The typical daily production capacity for residential space is in the range of 600 to 1000 m², depending on a number of technical and operational variables.

Several key elements influence this output:

• The degree of automation integrated into the production system — more automated processes result in faster cycle times and fewer manual interventions;
• The experience and skill level of the operating team, including both technical staff and floor workers;
• The architectural design complexity of the units being manufactured. Straightforward, standardized layouts allow for higher output compared to complex or custom designs;
• Whether production is serial and repetitive, or includes one-off or small-batch projects. High-mix, low-volume production typically requires more time for adjustments, setup, and coordination;
• The effectiveness of internal logistics, including material flow, handling systems, and dispatch coordination;
• The extent of factory-based finishing work — such as installing windows, doors, plumbing, or surface finishes — which can reduce throughput if carried out on-site.

This output range reflects the practical performance levels achievable under well-organized production workflows and with experienced personnel in place.

The production line can achieve an automation level of up to 90%, depending on the layout of the system, the selected equipment package, and the client’s operational targets.

The panel manufacturing process benefits from automation across many critical stages, such as:

• batching and raw material dosing,
• mixing and slurry distribution,
• in-line transport between work zones,
• packaging and palletizing,
• and digital control systems overseeing production flow and quality.

Importantly, all essential equipment that directly impacts the quality and consistency of the final panels is fully automated.

These include dosing units, mixers, curing process controllers, and systems responsible for geometric precision and product stability. This helps ensure uniform product output, minimal error margins, and continuous process monitoring.

While the system reduces reliance on manual labor, certain areas — especially those involving finishing adjustments, visual inspections, or service maintenance — still require qualified personnel.

The final degree of automation is determined by factors such as:

• whether production is highly repetitive or varied,
• the need for factory-based finishing,
• and the flexibility expected in switching between different panel types.

Automation levels are customized according to the client’s workflow model, investment capacity, and long-term productivity goals.

The estimated floor area required for the installation and operation of the panel production line is approximately 5,000 m².

This figure may vary depending on the specifics of the project and will be finalized during the design and planning phase.

Key factors influencing the total space requirements include:

• Compliance with local building and safety regulations, including health standards, fire safety rules, and labor protection requirements;
• Building configuration, which is determined by the desired output capacity, automation level, and material handling methods (e.g., forklifts, roller conveyors, or automated transport systems). Critical considerations include interior height, column spacing, floor strength, lighting and ventilation, and access openings such as industrial doors, ducts, and service passages;
• Integration of support zones and staff facilities, such as:
  • locker rooms, showers, and restrooms,
  • break areas or dining rooms,
  • supervisory offices and administrative spaces,
  • maintenance rooms for electricians, mechanics, or service crews,
  • tool rooms and spare part storage.

Additionally, the layout will depend on whether these support spaces are integrated into the main production facility or located in separate adjacent structures.

Zones for Raw Material Storage

Planning for raw material storage areas — whether it be a separate warehouse or an integrated loading zone — must be tailored to the specific needs of the project.

The required area is influenced by factors such as:

• expected volume of stored materials,
• delivery intervals,
• proximity and reliability of suppliers,
• and the stability of logistics chains.

For instance, if raw materials are delivered from distant regions or with unpredictable lead times, a larger storage buffer may be required. On the other hand, consistent and frequent deliveries allow for more compact storage solutions. Local transport access and material handling capacity also play a role in space planning.

Storage Space for Finished Panels

This area serves as a temporary holding yard where finished panels are stored prior to loading and shipment.

Its size depends largely on the overall logistics model: whether panels are dispatched immediately after production or stored for later delivery.

Additional determining factors include:

• dispatch frequency,
• vehicle fleet availability,
• synchronization with site delivery schedules,
• and loading/unloading efficiency.

A well-organized holding area ensures seamless logistics and avoids production interruptions.

Welfare and Support Areas for Staff

Facilities for employee comfort and support should include locker rooms, restrooms, break areas, and dining spaces.

The scope of these amenities is typically determined by labor laws, sanitary norms, and workforce size.

Important variables include:

• the number of work shifts,
• maximum occupancy during peak hours,
• requirements for separate male/female spaces,
• and whether the plant operates continuously or only in certain seasons.

Installation of the production line generally takes between 30 and 45 days, assuming that the facility is prepared in advance and the equipment is delivered on schedule.

Several variables can influence this timeframe:

• The site’s technical readiness, including structural preparation, access to power, water, and ventilation systems;
• The scale and layout of the production system, particularly when involving large-volume or multi-stage panel workflows;
• The integration of automation components, including control panels, sensors, and synchronization between equipment zones;
• The on-site conditions and support, such as lifting equipment availability, staging areas, and installation crew logistics;
• The effectiveness of coordination among the equipment supplier, site management, and other contractors working in parallel.

This period covers assembly, connection to utility systems, equipment tuning, and trial production runs.

With smooth coordination and a ready site, installation can be completed within 30 days. Projects requiring on-site adjustments or infrastructure upgrades may require additional time.

It is estimated that the panel production line will require around 24 to 40 personnel per shift.

The actual number will depend on multiple variables. These include the workers’ skill levels, their training progression, and how the team adapts as operations stabilize.

In the early stages of production startup and equipment calibration, a larger team may be needed. Over time, as workflows become more streamlined, it’s typically possible to reduce headcount without compromising output.

