The sand storage hopper is the starting point of the milling section. It serves as a buffer for holding dry quartz sand before it enters the grinding system. Its volume is designed to ensure continuous operation of the ball mill and a stable flow of material.

Sand is loaded into the hopper using a wheel loader. The hopper is equipped with a vibrating feeder, a slide gate, and a belt conveyor to ensure accurate and controlled sand discharge into the milling area. This setup prevents clogging, supports consistent material flow, and improves the overall reliability of the system.

Depending on the plant configuration, sand is transferred from the storage hopper to the ball mill using one of the following systems:

• A belt conveyor — used for inclined material feeding;
• A bucket elevator — suitable for vertical transport, especially where space is limited.

Both systems provide a stable and controlled sand flow to the grinding zone and are selected according to layout conditions and production needs.

The ball mill is designed for fine dry grinding of quartz sand to the required particle size. This is a key process step, especially when producing low-density blocks (D400–D600), where material uniformity is crucial for strength and pore structure.

The system includes adjustable material feed, allowing operators to control the grinding fineness according to production needs. Optimal loading of steel balls and controlled rotation speed ensure consistent and efficient grinding.

The mill body is protected by wear-resistant steel lining or specialized abrasion-resistant materials, significantly extending equipment service life. It is equipped with a dust extraction system and automatic discharge with particle separation.

Designed for continuous 24/7 operation, the mill requires minimal maintenance. Output capacity can be tailored to fit the production line's performance requirements.

The pneumatic transfer pump is used to convey dry ground sand through a pipeline using compressed air. This system enables contactless material transfer, minimizes dust generation, and ensures a stable sand flow during production.

The system includes an intermediate buffer hopper, which acts as a link between the ball mill and the pump, ensuring continuous mill operation during sand transfer to the silo.

The silo is used to store dry ground sand after grinding and pneumatic transfer. It ensures continuous and controlled sand feeding to the mixing station during concrete preparation.

The discharge system with controlled flow is equipped with a screw conveyor for precise material delivery. The silo also includes a dust filter to minimize dust emissions and improve workplace safety. Level sensors can be installed for fill monitoring, along with an emergency pressure relief valve to protect against overpressure.

The curing chamber is designed to maintain optimal temperature conditions during the initial setting phase of the aerated concrete mix. Once the mould is filled, it is transported into the chamber, where the fresh mass begins to gain strength and develop its porous structure.

To retain heat and reduce energy loss, the chamber is equipped with electric thermal curtains at the entry and exit points. These curtains automatically open and close during mould movement, preserving a stable internal environment.

This step is critical to ensure consistent curing across all batches, which directly affects the accuracy of cutting and the overall quality of the finished blocks.

This automated shuttle cart is designed to transfer freshly poured moulds from the vibrating platform to the pre-curing chamber. Equipped with friction-driven rollers, it gently receives the mould from the conveyor and moves it precisely to the assigned position inside the chamber.

The cart operates under a dedicated control cabinet with a programmable logic controller (PLC), which ensures accurate positioning based on the production schedule. It is fully integrated into the plant’s central control system, enabling synchronized operations with all other components of the production line.

To ensure safety, the shuttle is equipped with obstacle detection sensors and emergency stop systems. Manual override functionality is also provided for service and emergency scenarios.

Thanks to its automated logic, this cart ensures efficient material flow and eliminates manual handling, reducing labor costs and improving workplace safety.

The positioning conveyors are responsible for placing freshly filled moulds precisely within the pre-curing chamber. Based on automated control signals, each mould is directed to its designated track and held in place for the required curing time until it reaches the necessary cutting strength.

The conveyor system operates in strict synchronization with the loading and unloading shuttle carts and is fully integrated with the plant’s control system. The number of tracks (or curing lanes) within the chamber is determined by the specific configuration and production capacity of the plant.

This modular system allows for flexible layout design and optimized space utilization within the chamber, ensuring maximum efficiency and consistent curing quality for each batch.

This cart is designed to automatically extract fully cured moulds from the pre-curing chamber according to the programmed production sequence. Once the mould has reached the required cutting strength, the cart collects it and transports it to the Cover Handling Device, where the protective cover is removed.

