400,000 m3/Year AAC Plant

High-Efficiency 400,000m3/Year AAC Block Plant Manufacturer

The 400,000 m³/Year AAC Block Plant is a large-scale production line, with high efficiency and stable production. It is used in producing Autoclaved Aerated Concrete (AAC) blocks, with an annual output of 400,000 m³.

As one of professional manufacturers of AAC plants in China, we can supply customized solution and turnkey project based on your specific needs.

The main production process includes mixing and casting, curing and gasification, cutting and forming, autoclave curing, etc.

The high-capacity 400,000 m3/Year AAC plant is suitable for enterprises with the characteristics of large market coverage, high raw material demand, and long-term large-scale operation.

Capacity: 400,000m3/year
Type: Fully automatic
Used for: Producing standard-sized AAC blocks, plus AAC wall panels, load-bearing lintels and composite floor slabs.

Lihat Semua Loji AAC

Customize Your Cost

Price of 400,000 m3/Year AAC Block Plant

The total price of 400,000 m3/Year AAC Block Plant ranges from $2,000,000 to $6,500,000 (excluding land costs). The main factors affecting the price are: automation level, equipment brand, equipment configuration, customization requirements, after-sales service, etc.

1. Equipment Configuration

Manual batching systems: Lower cost (fits lower price range).
Automated computer-controlled batching: Higher cost (ensures quality, pushes price up).
Smaller autoclaves (e.g., 100 m³) & weak mixers: Cheaper.
Larger autoclaves (e.g., 150 m³) & strong mixers: More expensive (for higher output).

2. Customization

Non-standard block sizes (needs special molds/cutting tweaks) or more AAC wall panels (line rework): Adds cost.
Special gear for local raw materials (e.g., high-moisture sand) or site limits (space, noise/dust rules): Increases cost.

3. Brand/Manufacturer

Established brands: Pricier (proven quality, good after-sales, long warranties/training).
New brands: Cheaper (no strong track record).
Imported (German/Japanese): More expensive (plus shipping, duties, currency fees).

4. After-Sales Services

Longer warranty (3-5 years vs. 1-2 years) or full coverage (on-site repairs): Raises price.
On-site/online training, regular checks, fast spare parts: Adds cost (keeps plant running smoothly).

Advantages of 400,000 m3/Year AAC Block Plant

1. Cost Advantages

Large demand for raw materials, bulk buying cuts raw material prices by 8%-12%, saving over $500,000 yearly.
Unit fixed costs are 15%-20% lower than 200,000 m³ AAC plants, enabling flexible price competition.

2. Market Coverage

400,000 m3/Year Loji Pembuatan Blok AAC covers 300-500 km, meeting supply for 1-2 provincial regions. It can take 100,000-200,000 m³ large orders, with delivery 30%-40% faster than small/medium plants, boosting customer loyalty.

3. Environmental Benefits

Annual solid waste disposal: 350,000-450,000 tons (utilization rate >75%), bringing $1.75-6.75 million in annual subsidies. It can afford high-end environmental equipment, meets strict standards, and has access to green credit.

4. Efficient Production

Equipped with 6-8 large autoclaves and 50m³/h mixers, it runs 24/7. Equipment utilization rate is 85%+ (vs. 70%-75% for small/medium plants). Full automation ensures ≥98% qualified rate and 25%-30% higher efficiency.

5. Development Potential

Add 1-2 autoclaves to expand capacity to 500,000-600,000 m³. With extra equipment, it can produce AAC panels (1.5-2 million m²/year) to enter the high-end market.

400,000 m3/Year AAC Block Plant Process

Raw material process → Batching and Mixing → Pouring → Static pre-curing → Cutting → Autoclaving Curing → Finished product Processing

1. Raw Material Processing: Sand is crushed and ground to the desired fineness. Cement, lime, and gypsum are stored in silos, and aluminum powder is mixed with water to form an aluminum slurry.

2. Batching and Mixing: The various raw materials are weighed according to precise proportions and then thoroughly mixed in a mixer to form a uniform slurry.