The degree of automation and the equipment configuration chosen for the line are also major determinants of staffing. A highly automated setup with synchronized production systems can significantly lower the need for manual operations.

Staffing needs may increase depending on the scope and complexity of the finishing work, especially for panels that require cutouts, insertions, insulation, or precision trimming.

Tasks such as door/window installation, surface preparation, plumbing pre-fits, and coatings require qualified personnel if performed in-factory. Additional workforce may be needed if high volumes of finishing are carried out on-site.

Where required, companies may opt to engage trained specialists, organize in-house training programs, or use external crews for specific tasks.

Despite automation, the line will still require human supervision, particularly for process control, quality assurance, and equipment maintenance.

Certain tasks — such as material handling and finishing — often remain at least partially manual, depending on project specifications.

That said, labor costs remain modest in the total per-square-meter cost of the finished product. Even if workforce numbers are slightly above projections, the impact on overall unit cost is limited, thanks to the system’s high throughput and productivity.

The expected total installed power capacity for the panel production line ranges from approximately 200 to 300 kW.

This value is preliminary and may be revised as the project is further defined.

The final energy demand depends on several factors, including the chosen equipment lineup, the automation level, the electrical load of core machinery, and the internal material handling systems in place — such as motorized conveyors, hoists, or automated stacking equipment.

In addition to core production needs, it's important to include auxiliary systems in the calculation, such as:

• general lighting,
• HVAC systems (if applicable),
• ventilation units,
• water pumping and filtration systems,
• and air compressors or related equipment.

A full electrical load study will be performed during the detailed engineering stage to account for all operational requirements and facility-specific conditions.

The operation of the panel production facility requires an estimated 55 metric tons of water per day.

This amount may vary depending on specific project parameters — including the thickness of exterior panels, volume and layout of interior walls, and dimensions and frequency of openings for windows and doors. Most of the water is consumed in the foam concrete production process, with a smaller share used for cleaning and maintenance of equipment.

Water usage for cleaning tasks is closely tied to the consistency of daily operations — frequent start-stop cycles can lead to increased washing and rinsing needs.

For this reason, it is crucial to have a reliable and uninterrupted water supply, and to plan for supplemental water delivery if required.

The daily cement demand for panel production is estimated at approximately 120 tons, though the actual figure depends on various technical and operational parameters.

Key factors include:

• The volume of daily production — larger output requires more cement overall;
• The design configuration of the panels, such as increased thickness, insulation layers, or embedded channels for utilities;
• The efficiency and quality of the cement used — fresh, active cement allows for optimized consumption, while aged or low-grade cement typically requires a higher ratio to maintain strength;
• The formulation of the mix — load-bearing panels or those with specialized performance characteristics may require adjustments in the cement ratio;
• Internal quality control and batching precision, which help avoid overuse and maintain consistency across batches;
• Weather-related mix adjustments, especially when producing in extreme heat or cold.

The consumption figure of 120 tons is a general benchmark based on continuous production under normal conditions. In practice, values may fluctuate depending on design complexity, material quality, and operational stability.

In panel-based construction, the structural framing system is formed using cold-rolled galvanized steel, which combines high strength, lightweight characteristics, and corrosion resistance.

The steel is typically supplied as Zn275-coated coils, with a mechanical grade of S350GD, in accordance with EN 10346. This classification means:

• Zn275: 275 grams of zinc coating per square meter (both sides),
• S350GD: minimum yield strength of 350 MPa — ideal for supporting structural frames.

Coils are processed through slitting and roll forming, resulting in high-precision steel profiles for use in panel manufacturing.

While many suppliers offer pre-slit coils tailored to production needs, our company also offers optional coil slitting equipment, if in-house control is preferred.

The steel thickness used for panel systems typically ranges from 0.8 mm to 1.5 mm, depending on structural design, wind loads, and integration with insulation systems or embedded elements.

Key advantages of LGSF for panel structures include:

• fast and accurate framing of panels,
• seamless integration with insulation, electrical and plumbing systems,
• and long-term corrosion protection in diverse environments.

Profiles used in panel lines fully comply with international standards (EN 10346 / ASTM A653 / GOST 14918), ensuring strength, durability, and repeatability throughout high-volume production.

In panel-based construction, foam concrete is widely used as the internal core material due to its excellent insulating properties, low weight, and structural stability.

The typical mix delivers an optimal balance of thermal and acoustic insulation, dimensional accuracy, and minimal shrinkage — making it ideal for use in lightweight, factory-assembled wall systems.

By utilizing advanced protein-based foaming agents and custom-engineered chemical additives, it is possible to fine-tune the density of the material to meet specific performance goals.

Such specialized formulations are applied selectively, especially when design parameters call for further weight reduction without sacrificing structural or thermal integrity.

Our company supplies all required additives and admixtures as part of the solution, ensuring complete compatibility with the equipment and process, as well as repeatable high-quality results. These materials are developed in-house, drawing from global industry standards and best practices, and are specifically optimized for non-autoclaved foam concrete applications.

Should the project call for a different core density, mix design, or structural requirement, we can adjust the formulation and process accordingly.

We also offer hands-on training for plant technologists and provide in-situ commissioning support, ensuring that the foam concrete process is fully integrated and consistently reliable from day one.