After the cover is removed, the shuttle cart transfers the mould to the Cutting Section for further processing. The cart is fully automated and synchronized with the overall plant control system, ensuring seamless coordination between the curing chamber and the cutting area. It also features manual override options and safety systems to prevent collisions and ensure safe operation.

After the curing process, the aerated concrete cake, together with the wheeled pallet (part of the mold), is transferred by the unloading transfer trolley to the side trimming machine. The cover has already been removed at this stage.

The side trimming machine removes the outermost layers from both long sides of the cake. This process ensures a regular block geometry and eliminates any imperfections formed along the mold edges. The cake remains on the pallet with wheels during this operation.

Precise trimming of the side surfaces guarantees clean, even edges and optimal alignment for subsequent cutting stages. The operation is fully automated and synchronized with the movement of the wheeled pallet, ensuring seamless integration with the entire cutting process.

After the side trimming process, the cake — still resting on the original wheeled pallet — is transferred onto the tilting unit. This unit performs the critical operation of rotating the entire cake from a horizontal to a vertical position, which is necessary for accurate vertical and horizontal cutting in subsequent stages.

During tilting, the cake is carefully inverted together with the original pallet, and then gently placed onto a new, clean pallet prepared in advance. The new pallet continues to carry the cake through the rest of the cutting section.

Meanwhile, the original pouring pallet is automatically returned to the mixing and pouring area to begin a new production cycle.

The tilting unit operates smoothly and precisely, ensuring no damage to the cake during rotation. It is fully integrated into the production line and designed for high-speed, uninterrupted operation.

Once the cake has been tilted into a vertical position, it is transferred to the Vertical Side Trimming Machine. This unit performs precise trimming of the vertical side surfaces of the cake, removing outer layers and ensuring perfect geometric alignment for further processing.

This trimming step is essential to achieve accurate dimensions and clean surfaces in the final blocks, especially before vertical and horizontal cutting. The machine is fully integrated into the automated cutting section and operates without the need for manual intervention.

After passing through the Vertical Side Trimming Machine, the trimmed cake is transferred by conveyor to the Vertical Cutting Machine. Once in position, the cake is securely clamped using a special gripping system that prevents any movement during the cutting process.

The cutting unit, equipped with a high-precision band saw, moves along a programmed path, slicing the cake into vertical blocks of predetermined size. This method ensures exceptional dimensional accuracy, clean cuts, and consistent quality across the entire batch.

Vertical cutting is a critical step in achieving smooth surfaces and maintaining the structural integrity of the aerated blocks.

After vertical cutting is completed, the aerated concrete cake is conveyed to the Horizontal Cutting Machine.

Unlike vertical cutting, the cake here is not clamped. Instead, it is gently pushed through the machine by a conveyor system that ensures smooth and continuous movement. As the cake moves forward, it passes through one or more high-speed band saws that perform precise horizontal cuts, dividing the cake into blocks of the required height.

This method allows for efficient and accurate cutting without interrupting the flow of the production line, while also maintaining uniform block dimensions and surface quality.

The final curing chamber is a closed space with multiple rail lines for trolleys, designed to accommodate the cut blocks for the final stage of strength development. It maintains stable temperature and humidity conditions required for the blocks to reach their final strength before packaging.

The chamber is equipped with automatic thermal curtains that prevent heat loss and help maintain a consistent internal climate. Its configuration allows flexible adjustment of the number of curing lanes depending on the plant’s production capacity. The chamber’s internal conditions can be regulated based on the region’s climate and required curing time

The automated loading shuttle is designed to sequentially insert cut block trolleys into the final curing chamber. Unlike the pre-curing chamber, which uses positional conveyors, this chamber relies on the shuttle’s integrated pushing module to move the block-laden trolleys inside.

Mounted on wheeled pallets, the blocks are pushed one by one into the curing lanes until the current lane is fully loaded. The shuttle then moves to the next lane and continues the loading process. Once the chamber is fully loaded, the next incoming pallet automatically pushes the first pallet out, ensuring continuous and uninterrupted operation.

The shuttle is equipped with a control module integrated into the plant’s automation system, with sensors for positioning and collision protection. Manual control is also available for maintenance or emergency situations.

The automated unloading shuttle is used to retrieve fully cured block trolleys from the final curing chamber and transport them to the packaging area. Once the curing process is complete, the matured blocks—still on their wheeled pallets—are automatically pushed onto the shuttle, which then moves them to the next production stage.

