Production line and factory setup overview
Produces non-combustible calcium-silicate insulation and building boards from silica, lime, reinforcing fibre and water by slurry preparation, sheet forming, pressing, autoclave curing, drying, cutting, edge finishing, testing and packing.
Recommended lowest-entry line configuration This is a large strategic autoclaved-board project. Complete feedstock, fibre route, pressure-vessel, energy, water, dust, market and certification feasibility before selecting equipment; an ordinary cement-board line cannot substitute for calcium-silicate chemistry and hydrothermal curing.
Production process and implementation sequence
- Silica/lime and fibre qualification
- Slurry dosing and mixing
- Sheet forming and dewatering
- Pressing and green cutting
- Autoclave curing
- Drying and board calibration
- Cutting/edge finishing
- Fire, density, strength and dimensional release
Products, capacity and market fit
- Confirm the intended application, applicable standard and buyer acceptance test.
- Use a defined product family and documented formula/tooling at launch.
- Keep material, curing/firing and release records for every lot.
- Calcium-silicate boards - Density, thickness, flexural strength, moisture, thermal conductivity, fire classification, dimensional stability and edge finish - Fireproofing contractors, ceilings/partitions, industrial insulation, warehouses and commercial construction
Core production machinery and line specifications
| Machine / stage | Function / value | Production note |
|---|---|---|
| Raw-material silos and slurry system | Controls silica/lime/fibre formula | Qualified chemistry and water ratio |
| Sheet-forming and press line | Builds uniform green boards | Board density/thickness target |
| Autoclave system | Hydrothermally cures calcium silicate | Pressure/temperature cycle |
| Drying/calibration/cutting line | Produces saleable board formats | Moisture/edge tolerance |
| Fire and board laboratory | Releases certified product | Target standard test plan |
Raw materials, utilities and factory requirements
- Qualified silica, lime, reinforcing fibre, process water, approved additives, packaging, cutting consumables and autoclave seals/spares
- Industrial electricity, covered storage and protected finished-board handling
- Guarded machinery, maintenance plan, essential spares and material-specific dust/heat/chemical controls
Indicative low-entry investment and implementation plan
These planning ranges prioritize economical machinery, local labor and local civil works. Final pricing follows confirmed capacity, product specification, delivery terms and site conditions.
| Scope | Indicative range | Entry-plan note |
|---|---|---|
| Slurry, forming and press system | US$1.2m–3.5m | Industrial board route |
| Autoclaves, drying and finishing | US$1.8m–5.5m | Pressure/energy intensive scope |
| Utilities, laboratory, EPC and commissioning | US$1.0m–3.5m | Bankable-feasibility project |
| Indicative strategic total | US$4m–12.5m | Land/building/working capital excluded |
Detailed proposal and next step
The proposal contains the complete line flow, machinery scope, raw-material and utility requirements, implementation stages and indicative entry planning. Final configuration follows confirmed products, capacity, site and budget.