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India's Top Construction Machinery Manufacturer
When India's Oldest AAC Plant Chose Maruti Over German Imports
Location: Maharashtra, India | Capacity: 1,200 CBM/day | Plant Type: AAC Block Manufacturing Plant | Year: 2024
India's historic 1973 Siporex plant — running on original German machinery for over 50 years — selected Maruti Hydraulics to build a fully automated 1,200 CBM/day mega-plant with custom rotating tables. No European import. Built entirely in-house.
India's oldest AAC plant had operated on original German Siporex machinery continuously since 1973 — over 50 years. By 2023, the ageing line was producing at a fraction of its original capacity, requiring frequent halts for spare parts that could no longer be sourced from Germany. The plant owner evaluated multiple global suppliers including European and Chinese manufacturers. The challenge: engineer a 1,200 CBM/day plant — five times larger than a typical Indian AAC plant — using rotating tables and oversized mould frames that had never been built at this scale by an Indian manufacturer.
Maruti Hydraulics designed a bespoke production line specifically for the 1,200 CBM/day throughput requirement. The solution centred on custom rotating mould transfer tables — replacing the linear conveyor approach used in standard plants — to enable high-density mould cycling without increasing the footprint. The full SCADA-controlled batching system with recipe memory eliminated the manual weighing that had caused density variation on the Siporex line for decades. All autoclaves were fabricated in-house from SAE 516 Gr 70 steel to IBR standards, and the wire cutting machine was sized to handle the larger mould dimensions unique to this project.
The 1,200 CBM/day plant was commissioned in 2024 and is now India's largest operating AAC plant by daily output — matching and exceeding the original German Siporex design specification. Production density consistency improved dramatically versus the old manual batching line. The client achieved commercial production within the contracted commissioning window with zero import dependency for any component.
Tags: AAC Plant · Mega-Scale · SCADA Automation · Maharashtra
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