This shuttle operates in full automatic mode, integrated with the central control system to ensure smooth and continuous material flow. It features an onboard controller, collision protection sensors, and the ability to switch to manual operation if needed. The system provides precise positioning and safe handling of cured blocks in the packaging area.

The waste removal conveyor is designed to transport trimming and cutting waste from the entire cutting section to the recycling area. Installed along the full length of the cutting section, it ensures continuous removal of waste generated throughout the cutting process.

This conveyor helps maintain cleanliness and safety in the cutting zone and supports uninterrupted equipment operation. Depending on the plant layout, waste can be discharged into a hopper, a container, or directly into a crushing or recycling system. The operation is fully automated and synchronized with the rest of the cutting line.

This unit is designed to crush cutting waste into smaller fractions, simplifying subsequent handling, disposal, or potential recycling within the production cycle.

The belt conveyor, equipped with a receiving hopper, is designed to transport shredded waste material from the shredder to the mixer. The system ensures continuous and efficient material flow for the preparation of a new mix, enhancing overall production efficiency within the waste recycling section.

The cement silo is used for storing cement and supplying it to the dosing unit of the system that prepares a semi-dry mix for subsequent vibropressing. Cement is conveyed via a screw conveyor and precisely dosed. The silo is fully integrated into the plant’s central control system, ensuring automated operation and consistent material delivery.

This unit is designed for the preparation of semi-dry mixtures used in the subsequent vibropressing process. It includes a cement dosing system and a mixer installed on high-precision load cells, which ensure accurate dosing of raw materials and consistent mixture quality.The unit is fully integrated into the centralized waste recycling system, contributing to the efficient reuse of material residues generated during the production process.

This machine is designed for the production of high-strength blocks using semi-dry concrete mixtures. It forms blocks through a combination of vibration and compression, ensuring optimal density, dimensional accuracy, and surface quality.The unit operates in automatic or semi-automatic mode and is integrated into the waste recycling line, allowing for the reuse of crushed material. Its robust construction and efficient cycle time make it suitable for both continuous operation and integration into medium- to high-capacity production lines.

After the aerated concrete blocks have completed the final curing process inside the hardening chamber, the entire mold is transferred to the packaging area. The gantry-type automatic stacking robot is the first unit in this section.

This robot is fully automated and operates according to a predefined program. It picks up a full row of cured blocks from the mold and places it onto the rotating positioning table (see 8.2). The system ensures precise and damage-free handling, thanks to its carefully calibrated gripper mechanism and soft start/stop movement control.

This stacking robot can be adjusted to accommodate various block sizes and palletizing patterns, making it suitable for different customer requirements.

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

This precise rotation enables compact and stable stacking of blocks on the pallet and helps form a uniform stack geometry. The table is integrated into the automatic sequence and operates in synchronization with the stacking robot and the palletizing system.

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

When a new pallet is needed in the packaging line, the system automatically releases a single pallet and places it on the conveyor. This ensures uninterrupted operation of the packaging process and eliminates the need for manual pallet loading. The magazine can be refilled with a new stack of pallets without stopping the line, further enhancing efficiency.

This automated gantry-type palletizing robot picks up the stacked row of blocks from the rotating table and places it precisely onto the pallet. Operating according to a pre-programmed sequence, it ensures accurate positioning, stable stacking, and optimal load distribution.

The system is fully automated and integrated into the packaging line, allowing for continuous operation without manual intervention. It can be adapted to different block sizes and stacking patterns, providing high flexibility and consistent performance.

The Stretch Hood wrapping machine is the final stage of the packaging line. Once the pallet is fully stacked with aerated concrete blocks, it is transferred via a chain conveyor to the wrapping zone. Here, the machine applies a high-strength stretch hood film over the entire pallet in a single, seamless operation.

This modern wrapping method ensures:

• Tight and secure packaging without the need for heat or shrink Tight and secure packaging without the need for heat or shrink tunnels.
• Protection from moisture, dust, and mechanical damage during transportation and storage.
• A clean appearance, suitable for direct delivery to construction sites or customers.

The system is fully automated, energy-efficient, and adaptable to various pallet sizes and block configurations.