The sand storage hopper is the starting point of the grinding section. It serves as a buffer for dry quartz sand before feeding it into the ball mill. Its capacity is designed to ensure uninterrupted line operation and a stable material flow.

Sand is loaded into the hopper using a wheel loader. To provide accurate and controlled sand feeding, the hopper is equipped with a vibrating feeder, gate valve, and belt conveyor. This setup prevents clogging, maintains a constant flow, and ensures reliable grinding performance.

The sand feeding system for the ball mill plays a crucial role in maintaining grinding stability and raw material quality. Depending on the plant configuration, sand from the storage hopper can be delivered to the ball mill using:

• A belt conveyor — an efficient solution for inclined material feeding over medium distances;
• A bucket elevator — suitable for vertical transport, especially when space is limited or higher feeding is required.

Both systems ensure consistent and controlled sand delivery, preventing interruptions in milling. The choice depends on the plant layout, line capacity, and specific design requirements.

The dry ball mill is designed to grind quartz sand to the required particle size. This stage is critical in the production of NAAC blocks with low density (D400–D600), where consistent particle distribution directly impacts strength and pore structure uniformity.

The system is equipped with adjustable material feeding, allowing precise control of grinding fineness based on production requirements. Optimized steel ball loading and stable rotation speed ensure maximum efficiency and consistent milling performance.

The mill is built for continuous 24/7 operation with minimal maintenance needs. Output capacity and grinding parameters can be adapted to the specific requirements of the production line.

The pneumatic chamber pump is used to transport finely ground quartz sand through pipelines using compressed air. This technology ensures contact-free transfer, minimizes dust formation, and maintains a stable material flow throughout the NAAC production process.

The system includes an intermediate hopper that connects the ball mill with the pump. This design allows the mill to operate continuously while sand is conveyed into the storage silo, eliminating downtime and improving overall line efficiency.

This system includes two mixing tanks equipped with mechanical agitators, operating alternately. While one tank supplies the ready solution, the other prepares a new batch. Such an arrangement guarantees a continuous and reliable flow of chemical additives to the next production stage.

The process begins with weighing the components according to the recipe. The additives are manually loaded into the tanks and mixed with water. Built-in weighing systems ensure accurate dosing and allow operators to monitor solution volume in real time.

In addition, the tanks are equipped with temperature sensors and dosing pumps that deliver the solution to the concrete mixing unit. The entire process is controlled electronically, ensuring stability, repeatability, and consistent quality of the final product.

This unit consists of a single tank with a mechanical agitator and is designed for the precise preparation of aluminum slurry — the main gas-forming agent in NAAC production.

The process begins with accurate weighing of aluminum powder. The powder is then manually loaded into the tank, where it is thoroughly mixed with water until a homogeneous slurry is obtained.

To maintain stable reaction conditions, the tank is equipped with a weighing system for water dosing, a temperature sensor, and a monitoring system for volume control. This setup ensures precise gas formation, resulting in a uniform porous structure and high compressive strength of the finished blocks.

The aerated concrete mix preparation unit is designed for precise dosing and high-intensity mixing of all raw materials — cement, sand or other mineral fillers, water, chemical additives, and aluminum slurry. At this stage, the foundation of the future blocks is formed: the quality of the mixture directly determines the strength, uniformity, and stability of the final product.

Automation of the Process:

• High-speed activator mixer — ensures even distribution of all ingredients, activating them through intensive mixing and delivering superior quality of the aerated concrete mass.
• Sand weighing feeder — accurately measures and supplies the required amount of sand.
• Cement weighing feeder — provides highly accurate dosing of cement.
• Water dosing system — supplies the exact volume in strict accordance with the recipe.
• Chemical additives dosing system — introduces precisely measured portions of liquid additives into the mix.
• Intermediate tank for aluminum slurry — equipped with a circulation system to prevent separation, as well as a weighing system and temperature sensor to ensure dosing accuracy and mixture stability.

