AAC Block Plant

AAC block turnkey projects , We are the pioneers in INDIA to manufacture and setup complete AAC block manufacturing plants. Our expertise in AAC block machines, AAC Cutting machine, Dosing system , Plant automation, Autoclaving and Boiler System are simply and advanced. In house equipment and plant designing helps us improvise each time ahead. We have setup up plants from 150000 cbm per annum to 9000 cbm per annum with consistant feasibilty.


BATCH MIX SECTION

For AAC blocks manufacturing, entire dosing and mixing operation is completely automated and requires minimum human intervention. This entire operation is monitored using control systems integrated with computer and automated feedback mechanism.As with any industrial operation, there is provision for human intervention and emergency actions integrated inside the control system. After completion batching cycle the mixture is fed into the moulds for precuring/hardening process. Our Man machine interface allows the user to communicate with the machine efficiently and easy to understand SCADA screen make this complex batching process simple. The system has automated water , alluminium and temperature control system , with interlocked Discharge for absolutely zero wastage due to cyle.


Equipment & Process of Batching Mix Section
RAW MATERIAL STORAGE
POND ASH SHED

In areas where Pond ash is availaible storage shed is to be built. Pond ash stored in open is not recommended as in dry conditions and windy weather it will spread over wide area surrounding the Plant causing nuisance.

FLYASH SILO

Depending on the Plant capacities and availaibilty of raw material the storage capacity of the Silo is selected. Capacities 30 tons to 200 tons.

CEMENT SILO

Depending on the AAC Plant capacity and availaibilty of raw material the storage capacity of the Silo is selected. Capacities 30 tons to 200 tons.

LIME SILO

Depending on the AAC Plant capacity and availaibilty of raw material the storage capacity of the Silo is selected. Capacities 30 tons to 200 tons.

GYPSUM SILO

Depending on the AAC Plant capacity and availaibilty of raw material the storage capacity of the Silo is selected. Capacities 30 tons to 200 tons.


MATERIAL CONVEYING
SCREENING HOPPER (POND ASH ONLY)

Angle frame with vibration pads,Vibration Motor for Segregation of foreign matter

BELT CONVEYOR

Conveying Screened Pond ash to Slurry Mixer

SCREW CONVEYOR FOR FLYASH

Inclined Screw Conveyor for Flyash - 35 tph

SCREW CONVEYOR FOR CEMENT

Inclined Screw Conveyor for Lime -25/35 tph

SCREW CONVEYOR FOR LIME

Inclined Screw Conveyor for Lime-25/35 tph

SCREW CONVEYOR FOR GYPSUM

Inclined Screw Conveyor for Gypsum -25/35 tph


SLURRY PREPARATION,HANDLING AND STORAGE
SLURRY MIXER

Homegenous Mixing for Flyash/Pond ash with water, Unique Agitator designing for most efficient Mixing process

SLURRY SCREENING MACHINE

Rotary Screening machine for Separation of mine impurities and foreign material from the Slurry

POND MIXER AGITATOR

Underground Mixer which collects the screened slurry

SLURRY PUMP

For transfer of Slurry from the Pond mixer to Slurry storage tanks.

SLURRY STORAGE TANKS

Capacity 25 CBM to 50 CBM depending on capacity of AAC Plant with Agitator,In smaller capacity Plant Storage tank can be avoided

TRANSIT POND MIXER

Underground agitator Pond mixer which supplement the process for transfering the slurry from storage tank to Batching Area

SLURRY PUMP

For transfer of Slurry from the Pond mixer to Batching Area

AIR COMPRESSOR

Meets dry air requirement of all areas in the plant Valves, Cutting area and others


BATCH PREPARATION AND MIXING
MEASURE SCALE AND HOPPER DRY MATERIAL

Precise Weighing System for Cement, Lime ,Gypsum

MEASURE SCALE AND HOPPER FLYASH SLURRY

Precise Weighing System for Fresh and Waste Slurry

MEASURE SCALE AND HOPPER ALUMINIUM POWDER

Precise discharge hopper with Highly accurate dosing to Aluminium Mixer

AUTOMATIC WATER DOSING AND DISCHARGE

High precision water flow metering system to aluminium mixer.

ALUMINIUM POWDER MIXER

Discharge Valve point,Mounted in main pouring mixer

BATCH MIXER

Heavy duty shell plate , Discharge valve point , temperature sensorand control,Auto Rinsing Feature to clean the shell.