3. Pouring: The mixed slurry is poured into steel molds. The size and shape of the molds can be designed to meet the desired block specifications.

4. Static Pre-curing: The molds containing the slurry are transported to a pre-curing area where the slurry gradually hardens under suitable temperature and humidity conditions to achieve initial strength. This process typically takes several hours.

5. Cutting: After the slurry is pre-cured, it is cut into the desired size and shape using high-precision cutting equipment like steel wire or blades.

6. Autoclave Curing: Blocks are placed in an autoclave and cured for several hours at temperatures of 175-200°C and pressures of 10-15 bar, significantly enhancing the blocks’ strength and durability.

7. Finished Product Processing: After autoclave curing, the blocks are removed from the autoclave and transported to a storage area. After inspection and packaging, they are ready for shipment.

Raw Materials of AAC block

Cement (Portland Cement): Acts as a primary binder, providing strength and durability to the blocks. Typically, 43 or 53-grade OPC is used.
Fly Ash or Sand: Serves as the main siliceous material. Fly ash, a byproduct of coal-fired power plants, is an eco-friendly alternative to sand, providing the necessary silica content.
Lime: A key calcareous material that reacts with other components to form the binding matrix and contributes to the chemical reactions during production.
Gypsum: Added in small quantities to regulate the setting time and improve the workability of the mix.
Aluminum Powder or Paste: Functions as a foaming agent. It reacts with lime and water to produce hydrogen gas, creating the characteristic porous, lightweight structure.
Water: Essential for the hydration of cement and lime, and to facilitate the chemical reactions necessary for the setting and hardening of the blocks.

Dapatkan Sebut Harga Percuma

These materials are carefully proportioned and mixed to form a slurry, which is then cast, pre-cured, cut, and finally autoclaved to produce the finished AAC blocks.

Main Equipment in 400,000 m3/Year AAC Block Line

1. Jaw Crusher

Function: Crushes large lumps of raw materials such as limestone and gypsum into 50-150 mm pieces, facilitating subsequent fine grinding. It is a key piece of equipment for raw material pretreatment.

Structure: A fixed jaw plate and a movable jaw plate form a deep-chamber crushing chamber lined with impact-resistant, replaceable high-manganese steel tooth plates.

Capacity Range: Common models range from 100 to 500 t/h. The motor and main unit are integrated on a steel frame base, occupying only 4-6 m² of floor space.

2. Ball Mill

Function: Grinds crushed lime, sand, or fly ash into a fine powder with a mesh size of 80-400 (0.2-0.045 mm) to enhance reactivity.

Structure: Horizontal cylinder+wear-resistant liner+steel ball media. It driven by a motor, reducer, and large gear.

Key Parameters: Cylinder diameter 1.2-2.4 m, ball load 5-30 t, power 55-800 kW.

3. Batching System

Function: Accurately weighs cement, lime, fly ash, aluminum powder, and water according to the recipe, with an error of ≤ ±0.5%. Equipped with multiple silos, metering, and conveying equipment.

Module components: Electronic scale, screw feeder, pneumatic butterfly valve, PLC touch screen; one-touch recipe call, batching completed within 30 seconds.

4. Mixing & Casting Machine

Function: Rapidly mixes weighed dry materials with water and aluminum powder into a fluid slurry, which is then poured into a mold for foaming.

Features: Twin-shaft forced mixing completes one batch in 60-90 seconds; hydraulically tilts 90° for drip-free pouring.

Key Parameters: Effective volume 2-4 m³, motor power 37-55 kW, removable mixing blades, wear life ≥ 30,000 cycles.

5. Tilting Cutter

Function: Cuts pre-cured billets into desired specifications with an accuracy of ±1 mm. Offcuts are recycled online.

Structure: Three sets of longitudinal, transverse, and horizontal steel wire frames; servo motors synchronize lifting and lowering, automatically compensating for wire wear.