Automation of the Process:

The entire unit is operated by a centralized automation system with industrial controllers and an operator panel (HMI). The operator can set recipes, control material weights, temperature, and mixing time, as well as monitor the process in real time. This eliminates errors and ensures repeatable, consistent production results with every batch.

The cover removal and handling device plays a crucial role in the production cycle of non-autoclaved aerated concrete. It performs a dual function: automatically lifting the cover after the initial hardening stage and placing it back before the next casting cycle.

Once the mixture has undergone primary setting, the mechanism lifts the cover and releases the mold to move to the next section of the line. When the pallet without the block returns to the casting zone, the device accurately places the cover back, fully preparing the mold for the next cycle.

Automation of this process eliminates manual labor, ensures proper protection of the mixture during hardening, and guarantees the stability of the technological flow. As a result, production efficiency increases and the risk of errors is minimized.

The vibro-impact platform is used exclusively in aerated concrete production. Its purpose is to create a stable and uniform pore structure in the mix after it has been poured into the mold.

The filled mold is subjected to controlled vertical impulses and high-frequency vibrations, which evenly distribute the gas throughout the mass. This process prevents the formation of large air pockets and density irregularities, ensuring higher quality and strength of the finished blocks.

The platform is fully integrated into the production cycle and operates in synchronization with the Aerated Concrete Mixing Section and the Automatic Loading Cart, guaranteeing precise mold positioning and a stable workflow.

The system also allows adjustment of vibration intensity and frequency depending on the raw materials used and the selected recipe, providing maximum flexibility and optimal results under different production conditions.

The casting mold is designed for pouring freshly prepared aerated concrete mix and allowing it to set before being transferred to the cutting unit for block sizing.

The mold consists of two main parts:

• Base with wheels — a durable mobile platform that enables easy transport from the casting zone to the cutting area.
• Removable top cover (hood) — placed during casting to ensure accurate block geometry and removed before cutting.

This design guarantees precise block dimensions, ease of handling, and a smooth, efficient production process. Reliable sealing elements prevent leakage during filling and transport.

The cement silo is the primary storage unit in non-autoclaved aerated concrete (NAAC) production, ensuring a stable and controlled supply of cement to the line. It is equipped with a pneumatic loading system and dust filters to minimize emissions and comply with environmental standards.

Cement discharge is carried out through a screw conveyor with adjustable speed, allowing precise dosing into the mixing unit. This flexibility reduces the risk of interruptions and improves process efficiency.

Additional features include level sensors, vibration cleaning, and safety valves, providing reliability, safety, and long service life.

The sand storage silo is designed to accumulate dry ground sand after milling and pneumatic conveying. It ensures stable and controlled feeding of sand into the mixing unit during NAAC mixture preparation.

The discharge system is equipped with a screw conveyor for precise material dosing. For safety, the silo includes a dust filter to minimize emissions, level sensors for monitoring filling, and a safety valve to prevent overpressure.

The pre-curing chamber is a vital part of the non-autoclaved aerated concrete production line. After pouring, the molds are transported into the chamber, where the fresh mass gradually gains strength and develops a stable cellular structure.

Molds are typically kept inside the chamber for 2 to 4 hours, depending on raw material quality, mix design, and ambient conditions. This ensures consistent expansion of the mix and precise geometry of the green cake.

To reduce heat loss, the chamber is equipped with automatic electric air curtains at both entry and exit points. These open only during mold movement, maintaining a stable internal climate while minimizing energy consumption.

The automated transfer cart is designed to move freshly cast molds filled with NAAC mix from the preparation area to the pre-curing chamber. Acting as a crucial link in the production cycle, it ensures smooth material flow and consistent production rhythm.

The cart is equipped with a roller system driven by friction, gently receiving the mold from the conveyor and transporting it along a programmed route. A PLC-based control cabinet manages all movements, keeping the cart fully synchronized with the rest of the production line.

