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PRODUCTION TECHNOLOGY44 PRODUCTION TECHNOLOGY AAC WORLDWIDE %u2022 3.2025Ublok - from technological innovation to global collaborationModernizing ageing AAC production plantsAutoclaved Aerated Concrete, as a core building material for green building, requires modernization of production facilities to achieve global carbon neutrality goals. China, the world%u2019s largest AAC producer, faces systemic challenges such as low-capacity utilization, high energy consumption, and unstable product quality, with 70% of its factories having been in operation for longer than a decade. This paper examines UBlok Group%u2019s transformation of the Changxing Ytong plant, detailing comprehensive technical improvements covering energy optimization, material innovation, and automation upgrades. Postretrofit results show significant improvements: steam consumption reduced by 50% (from >200 kg/m%u00b3 to <100 kg/m%u00b3), lime and cement consumption were cut in halve (from 210 kg/m%u00b3 to 115 kg/m%u00b3), and per capita productivity tripled. The study further explores the global applicability of this technical framework, particularly its synergy with the EU Green Deal, providing a replicable blueprint for industry transformation.Chen Haiming, Senior Engineer, UBlok Group; Expert Committee Member, China AAC Association, ChinaGlobal AAC industry challenges and transformation opportunitiesSince its industrialization in the 1980s, China%u2019s AAC industry has experienced rapid expansion, and it now faces overcapacity and inefficiency. Over 70% of China%u2019s 3,000+ AAC factories are more than a decade old, with average capacity utilization below 60% and steam consumption exceeding 200 kg/m%u00b3. Similarly, Europe faces aging equipment and tightening environmental regulations. The IEA reports that the building materials sector accounts for 11% of global carbon emissions, with energy and raw material consumption in AAC production being major contributors. Against this backdrop, UBlok transformed the Changxing Ytong plant into a high-efficiency, low-carbon benchmark, offering a practical model for global modernization of aging factories.Current status and core challenges of China%u2019s AAC industryComparative analysis of old vs. new factoriesNew factories with automated lines and advanced processes achieve daily outputs exceeding 3,000 m%u00b3 and steam consumption levels below 100 kg/m%u00b3. In contrast, ageing factories face the following challenges:%u2022 Low-capacity utilization: Inefficient workflows, slow production cycles, and poor mould turnover.%u2022 High energy consumption: Steam consumption >200 kg/m%u00b3, with 20% thermal loss.%u2022 Quality fluctuations: Cutting inaccuracies and uneven pore structures result in product qualification rates less than 95%.