Inside the Brickcem plant: the cutting line, moulds and autoclaves under one roof

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Precision is programmed, not inspected.

The AAC industry struggles with inconsistency, operator dependency and short-term decisions. Brickcem was set up in 2024 to remove them — with a fully automatic plant at Salod, near Kapadvanj in Kheda district, built to run reliably for decades.

The line, station by station

Raw material → mixing → casting → precision cutting → steam curing and autoclaving. The same programme runs for the first block of the day and the last.

Raw materialBulk handling instead of manual feeding. Fly ash and sand are stored apart and discharged in measured ratios, which is what keeps density and strength repeatable.
MixingKEDA dosing and mixing: lime, cement, gypsum, water and a trace of aluminium powder, to a fixed recipe.
CastingThe slurry is cast into moulds, where it rises and sets into a firm green cake.
Precision cuttingAn automatic gantry cuts the cake with wires to a tolerance of ±2 mm.
AutoclavingHigh-pressure steam curing with Forbes Marshall and Olymspan systems, the same cycle every time.

Six Olymspan autoclaves, two with their doors open, and finished AIWON blocks stacked on the left — Six autoclaves. Steam at high pressure turns the cake to stone — the same cycle, every time.

Numbered moulds, some empty, some filled with risen cake — Numbered moulds. Every cake is traced from the mixer to the autoclave.

A full green cake on the cutting line beside the gantry — A green cake on its way through the cutting gantry.

The production hall seen from the gallery — The hall from the gallery: casting, cutting, curing and the yard in one line.

Eight moments from the line

Stills from our factory film — the same process, every cake, every day.

An operator oiling a mould before casting — Every mould is oiled before the pour.

Spread test of the AAC slurry — Spread test of each batch of slurry.

A green cake demoulded on the KEDA line — The green cake leaves the mould.

A cake cut into blocks by the wires — Cut to size by wires — ±2 mm.

Cut cakes inside an autoclave — Into the autoclave for high-pressure steam.

Checking block dimensions with a steel tape — Sizes checked by hand, too.

An operator separating finished AIWON blocks — Finished blocks separated and stacked.

AIWON blocks loaded onto a truck — Loaded for your site.

Capital-intensive, on purpose

Machines chosen for control, not convenience.

KEDA mould tilting and cutting gantry — **KEDA Suremaker, China.** A fully automatic AAC line with high-precision cutting.

Forbes Marshall automatic steam valves over the autoclaves — **Forbes Marshall.** Engineered steam distribution and control for consistent curing cycles.

The automatic steaming control screen — **One control room.** The process runs on settings, not on whoever is on shift.

The economics of precision

A block that is the right size saves money twice: once in the joint, once in the plaster.

±2mm

Dimensional tolerance from the automatic gantry.

25%

Up to this much less plaster and mortar, because thin-bed masonry works on true blocks.

3mm

Joints with AIWON Bond — the block and the mortar are designed together.

1system

Block and bond engineered together, so walls go up faster with less waste.

An autoclave opened in a cloud of steam — from the factory film

Watch the factory film

Responsibility beyond the factory gate

We monitor the plant continuously and change the process when the data says so. We run it under ISO 9001 quality, ISO 14001 environmental and ISO 45001 health-and-safety management, and the blocks carry the GreenPro ecolabel.

Standards enforce discipline. We operate within them.

Visit the plant

Bring your engineer. See the line run, pull blocks from the stack, and take them to a lab of your choice.

Survey No. 316/1, 316/2, Kapadvanj – Ladvel Road, Salod, Ta. Kapadvanj, Dist. Kheda, Gujarat 387620

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