Capacity: Cutting cycle ≤ 5 minutes/die; can cut 75-300 mm thickness, 600 mm standard length, or 1200 mm slabs.

6. Autoclave

Function: High-temperature, high-pressure steam curing allows the green body to complete the hydrothermal synthesis reaction within 8 hours, increasing its strength by 5-8 times.

Specifications: Φ2.68×32 m or Φ2.85×38 m; design pressure 1.6 MPa, operating temperature 200°C; equipped with safety interlock and automatic blowdown.

Configuration: Each medium-sized line is equipped with 4-8 units, which can be connected in series or parallel. Energy-saving models include a waste heat recovery interface.

7. PLC Control Room

Function: Serves as the control center for the entire production line, offering features such as recipe management, parameter adjustment, process monitoring, energy consumption analysis, fault alarms, and remote app viewing.

Hardware: Reserved OPC UA interface for integration with the factory’s MES/ERP system.

8. Waste Gas Heat Recovery System

Principle: Autoclave exhaust gas at 160°C is preheated to 90°C via a heat exchanger, saving 8–12% of natural gas annually.

Configuration: Plate heat exchanger+circulation pump+automatic temperature control valve.

Main Parameters of 400,000 m³ Loji Blok AAC

Parameter Category	Specific Parameters	Details
Capacity & Production	Annual Design Capacity	400,000 m³
	Daily Production Capacity (Working Days: 300/Year)	About 1,330 m³/day
	Production Shift	2-3 shifts/day (8 hours/shift, 24-hour continuous operation optional)
Raw Material Consumption	Siliceous Material (Fly Ash/Sand/Slag)	About 1,250-1,400 kg/m³ (annual demand: 500,000-560,000 tons)
	Calcareous Material (Cement/Lime)	About 300-350 kg/m³ (annual demand: 120,000-140,000 tons)
	Aerating Agent (Aluminum Powder/Paste)	About 0.5-0.8 kg/m³ (annual demand: 200-320 tons)
	Water Consumption	About 400-500 kg/m³ (recyclable water ratio: 35%-45%)
Key Equipment Specs	Raw Material Batching System	Capacity: 60-90 m³/h; Batching accuracy: ±0.5%
	Mixing-Pouring Machine	Mixing capacity: 40-60 m³/h; Pouring accuracy: ±1%
	CNC Cutting Machine	Cutting size range: based on your needs
	Autoklaf	Quantity: 6-8 units; Single volume: 180-220 m³; Working pressure: 1.2 MPa; Working temperature: 200℃
	Automatic Conveying System	Speed: 0.6-1.2 m/s; Load capacity: 8-12 tons/section
Finished Product Index	Dry Density of AAC Blocks	400-800 kg/m³ (compliant with GB/T 11968-2020 / ASTM C1386 standards)
	Compressive Strength	≥3.5 MPa (for 600 kg/m³ density; ≥5.0 MPa for load-bearing models)
	Thermal Conductivity (Dry State)	0.10-0.20 W/(m·K)
	Sound Insulation (Airborne Sound)	≥40 dB (200 mm thick) / ≥45 dB (250 mm thick)
Energy & Environmental	Power Consumption	About 85-105 kWh/m³ (total production line)
	Steam Consumption	About 320-370 kg/m³ (boiler thermal efficiency: ≥92%)
	Industrial Solid Waste Utilization Rate	≥75%
	Waste Gas Emission	NOₓ ≤50 mg/m³, SO₂ ≤35 mg/m³ (meets ultra-low emission standards)
Automation & Site	Control System	PLC + HMI + IoT monitoring (real-time production data tracking)
	Automated Processes	Batching, mixing, cutting, autoclaving, packaging (100% automated)
	Total Land Area	~18,000-25,000 ㎡ (including workshops, warehouses, yards)
	Workshop Height	≥9 m (for autoclave & overhead crane operation)

300,000 m3 Plant VS 400,000 m3 Plant

Item	300 k m³/year	400 k m³/year
Specific investment	US $13–14 /m³	US $12 /m³
Steam consumption	32–34 kg/m³	27–29 kg/m³
Labor head-count	110–120	125–135 (only +15 % for +33 % output)
Electricity draw	≈ 18 kWh/m³	≈ 16.5 kWh/m³
Minimum order to qualify for “bulk ship” rail freight	18,000 m³	24,000 m³ (lower freight quote/m³)
Typical EPC delivery	10-11 months	11-12 months (parallel assembly)

What Is An AAC Block？

Autoclaved aerated concrete (AAC) blocks are a lightweight, porous, high-strength new building material.