ELECTRICAL CONTROLLED COMPUTER BATCTHING CONTROL SYSTEM

Completely automatic cycle for fast and precise batch mixing of AAC mix design.Scada based system driven by high end PLC and Accurate weight ,temperature and Flow Sensors.

PNEUMATIC BUTTERFLY VALVE

Φ200/100mm Actuator with FRL Unit

MANUAL BUTTERFLY VALVE

Φ200/100mm heavy duty LP make+A25


PRE-CURING / PRE HARDENING AREA
MOULD TRANSFER CAR

Automatic controlled Mould carraige from Batching area to Precuring Section

MOULD BOX AND BASE PLATE

Heavy Duty Mould Box .We select mould size as per capacity of the plant 1 cbm , 3 cbm , 4 cbm

MOULD BOX SHIFTING WINCH MACHINE

Effortless operation to shift the moulds from Mould Transfer trolley into the precuring room with a touch of a button

PRE CURING ROOM

Temperature Controlled Hardening area .

DEMOULDING AND CUTTING SECTION
DEMOULDING CRANE

Smooth Operation and movement controlled with advanced Electronics.

DEMOULDING HYDRAULIC MACHINE

Hydraulic Operated with Mechanical Pricision System,Makes sure that no mould is damaged , Hydraulics tilting arrangements and up down movement for mould demould run smooth and effortless. Base plate refitting is accurate for each cycle.

WIRE CUTTING MACHINE

Two stage Horizontal and Vertical Cutting machine, Pneumatic Wire Tensioning , Variable speed automatic cutting operation as per the hardness of the Block. Variablee Frequency Drives and Advanced PLC Controllers with Touch Screen Monitoring System.

CUTTING WASTE MIXER POND

Waste material mixing agitator which prepares slurry of excess material post cutting..

SLURRY PUMP

For transfer of waste Slurry

AUTOCLAVE LOADING
MOULD PLATE GROUPING CRANE

Smooth Operation and movement controlled with advanced Electronics.

MOULD PLATE GROUPING MACHINE

Hydraulic operated with mechanical precision gear system ,can shift the mould with high precision post cutting .

AUTCLAVE TROLLEY

Heavy duty Steel fabricated trolleys with steel wheels to sustain continuos cycles of heating and cooling.

AUTOCLAVE LOADING WINCH MACHINE

Machincal Geared type Wire Rope Winch to load the Steam trolleys with green cakes

STEAM TROLLEY RE-TURN DRAG MACHINE

Mechanical Geared type Wire Rope Winch for Shifting Steam trolleys across the plant from Unloading area to Loading Area.

BOILER & AUTOCLAVES
BOILER

We supply best quality boilers Standard, package type ,Smoke tube water tube with Skid type mounting for pre heaters and FD

AUTOCLAVE

Pressure Vessel made from Special Boiler quality SAE 416 Gr 70 material, welded and 100% radiograph test is conducted for Complete Safety assurance. Autoclaves are fitted with Safety Valves ,Condensate Removal Valves,and Are Insulated with Best quality insulating material.

AUTOMATIC SCADA BASED AUTOCLAVING PROCESS

One touch Autoclaving Cycle controlled by our high end PLC based Control system ,that gives you a perfect cycle, with safety assurance. You can easily trac the autoclave cycle with grapical presentation and customised reports. It can precisely control the steam transfer and exhaust cycle.

UNGROUPING AND BLOCK SEPARATION
MOULD PLATE UNGROUPING CRANE

Smooth Operation and movement controlled with advanced Electronics.

MOULD PLATE UNGROUPING MACHINE

Hydraulic operated with mechanical precision gear system ,can shift the mould with high precision post cutting .

FINISHED BLOCK GRABBING AND PLACING MACHINE

Precise controlled hydraulic machine for fast and easy removal of complete ready AAC block of any size ,so the base plate is free for batching cycle.

BLOCK SEPERATING MACHINE

Hydraulics Operated Block Seperating machine, is used I case where mould is not tilted before autoclaving cycle. To removed the Horizontal cut joints withou damaging the Finished Autoclaved Aerated Concrete Blocks

BASE PLATE RETURN MACHINE

Smooth Operation and movement controlled with electrical gearhead system.

SEGREGATION , PACKING AND LOADING
FINISHED GOODS SGEREGATION

Perfect solution where size variatians are minimal, the finished block line offers effortless sizing of AAC Block

FORK LIFT AND BLOCK GRABBER

Post seggregation as per size , the wodden /steel pallets were required , block grabber works with out these pallets thus saving cost of pallets.It saves Labour cost for loading vehicle, and the time required thus overall increasing the efficiency of the AAC Block Plant.