolley is used for the automatic transfer of molds with foam concrete mass from the pre-curing chamber to the next stage of the production line. Once the mold has gained sufficient strength, the trolley removes it and delivers it to the hood removal unit.

From there, the mold is automatically directed to the cutting section, where the blocks are processed and prepared for subsequent operations. The trolley is controlled by a programmable logic controller (PLC) and fully integrated into the plant’s central control system.

Safety mechanisms include obstacle detection sensors and an emergency stop function. In addition, operators can use the manual mode for maintenance or in case of unexpected situations.

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Cutting Section

5.1Conveyor 5.2Horizontal Cutting Machine 5.3Rotary Positioning Table 5.4Cutting Machine

The cutting section is a crucial stage in foam concrete production, ensuring precise block geometry and consistent product performance. After controlled pre-curing, the mass is transferred to the cutting complex, where it is divided into blocks of required sizes.

The cutting system is always supplied as fully automated, regardless of whether the line is semi-automatic or fully automatic. It delivers both horizontal and vertical cutting at high speed and accuracy, with dimensional deviations not exceeding ±1 mm.

Adjusting block dimensions is straightforward: the operator simply sets the required parameters on the control panel, making the process quick and user-friendly. Full integration into the central control system guarantees synchronization with other stages of the line and maximum production efficiency.

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5.1.

Conveyor

The cutting section conveyor plays a key role in the automation of foam concrete block production. Once the unloading trolley delivers the cured “cake” from the pre-curing chamber, the conveyor receives it, pushes it through the horizontal cutting machine, and moves it onto the turning table.

This conveyor is always supplied as a standard part of the cutting complex and is fully integrated into the line’s control system. The frequency-controlled drive provides flexibility and precise speed control, ensuring smooth cutting results and adaptability to different mix designs and block densities.

Additionally, the system is equipped with overload protection and automatic motion monitoring, guaranteeing stable operation and operator safety. Its innovative design reduces vibration and noise, delivering long-term durability and more comfortable working conditions.

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5.2.

Horizontal Cutting Machine

The horizontal cutting machine is an essential part of the foam concrete block production line, ensuring accurate leveling of the cake’s height. After removal from the curing chamber and placement onto the conveyor, the cake passes smoothly through the machine, where a band saw executes horizontal cuts along the top and bottom surfaces.

This process produces a perfectly even cake height, simplifying subsequent vertical cutting and guaranteeing clean geometry of the blocks. As a result, material waste is minimized, and overall production efficiency is increased.

The machine is equipped with a frequency-controlled drive, enabling flexible adjustment of the saw speed according to the cake’s density and strength. This provides high precision and universal adaptability.

Fully integrated into the line’s automation system, the machine delivers reliability, long service life, and consistent performance under continuous production loads.

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5.3.

Rotary Positioning Table

The turntable plays a central role in the foam concrete cutting complex. Once the cutting carriage has sliced the cake to the required width, the table secures it, rotates it 90°, and places it under the cutting carriage for lengthwise cutting.

Equipped with a frequency-controlled drive, the system guarantees smooth acceleration and deceleration, which is especially critical for precise positioning at stop points. This ensures block dimensions strictly meet the required specifications with high repeatability.

Because the turntable is fully programmable and can move varying distances, it allows blocks of different sizes to be cut from the same cake. This flexibility gives producers a competitive advantage in meeting diverse customer needs. Automated integration with the rest of the line keeps the production rhythm stable, enhances cutting accuracy, and boosts overall efficiency.

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5.4.

Cutting Machine

The cutting machine for foam concrete blocks is a central element of the production line, designed to deliver precise block geometry and reliable processing.

Its reciprocating cutting carriage ensures:

Slow, controlled downward motion for accurate cuts and stable positioning.
Fast upward return for shorter cycle times and increased throughput.

A band saw, integrated into the unit and driven by a frequency inverter, enables flexible speed adjustment depending on the density, strength, and characteristics of the foam concrete mass. This ensures uniform results even when recipes or raw materials vary.

As a key component of the cutting section, the machine guarantees high accuracy, operational efficiency, and consistent quality of foam concrete blocks.

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Final Curing Section

6.1Final Curing Chamber 6.2Automatic Loading Trolley 6.3Pusher Module (Conveyor) 6.4Automatic Unloading Trolley

Final Curing Section — a key section of the line designed to bring blocks to their final strength and geometric stability. The chamber ensures even curing of the foam concrete mass, preventing deformations and shrinkage cracks, while lowering the overall risk of shrinkage, which directly affects the quality of finished blocks.

The chamber features thermal insulation and automated transport systems, streamlining the production cycle and supporting high line efficiency.

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6.1.

Final Curing Chamber

The final curing chamber ensures optimal conditions for holding foam concrete blocks after cutting. During this stage, the blocks achieve their design strength, acquire stable geometry, and fully form their porous structure.

