Page 45 - Demo

AAC WORLDWIDE %u2022 3.2025 PRODUCTION TECHNOLOGY 45%u2022 High maintenance costs: Outdated equipment operates at <85% efficiency, with maintenance costs 2-3 times higher than those of new factories.%u2022 Import dependency: The procurement time for imported parts increased 4-8 times, with prices being 3-4 times higher.Deep-rooted cost structure issuesEnergy (30%), lime and cement (50%), and labour (12%) dominate costs in ageing factories. Steam consumption is concentrated in autoclave curing (80%), while traditional aluminium powder foaming wastes 15% of raw materials. The import dependency further escalates maintenance costs.UBlok%u2019s three-dimensional cost-reduction strategy: technical pathways andengineering practicesEnergy optimization: reducing steam consumption from 200 to 100 kg/m%u00b3Autoclave expansion and thermodynamic reconfigurationIncreased autoclave capacity, full-process insulation upgrades, and staged curing (gradient pressurization) raised thermal efficiency from 60% to 90%, shortening curing cycles by 20% and improving steam utilization by 40%.Waste heat utilizationWith the upgraded processes, 120%u00b0C condensate is recovered via flash tanks, saving 260 tons of steam annually. UBlok%u2019s proprietary non-condensable gas separator boosted secondary steam reuse by 20%.Autoclave capacity expansion and automated steam distribution at the Changxing Ytong plant [1].Post-transformation Changxing Ytong production plant [1].AAC cost distribution chart (sourced from the UBlok Group Annual Report).