The unique internal pore structure provides lightweight, high strength, thermal insulation, fire resistance, and sound insulation.

It is an ideal choice for achieving energy-saving and structural safety in buildings.

Mengapa Memilih Kami?

Investing in a 400,000 m³/Year AAC Block Plant is a big decision, and we’re here to make sure your investment pays off. Here’s what you get when you work with us:

1. Turnkey Solution:

We offer full turnkey service, from plant design, equipment manufacturing, to installation, commissioning, and staff training. Our engineers have over 15 years of AAC plant experience, so we’ll build the plant exactly as you need, and make sure it meets local rules.

2. After-Sales Support:

We’re here for you 24/7 with after-sales service, including:

Regular maintenance checks (on-site or online).
Fast spare parts supply (we keep lots of parts in key areas).
Technical training for your operators and maintenance team (in-person or online).

3. Customization Options:

We know every customer has different needs. Whether you want to adjust the plant’s capacity, add special equipment (like a waste water recycling system), or adapt to local raw materials, we can customize the plant to fit you.

4. Proven Track Record:

We’ve supplied AAC block plants to over 50 countries (e.g., India, Indonesia, Nigeria, Brazil). Our 400,000 m³/Year AAC Block Plant works well in many projects, and customers say it hits or exceeds the annual capacity target 95% of the time.

Services We Offer

Perancangan & Reka Bentuk Projek
Menyediakan perancangan keseluruhan dan skim reka bentuk terperinci untuk loji blok AAC berdasarkan keperluan pelanggan dan keadaan sebenar, termasuk reka bentuk proses, susun atur peralatan dan reka bentuk kejuruteraan awam.
Bekalan & Pemasangan Peralatan
Supply full sets of AAC production line equipment, and undertake installation and commissioning to ensure normal operation, meeting designed capacity and product quality standards.
Latihan Teknikal
Menawarkan latihan profesional untuk pengendali, juruteknik dan pengurus yang meliputi proses pengeluaran, pengendalian peralatan, penyelenggaraan dan pengurusan kualiti.
Perkhidmatan Selepas Jualan
Wujudkan sistem selepas jualan yang kukuh menyediakan panduan penyelenggaraan harian, penyelesaian masalah dan bekalan alat ganti untuk memastikan pengeluaran stabil yang berterusan.
Sokongan Teknikal & Naik Taraf
Menyediakan sokongan teknikal yang berterusan dan menawarkan penyelesaian peningkatan peralatan/transformasi teknikal berdasarkan keperluan pelanggan dan trend industri untuk meningkatkan kecekapan dan kualiti.
Kontrak Am EPC
Perkhidmatan EPC sehenti daripada reka bentuk, perolehan peralatan, pembinaan awam, pemasangan dan latihan kepada pengeluaran percubaan untuk pengalaman tanpa kerumitan.

Other Hot-sale Block Manufacturing Plant

Annual Production	Price (USD)	Core Configuration
100,000 m³	1.5–1.9 M	Air-turning cutting, 3×31 m autoclaves
150,000 m³	1.5–2.6 M	Robotic palletizing, 4×31 m autoclaves
200,000 m³	1.5–3.5 M	Six-sided cutting, 4×37 m autoclaves
300,000 m³	1.5–4.8 M	Dual cutting lines, 6×37 m autoclaves
400,000 m³	2–6.5 M	Fully automatic air-turning, 8×37 m and above autoclaves