The blocks typically remain in the chamber for 8 to 14 hours, with the exact duration determined by raw material composition, temperature, and humidity. Automatic thermal curtains installed at the chamber’s entry and exit maintain uniform internal conditions by opening only during mold transfer.

The chamber is equipped with thermal insulation and energy-efficient solutions to reduce operating costs. Automated transport systems are fully integrated into the production cycle, providing consistent mold movement without manual intervention.

This process ensures even curing, prevents deformation, and improves the long-term durability of the final products.

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6.2.

Automatic Loading Trolley

The automatic loading trolley is responsible for the accurate and reliable placement of foam concrete block carts into the final curing chamber. Unlike in the pre-curing section, where positioning conveyors are applied, here an integrated pushing mechanism transfers the block carts inside the chamber.

The loading process is fully sequential: once one curing lane is completely filled, the trolley automatically switches to the next. As new carts arrive, they push the earlier ones further, creating a continuous flow and steady production rhythm.

Equipped with a friction drive and a PLC-based control system, the trolley ensures gentle movement, precise positioning, and synchronization with the overall plant automation.

Safety is guaranteed through integrated detection sensors, collision-prevention logic, and an emergency stop system. Manual control is provided for servicing and emergencies. The automated trolley minimizes labor costs, improves operator safety, and contributes to a stable and efficient production cycle.

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6.3.

Pusher Module (Conveyor)

The pusher module is an essential part of the final curing chamber loading system for foam concrete blocks. Its operation is based on a reciprocating motion: each new trolley with a foam concrete cake pushes the previous one further inside the chamber, gradually filling the entire track until fully loaded.

A frequency-controlled drive enables smooth movement, avoiding jerks and ensuring accurate positioning of pallets. The guiding and pushing mechanisms are designed for heavy-duty, 24/7 operation.

Integrated with the automatic loading trolley and the plant control system, the module supports continuous production, minimizes manual involvement, and guarantees consistent curing quality of foam concrete blocks.

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6.4.

Automatic Unloading Trolley

The automatic unloading trolley for foam concrete handles the removal of trolleys carrying fully cured foam concrete blocks from the final curing chamber and delivers them to the packaging area. After curing, pallets are automatically pushed onto the trolley, which provides stable and accurate transportation.

The friction drive system guarantees steady motion and precise alignment. Fully automated and integrated into the plant’s control system, the trolley is equipped with onboard controllers, collision-prevention sensors, and manual operation options. This setup reduces labor costs, maintains workflow continuity, and ensures safe handling of finished blocks.

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Waste Collection and Recycling Section

7.1Gantry-Type Automatic Stacking Robot 7.2Rotating Positioning Table 7.3Pallet Magazine 7.4Automated Gantry Palletizing Robot 7.5Stretch Hood Wrapping Machine

The Packaging Section marks the final stage of the production cycle, where blocks are carefully stacked on pallets and securely wrapped for storage or transportation. Proper packaging ensures product integrity throughout the logistics chain and preserves its professional appearance.

Depending on project requirements, a variety of solutions can be implemented — from basic strapping systems to advanced fully automated equipment. One of the most effective options is the Stretch Hood system, which provides a strong elastic film cover. This method delivers excellent protection against dust, moisture, and mechanical impacts, making it ideal for long-term storage and long-distance shipping.

By automating packaging operations, labor costs are reduced, production flow is accelerated, and workplace safety is improved — turning packaging into an efficient and reliable conclusion of the entire production process.

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7.1.

Gantry-Type Automatic Stacking Robot

Once the pallets with foam concrete blocks exit the final curing chamber, they are directed to the packaging area. The process begins with the automatic gantry-type stacking robot.

The robot works in a fully automated mode, executing programmed operations to pick up blocks from the pallet and place them neatly onto the rotary positioning table (see 7.2). Its gripping system is designed to minimize stress on the blocks, preserving their geometry and ensuring reliable, precise handling.

With the ability to adapt to different block dimensions and stacking schemes, this stacking robot provides a universal solution that increases productivity, ensures consistent quality, and streamlines the packaging workflow for projects of any scale.

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7.2.

Rotating Positioning Table

The rotary positioning table is positioned immediately after the stacking robot and is designed to rotate each row of foam concrete blocks by 90 degrees. This step ensures the correct orientation for accurate and dense pallet stacking.

By working in full synchronization with the rest of the packaging line, the table guarantees uniform stack formation, stable load geometry, and reliable preparation of blocks for shipment. It is seamlessly integrated with the palletizing system for smooth, automated operation.

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7.3.

Pallet Magazine

The automated pallet magazine serves as a buffer system for empty pallets, storing them in stacks and supplying them sequentially to the conveyor.

When the packaging process needs a new pallet, the magazine automatically delivers one, keeping production continuous and minimizing downtime.

Fully integrated into the packaging line, the magazine works in sync with the palletizing robot, conveyors, and other systems. This ensures a steady flow of materials and smooth coordination across the entire process. Pallets can be reloaded at any time without interrupting operations, making the solution both reliable and highly efficient.

