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Technical Services
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23
2026
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07
Guangzhou Hengde: How to Implement a Production Line Capable of Manufacturing 200 Cubic Meters of Lightweight Masonry Wall Panels Per Shift
Guangzhou Hengde’s production line for 200‑cubic‑meter lightweight concrete blocks and wall panels explains how metering, physical foaming, mixing and pouring, mold circulation, PLC control, and automatic cutting collectively determine the actual output.
As the market for lightweight masonry blocks, lightweight wall panels, and green wall materials continues to expand, an increasing number of investors are exploring opportunities to establish manufacturing facilities for these innovative building materials.
Faced with identical equipment configurations labeled as “200 cubic meters per shift,” why are some plants able to maintain continuous production, while others experience frequent shutdowns after commissioning, resulting in a significant gap between actual and planned output?
On this issue, Guangzhou Hengde Construction Technology Co., Ltd. has proposed:
What customers really need is not a quotation listing dozens of pieces of equipment, but rather a fully integrated production line that can operate continuously according to schedule and deliver products reliably.
Output is not determined by a single host.
The production of lightweight masonry blocks and wall panels is a continuous manufacturing process.
From the moment raw materials enter the factory, the process involves multiple stages, including powder and water metering, slurry mixing, physical foaming, slurry conveying, mold pouring, green-body curing, demolding and handling, surface treatment, and automated cutting.
If any one of these stages operates at an insufficient speed, it will affect the entire production line:
- If water measurement is inaccurate, the slurry’s condition will change.
- If foam quality is unstable, it becomes difficult to control the product’s bulk density and internal structure.
- If the slurry delivery is intermittent, the pouring station must wait.
- With an insufficient number of molds, even the fastest front-end equipment cannot operate without available molds.
- If the cutting speed cannot keep up, the cured green bodies will accumulate.
Therefore, the daily production capacity of 200 cubic meters is not a figure listed on the quotation; rather, it represents the actual production capability achieved through the coordinated efforts of all work sections.
The “Work Plan for the Digital Transformation of the Raw Materials Industry (2024–2026),” jointly issued by the Ministry of Industry and Information Technology and eight other departments, also emphasizes that building-materials production should strengthen software–hardware integration, enhance process control, and improve equipment interconnectivity, while promoting the adoption of industrial control systems such as PLCs and digitalized equipment.
With a daily output of 200 cubic meters, the first step is to calculate the production takt time.
When planning a production line capable of manufacturing 200 cubic meters of lightweight concrete blocks and wall panels per shift, Guangzhou Hengde does not merely calculate how much slurry the mixer can handle in a single batch; it also performs a concurrent calculation:
- How many cubic meters can a single mold produce in one cycle?
- How long does it take for the green body to reach the conditions required for demolding and cutting?
- How many mold turnover cycles can be completed in a single shift?
- How many sets of molds are required to meet the planned production volume?
- Can the processes of concrete placement, curing, formwork removal, and formwork reinstallation be seamlessly coordinated?
- How long does it take to peel, make vertical cuts, and make horizontal cuts?
- When equipment maintenance occurs, does the production line have sufficient flexibility for adjustments?
This 200-cubic-meter-per-shift production line not only includes mixing, foaming, and cutting main units, but also incorporates a pouring conveyor line, a demolding conveyor line, a re‑molding conveyor line, a shuttle vehicle, molds, and cutting power lines, among other systems.
Although these auxiliary devices may not appear to be part of the “main machine,” they directly determine whether the molds can be returned on schedule, whether the green bodies can be transferred promptly, and whether the entire production line will come to a halt waiting.
PLC control is not intended to merely appear automated.
The production line is equipped with a PLC-based master control system, not merely to reduce the number of buttons, but to ensure that metering, mixing, foaming, conveying, and pouring operate in coordinated sequence according to the preset production workflow.
During the production process, operators must use the control system to monitor equipment operating conditions and adjust relevant parameters, ensuring coordination between upstream and downstream processes.
Truly effective automation should address three key issues:
- Reduce excessive reliance on workers’ individual experience;
- Improve the consistency of products across different batches;
- Reduce waiting and downtime caused by operational handover errors.
If you simply add a control cabinet without integrating the operational logic of the upstream and downstream equipment, it cannot be considered a complete automated production line.
Cutting capacity determines whether the line’s throughput can be realized.
The cured green bodies must undergo surface treatment and dimensional cutting within the prescribed time frame.
To meet the continuous production requirements of approximately 200 cubic meters, the solution is configured with a debarking machine, a nine‑station panel saw, and a dual‑mode, three‑station gantry CNC vertical panel saw. Additionally, equipment such as grooving, flipping, and clamping units are incorporated to align with the specific product specifications for wall panels.
Peeling, horizontal slicing, and vertical slicing each assume distinct processing tasks, thereby establishing a clear division of labor within the cutting process. This approach not only enhances continuous processing capacity but also mitigates the impact of prolonged waiting times for workpieces on production rhythm.
If the front-end line can produce 200 cubic meters of billets per day, while the cutting system can handle only a few dozen cubic meters daily, the cutting section will become the bottleneck of the entire production line.
Therefore, when comparing production lines, you shouldn’t just ask, “How much does the cutting machine cost?” You also need to find out:
How many workpieces can be processed at one time? How long does it take to complete a single cut? Can the cutting speed keep pace with the upstream production rate?
Hengde’s delivery should be a fully operational factory.
For overseas plant‑construction projects, the availability of cement, sand, stone powder, fly ash, and other raw materials varies across countries and cities, while differences also exist in power supply conditions, worker skill levels, product specifications, and market demand.
Before finalizing the equipment plan, Guangzhou Hengde must first determine where the customer intends to build the plant, what raw materials will be used, what products will be manufactured, who the target customers are, and the planned production capacity.
On this basis, further progress is made in raw material testing, product selection, plant layout, production takt time calculation, and full-line equipment configuration.
The completion of manufacturing and shipment of the equipment does not signify the end of project delivery. Upon arrival at the customer’s site, the production line must undergo further installation, commissioning, operator training, and integration with the existing production process to ensure the equipment is fully operational.
Guangzhou Hengde stated:
The true measure of a production line is not how many pieces of equipment it has deployed, but whether it can consistently produce market‑compliant products at the customer’s site.
Going forward, Guangzhou Hengde will continue to focus on lightweight masonry blocks, lightweight wall panels, and automated cutting systems, enhancing the integrated design of its end-to-end equipment lines to provide plant‑design solutions that better align with the actual production conditions of customers in diverse markets and with varying capacity requirements.
For customers planning to build a lightweight block or wall panel manufacturing plant, please first provide Hengde with the following information:
- Country and city of the plant’s location;
- Locally available raw materials;
- Planned products and their specifications;
- Plan the shift output or daily output;
- Existing factory floor space and site conditions.
Hengde will conduct an analysis based on the project’s actual conditions and then determine a production line configuration that aligns with market demands and output levels.
Note: Actual production output is influenced by raw material availability, product specifications, curing time, mold turnover, personnel management, and on-site production conditions. The final plan shall be based on the project’s cost estimates and technical validation results.
Lightweight Block Production Line,Lightweight wall panel production line,CLC block equipment
No.25, Fulian Road, Fu'an Industrial Zone, Foshan City
No. 7, Jianyi Road, Xinjiang Wujiaqu Industrial Zone, Bingtuan New Building Materials Industrial Park
12 Potsdam Avenue, Berlin, Germany
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