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AAC WORLDWIDE %u2022 2.2025 PRODUCTION TECHNOLOGY 41Overview of the upgrade to produce AAC panelsFrom the outset, Brimax envisioned manufacturing a full range of AAC panels. However, given that AAC was still an emerging product in South America, the company strategically chose to begin with blocks-only production. This approach allowed them to establish a strong market presence, build brand recognition, and refine their operations before expanding into more advanced AAC applications. Recognizing this long-term vision, Aircrete designed the plant layout to accommodate a seamless future transition to panel production. In the end of 2024, this vision was realized as Aircrete successfully completed the panel upgrade (Fig. 1), enabling Brimax to manufacture a comprehensive range of reinforced products, including partition panels, load-bearing wall panels (e.g. Fig. 2), and roof and floor panels and lintels. In a large, well-organized inauguration, which was attended by many local and national government officials, Brimax officially marked the historical milestone of being the first AAC factory in South America than can produce both blocks and a large range of panels with a super smooth surface.The upgrade project focused on enhancing two key areas: reinforcement and unloading. In the reinforcement section, two new reinforcement manipulators, two additional buffer lines, and an automated wax bath with a lifting station were installed to support efficient and high-quality reinforcement preparation. On the unloading side, a splitting table and additional roller conveyors were added to create an additional unloading line for all panels. Thanks to the foresight of the original plant design, the necessary civil works for these upgrades had already been allocated, minimizing disruptions with Brimax%u2019 current operations and ensuring a smooth integration. Executing such a complex upgrade within a tight schedule required meticulous planning and strong collaboration between Aircrete and Brimax. Their expertise and dedication, combined with Aircrete%u2019s experience in Building Information Modelling (BIM), allowed for extensive preparations ahead of time, significantly reducing the need for on-site intervention and plant downtime.Brimax AAC plant todayRaw materials, mixing and risingIn the Brimax plant, sand and gypsum are ground in the ball mill that is already prepared for future portfolio and capacity extensions. Lime and cement are stored in silos within the mixing tower, while aluminium is precisely dosed using Aircrete%u2019s Alu Safe System for maximum safety. The mixing process is managed by an advanced control system, which, together with Aircrete%u2019s low-speed mixer, delivers highly accurate dosing and homogenous material distribution. The mixer%u2019s design is ideal for panel production, where variable cake volumes demand flexibility and precision. Flat-cake moulds with fully opening sides simplify cleaning and oiling, using an automatic brushing and low-pressure oiling system with individually adjustable nozzles that significantly reduce oil consumption. After casting into freshly cleaned moulds, vibrating needles are inserted to eliminate air Fig. 2: Some of the first 150 mm thick panels produced at Brimax. Strapped with gluts, ready to be shipped.Plant manager quoteMattias Flores, Brimax Plant Manager\ ability to manufacture AAC panels has always been part of our long-term vision. Thanks to Aircrete%u2019s advanced technology and well-planned design, we were able to upgrade our plant without disrupting operations. We can now offer a wider range of high-quality AAC products to the market.\