For safety, the cart is fitted with obstacle detection sensors, emergency stop systems, and a manual operation mode for servicing or emergencies. Full integration with the plant’s automation system guarantees precise positioning, reduces manual labor, and enhances process stability.

Positioning conveyors ensure the precise placement of molds filled with NAAC mix inside the pre-curing chamber. Based on automated control signals, each mold is accurately guided to its position and held in place until it reaches the required strength for cutting.

The system operates in full synchronization with automated loading and unloading carts and is fully integrated with the plant’s control system. The number of curing lanes is defined by the factory configuration and required output capacity.

Thanks to its modular design, the layout can be flexibly adapted, optimizing chamber space and ensuring consistent curing conditions. This eliminates manual handling, reduces labor costs, and maintains a stable production rhythm.

The automatic unloading trolley is designed to remove molds with aerated concrete mass from the pre-curing chamber once the required strength has been reached. According to the production program, the trolley carefully takes the mold and transports it to the hood removal unit.

After the hood is removed, the mold is transferred to the cutting section, where the mass is prepared for block sizing. The trolley is fully integrated into the plant’s automation system, operating in synchronization with positioning conveyors and loading trolleys, ensuring a continuous production flow.

For service and flexibility, a manual operation mode is available. Built-in safety sensors and an emergency stop system prevent collisions and ensure safe, reliable operation.

The cutting section conveyor is an integral part of the entire cutting complex. Its main function is to receive the fresh “cake” delivered by the automatic unloading trolley from the pre-curing chamber, push it through the horizontal cutting machine, and transfer it onto the turning table for further processing.

The conveyor is equipped with a frequency-controlled drive, allowing smooth adjustment of movement speed depending on production needs and cutting precision requirements. This ensures high accuracy, perfect synchronization with the cutting equipment, and balanced system loading.

Its reinforced frame guarantees durability, while modular design elements allow easy integration into the production line. Thanks to automatic synchronization with upstream and downstream equipment, the conveyor ensures uninterrupted material flow, boosting productivity and minimizing downtime risks.

The horizontal cutting machine is a key element of the cutting section, responsible for precise calibration of the cake’s height. Once the mold with the hardened NAAC mass is placed on the conveyor, the system smoothly feeds it through the machine, where a band saw performs horizontal cuts on the top and bottom surfaces.

As a result, the cake obtains a perfectly even height, creating optimal conditions for subsequent vertical cutting and ensuring the superior geometry of finished NAAC blocks.

The turntable is a key element of the aerated concrete cutting section. After the cutting carriage performs the horizontal and vertical cuts across the width of the cake, the table automatically rotates the mass by 90° and positions it under the cutting carriage for lengthwise cutting.

Moving along rails, the platform is operated by a programmable control system. Its frequency-controlled drive not only adjusts speed but also ensures smooth start and stop. This feature allows the mass to be positioned with precision, guaranteeing exact block dimensions with minimal deviation.

Importantly, the programmable movement of the turntable enables cutting blocks of different sizes within the same cake, making the system f-lexible for varying production requirements. Full integration with the automated line eliminates misalignments and maintains synchronized workflow, ensuring both high productivity and consistent quality.

The cutting machine for aerated concrete blocks is the core unit of the line, responsible for forming blocks of precise dimensions with consistent quality.

Its reciprocating cutting carriage operates with variable speeds:

• during the downward stroke, reduced speed ensures an accurate cut and precise positioning at the lower point of the mass,
• during the upward stroke, increased speed significantly accelerates the cycle, boosting overall productivity.

The system is equipped with a band saw integrated into the cutting unit, driven by a frequency-controlled motor. This allows operators to adjust the blade speed according to the density, strength, and specific properties of the aerated concrete mass, guaranteeing flexibility and accuracy.

The machine is fully automated and synchronized with other sections of the line, ensuring stable geometry, repeatability, and high performance of the final product.