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7.4.

Automated Gantry Palletizing Robot

The gantry palletizer robot provides the final step in the packaging process by lifting block rows from the rotary table and positioning them on pallets with high precision.

Operating under a pre-programmed sequence, the robot guarantees accurate alignment and stable stacking. Its full integration with the packaging line ensures continuous workflow, while its versatility allows adjustment to various block dimensions and stacking layouts, making it an ideal solution for modern high-capacity plants.

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7.5.

Stretch Hood Wrapping Machine

The Stretch Hood Packaging Machine completes the packaging process. When the pallet with foam concrete blocks is ready, it is automatically transferred to the wrapping zone. The film is sealed at the top, then expanded and drawn down over the pallet, tightly securing the blocks and stabilizing the stack.

Advantages:

Reliable protection from dust, moisture, and impacts;
No need for additional shrink equipment;
Clean, professional look, ensuring the product is market-ready.

The unit is fully automated, seamlessly integrated into the packaging line, and designed for continuous operation.

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Packaging Section (optional)

8.1Waste Removal Conveyor 8.2Waste shredder 8.3Belt Conveyor with Receiving Hopper (optional) 8.4Cement Silo (optional) 8.5Semi-Dry Mix Preparation Unit (optional) 8.6Semi-Dry Vibropressing Machine (optional)

The Waste Collection and Recycling Section transforms production waste into new opportunities. Offcuts and rejected blocks from the cutting stage are transported on an automated conveyor and carefully processed in a crushing system.

Once recycled, the material can be returned to the ball mill and reused in the mix — reducing costs, saving raw materials, and boosting the efficiency of the entire plant.

For companies seeking even more value, the section can optionally include equipment for vibropressed block production. This not only eliminates waste but also creates an additional product line, making the plant more sustainable, profitable, and environmentally responsible.

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8.1.

Waste Removal Conveyor

Waste Removal Conveyor is a key element that guarantees a clean and stable production process. It collects all residues from the cutting section and automatically transports them to the recycling zone.

Thanks to its continuous operation and full integration with the cutting line, the conveyor eliminates the need for manual handling, increases workplace safety, and reduces labor costs. Depending on the configuration, the waste can be discharged into a container, a storage bunker, or directly into the crushing system, making the process flexible and highly efficient.

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8.2.

Waste shredder

Waste Shredder is designed to process cutting residues and rejected blocks into fine fractions, simplifying further handling, disposal, or reintroduction into the production cycle. With its robust design and reliable performance, the unit ensures continuous operation of the line while maintaining a clean and organized production environment.

At the same time, the processed material becomes a valuable secondary resource: it can be reused, reducing raw material costs and minimizing disposal expenses. In this way, the shredder not only optimizes production efficiency but also enhances the plant’s sustainability and overall profitability.

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8.3.

Belt Conveyor with Receiving Hopper (optional)

Belt Conveyor with Receiving Hopper (option) serves as the link between the crusher and the mixer, providing reliable transportation of shredded waste. The variable-frequency drive enables flexible control over material feed, ensuring uniform loading and consistent mix quality.

By automating material handling, the conveyor enhances productivity and minimizes downtime. The system is engineered for long-term operation, easy maintenance, and can be adapted to different plant configurations, making it a valuable addition to any recycling setup.

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8.4.

Cement Silo (optional)

Cement Silo plays a key role in the recycling section, providing reliable storage and controlled feeding of cement into the dosing unit. The screw conveyor with a frequency-controlled drive allows the feeding speed to be adjusted according to the recipe, delivering precise dosing and high-quality mix preparation.

For maximum efficiency and safety, the silo may be fitted with a dust collection system (filter), level sensors, and a safety valve. Seamlessly integrated into the plant’s automation system, it ensures uninterrupted production, operational efficiency, and long-term reliability.

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8.5.

Semi-Dry Mix Preparation Unit (optional)

Semi-Dry Mix Preparation Unit is a key component of the waste recycling section, providing highly accurate dosing of cement, water, and recycled materials. The mixer, mounted on load cells, guarantees consistent quality and homogeneity of the mix, directly contributing to the strength and durability of the final products.

Fully integrated into the plant’s automated recycling system, this unit maximizes efficiency by turning production waste into valuable raw material, delivering both economic benefits and long-term sustainability.

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8.6.

Semi-Dry Vibropressing Machine (optional)

Semi-dry vibro-pressing machine offers a modern solution for producing premium-quality blocks from semi-dry mixes. By combining vibration and compression, it delivers products with superior density, precise geometry, and durable surfaces that meet international standards.

Integration with the recycling line allows production waste to be converted into valuable raw material, reducing costs and improving the sustainability of the process. A strong construction, energy-efficient cycle, and the option of automatic or semi-automatic operation make this machine the perfect choice for both continuous production facilities and rapidly growing enterprises.

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