Engineered for maximum operational uptime, exact dimensional control, and low energy consumption per square meter produced.
An authoritative technical breakdown of wet-forming slurry filtration, hydrothermal reaction kinetics, and automated mechanical execution in non-asbestos building board plants.
The production of modern Calcium Silicate Boards (CSB) represents one of the most sophisticated chemical and mechanical engineering processes in the non-metallic building materials sector. Unlike basic air-cured fiber cement sheets, calcium silicate boards rely on a precise hydrothermal synthesis reaction inside high-pressure autoclaves to form Tobermorite crystal matrixes ($5CaO \cdot 6SiO_2 \cdot 5H_2O$).
As a leading Hatschek Calcium Silicate Board Equipment Manufacturer and Supplier, China Amulite Group integrates heavy machinery precision with industrial automation. The core of this system is the refined Hatschek Wet-Forming Process, which utilizes multiple mesh-covered forming cylinders submerged in agitated slurry vats. Slurry consisting of fine silica quartz powder, unslaked lime (CaO), Portland cement, and reinforcing cellulose fibers is continuous filtered to create ultra-thin film layers ($0.2\text{ mm} - 0.3\text{ mm}$ per rotation) onto a running felt belt under high vacuum dewatering.
These microscopic film layers are continuously wound around a forming drum until the desired board thickness ($4\text{ mm} - 30\text{ mm}$) is reached. The laminated green sheet is then subjected to pre-curing, high-tonnage hydraulic pressing (up to 10,000 tons for high-density boards), and 12-hour high-pressure saturated steam autoclaving at 180°C - 190°C.
From raw material dosing to final automated stacking, explore how our complete turnkey Hatschek lines achieve operational efficiency.
China Amulite Group brings together heavy engineering capacity, complete supply-chain integration, and world-class automated control systems.
Our 100,000 m² workshop houses heavy CNC floor-type boring machines, large lathe turning centers for 1,600mm forming drums, and robotic welding stations. Every autoclave and frame is stress-relieved and non-destructively tested in-house.
We don't force rigid raw material requirements. Our process chemical engineers test your local silica sand, lime, cement, and alternative fibers (such as fly ash or recycled paper pulp) to formulate an optimal mix ratio that minimizes raw material CAPEX.
Equipped with Siemens S7-1500 PLC control, Profinet communication networks, closed-loop vacuum regulation, real-time board weight tracking, and remote cloud diagnostic interface for instant global technical support.
Standard plant configurations for calcium silicate and fiber cement production lines engineered by China Amulite Group.
| Plant Capacity (Annual) | Forming Vat Configuration | Sheet Width / Length | Board Thickness Range | Autoclave Units Required | Installed Electrical Load |
|---|---|---|---|---|---|
| 3,000,000 m² / Year | 3 Cylinder Vats (Hatschek) | 1220 mm × 2440 mm | 4 mm – 20 mm | 2 Units (Φ2.8m × 31m) | ~ 650 kW |
| 5,000,000 m² / Year | 4 Cylinder Vats (Hatschek) | 1220 mm × 2440 / 3050 mm | 4 mm – 25 mm | 3 Units (Φ2.8m × 31m) | ~ 980 kW |
| 8,000,000 m² / Year | 5 Cylinder Vats (Hatschek) | 1220 mm × 2440 / 3050 mm | 4 mm – 30 mm | 4 Units (Φ2.8m × 35m) | ~ 1,450 kW |
| 10,000,000+ m² / Year | 6 Cylinder High-Speed Line | 1220 mm × 2440 / 3660 mm | 4 mm – 30 mm | 5 Units (Φ2.8m × 38m) | ~ 1,850 kW |
How modern environmental regulations, green building standards, and energy costs are shaping equipment design.
Global bans on chrysotile asbestos have accelerated the demand for high-freeness bleached/unbleached kraft pulp combined with synthetic matrix fibers (such as PVA or PP fibers). Amulite's Hatschek vat systems are designed with high-torque agitators to prevent fiber clumping and ensure homogeneous distribution.
Autoclave steam costs account for over 35% of total plant OPEX. Our new generation autoclave systems incorporate automated steam-transfer piping loops. Waste steam from one finished autoclave vessel is transferred into a newly loaded vessel, reducing overall thermal energy consumption by 22% - 28%.
Demand for indoor acoustic ceiling boards and fireproof partition linings requires low-density boards ($0.8 - 1.0\text{ g/cm}^3$). Amulite machinery integrates perlite/mica micro-dosing systems into the wet slurry phase to reduce board weight while retaining Class A1 fire rating integrity.
Calcium silicate boards produced by Amulite Hatschek machinery serve high-grade architectural, commercial, and industrial markets worldwide.
Medium-density calcium silicate boards ($1.1 - 1.3\text{ g/cm}^3$) are ideal for 2-hour to 4-hour fire-rated dry wall partition systems in office towers, hospitals, and hotels. Excellent screw-holding power and total resistance to moisture degradation.
High-density compressed calcium silicate boards ($1.4 - 1.7\text{ g/cm}^3$) subjected to 10,000-ton hydraulic pressing deliver high flexural strength (> 16 MPa), low water absorption (< 25%), and extreme freeze-thaw durability for exterior building envelopes.
100% fiber-reinforced non-combustible panels engineered for cleanroom wall systems, pharmaceutical facilities, subway tunnel passive fire protection, and high-temperature industrial duct isolation.
Essential factors industrial investors and EPC contractors must evaluate before selecting a Hatschek calcium silicate board equipment partner.
Inquire about the dynamic balancing and machining tolerance of the forming cylinders. Concentricity must be within ±0.05mm to ensure consistent web thickness and prevent premature felt wear.
Evaluate the water-ring vacuum pump staging. Multi-chamber dewatering boxes with automatic vacuum control ensure moisture content drops from 70% to under 28% prior to green sheet wrapping.
Ensure autoclaves are manufactured according to ASME Section VIII Div 1 or European PED (2014/68/EU) standards, complete with quick-opening safety interlock doors.
In-depth technical answers addressing operational, mechanical, and material queries from plant managers and global procurement teams.
Full-line machinery solutions for non-metallic building panel production, recycling, and material processing.
Submit your target annual board capacity, desired board dimensions, and raw material availability. Our engineering director will deliver a complete machinery list, civil layout drawing, and consumption analysis within 24 hours.