The final curing chamber is designed to provide stable conditions for holding NAAC blocks after cutting. At this stage, the blocks gain their final strength, reach the required density, and achieve dimensional stability.

The molds remain in the chamber for 8 to 14 hours, depending on raw material quality, regional climate conditions, and mix parameters. To maintain a stable internal environment, the chamber is equipped with automatic thermal curtains at both entry and exit points, which open only during loading or unloading.

The chamber’s insulated design minimizes heat loss and reduces energy consumption, while integrated transport mechanisms move molds in a synchronized cycle. This eliminates manual handling, ensures process rhythm, and supports high operational efficiency.

Such organization prevents uneven curing, reduces the risk of shrinkage cracks, and guarantees consistent product quality.

The automatic loading trolley is designed to organize and streamline the transfer of cut gas concrete blocks into the final curing chamber. Unlike the pre-curing section, which relies on positioning conveyors, this chamber employs an integrated pushing module that moves the block carts smoothly inside.

The carts are loaded sequentially: once one curing lane is filled, the trolley automatically shifts to the next lane. Each incoming cart pushes the previous one forward, ensuring uninterrupted operation and efficient space utilization inside the chamber.

A friction drive provides smooth motion without shocks, while a PLC-based control system synchronizes the trolley’s movements with the plant’s central automation and production schedule.

Safety features include positioning sensors, anti-collision systems, and an emergency stop function. Manual operation is also available for service or emergency use. This solution reduces human involvement, lowers operating costs, and enhances safety, reliability, and overall production efficiency.

The pusher module is a key component of the final curing chamber loading system for NAAC blocks. It operates on a reciprocating principle: each incoming trolley with an NAAC cake pushes the previous one further into the chamber, and this sequence continues until the entire curing track is fully loaded.

Equipped with a frequency-controlled drive, the module ensures smooth start and stop, eliminating jerks and guaranteeing precise pallet positioning. Its robust design is built for continuous 24/7 operation under heavy loads.

Synchronized with the automatic loading trolley and the plant’s central control system, the module maintains a seamless production flow, reduces manual labor, and ensures uniform curing quality for every batch.

The automatic unloading trolley for gas concrete is designed to remove trolleys with fully cured blocks from the final curing chamber and transport them to the packaging area. Once the curing cycle is complete, the block pallets are automatically transferred onto the trolley, which carefully moves them to the next production stage.

The friction drive ensures smooth acceleration and deceleration, eliminating jerks and guaranteeing precise positioning. The trolley is fully integrated into the plant’s automation system and equipped with safety sensors, emergency stop functions, and a manual control mode. This solution improves production efficiency and enhances workplace safety.

After completing the final curing process in the chamber, pallets with NAAC blocks are transferred to the packaging area. The first unit in this section is the automatic gantry-type stacking robot.

This fully automated system, operating under a pre-set program, carefully lifts a full row of hardened blocks directly from the pallet and places it onto the rotary positioning table (see 7.2). The precisely calibrated gripping mechanism and smooth motion control ensure accurate and safe handling of the blocks.

The stacking robot can be easily adjusted to handle different block sizes and stacking patterns, making it a versatile solution for both serial production and customized orders. It enhances overall efficiency while significantly reducing manual labor requirements.

The rotary positioning table is installed directly after the automatic stacking robot. Its primary function is to rotate each row of NAAC blocks by 90 degrees, ensuring the correct orientation for pallet stacking.

This precise rotation allows blocks to be stacked compactly and securely, improving the geometry of the palletized load and reducing the risk of deformation. The table is fully integrated into the automated packaging sequence and operates in synchronization with the stacking robot and palletizing system.

The pallet magazine is an automated storage unit designed to hold a stack of empty pallets and feed them one by one onto the conveyor system.

Whenever the packaging line requires a new pallet, the system automatically releases it, ensuring uninterrupted operation and eliminating the need for manual handling.

The magazine is fully integrated into the overall packaging line and operates in perfect synchronization with other units, guaranteeing precise coordination and a stable production rhythm. It can be replenished with a new stack of pallets without stopping the line, which significantly increases efficiency and ease of operation.

The automatic gantry-type palletizer robot is designed to gently and precisely place block rows onto pallets. Receiving layers directly from the rotary positioning table, it forms uniform and stable stacks with consistent accuracy.

Fully automated and integrated into the packaging line, the system eliminates manual handling and ensures seamless operation. With flexible configuration options, the robot adapts to different block sizes and stacking patterns, delivering reliable performance and long-term efficiency.

The Stretch Hood Wrapping Machine is the final stage of the packaging line. Once the pallet is fully loaded with NAAC blocks, it moves via conveyor into the wrapping zone. The film is sealed at the top, expanded, and smoothly stretched down over the entire pallet, providing tight and seamless coverage in a single operation.

Advantages:

• Airtight packaging without shrink tunnels;
• Protection against moisture, dust, and mechanical damage;
• Neat appearance suitable for direct delivery to clients or construction sites.

The system is fully automated, energy-efficient, and adaptable to different pallet sizes.

Waste Removal Conveyor is designed to transport offcuts and rejected pieces generated at the cutting section to the recycling zone. Installed along the entire length of the cutting line, it ensures continuous removal of waste, preventing accumulation and equipment downtime.

The system maintains cleanliness and safety in the cutting area, operates in a fully automated mode, and is synchronized with the rest of the cutting line. Depending on the plant layout, the waste can be discharged into a bunker, a container, or directly into the crushing unit.льными элементами линии. В зависимости от конфигурации завода, отходы могут направляться в бункер, контейнер или напрямую в установку дробления.

Waste Shredder is a vital component of the recycling section, designed to efficiently crush cutting residues and defective products into a consistent fraction. This process enables either safe disposal or their reintegration into the production cycle.

The unit operates in fully automated mode, seamlessly integrates into the line, and is engineered for continuous 24/7 use. By incorporating the shredder, producers can reduce dependence on fresh raw materials, strengthen the plant’s environmental performance, and achieve tangible cost savings through the reuse of production waste.

Belt Conveyor with Receiving Hopper (optional) is designed to transport crushed waste material from the crusher to the mixing unit. Equipped with a variable-frequency drive, it allows precise adjustment of conveying speed according to production needs and mix requirements.

This solution ensures a continuous and stable flow of recycled material, reduces manual handling, and streamlines the overall workflow. Thanks to its modular design, the conveyor can be seamlessly integrated into existing lines, boosting the efficiency of the waste recycling section.

Cement Silo is designed for the storage of cement and its precise feeding into the dosing unit of the system that prepares the semi-dry mix for vibro-pressing. Material is supplied via a screw conveyor with adjustable speed, ensuring accurate dosing and consistent loading.

The silo can be equipped with a dust collection system (filter), level sensors, and a safety valve to improve process safety and control. Fully integrated into the plant’s central control system, it guarantees automated operation, stable material supply, and minimal human intervention.

Semi-Dry Mix Preparation Unit is designed for precise dosing and mixing of raw materials used in the vibro-pressing process. The system includes cement and water feeding modules, along with a high-performance mixer mounted on load cells, ensuring stable quality and repeatability of each batch.

Integration into the centralized waste recycling system allows efficient use of cuttings and residual materials, reducing production costs and increasing the environmental efficiency of the plant.

Semi-dry vibro-pressing machine is designed for the production of high-strength blocks from semi-dry concrete mixes. The blocks are formed through the combined action of vibration and compression, which guarantees the required density, dimensional accuracy, and high-quality surface.

The equipment can operate in automatic or semi-automatic mode and is fully integrated into the waste recycling line, enabling efficient use of crushed material. Its robust design and stable production cycle make the machine suitable both for continuous operation and for integration into medium- and high-capacity production lines.