Closed Mould Oiling Machine for AAC Manufacturing: developed by Aircrete Europe, an automated system engineered specifically for precise and repeatable oil application in AAC mould preparation. The machine is designed to operate in both Flat-Cake and Tilt-Cake production environments, supporting consistent demoulding performance and stable product quality.

The machine is built around a rigid mechanical frame and a fully enclosed oiling chamber, forming a closed process that isolates oil application from the surrounding production area. This design minimizes contamination, improves operator safety, and allows controlled recovery of oil particles during the spraying process.

At the center of the system is an L-shaped oiling arm that provides full 360° coverage of the mould interior. The arm is equipped with five oil nozzles, arranged with two downward-facing nozzles, two side nozzles, and one corner nozzle. This configuration ensures uniform oil distribution across all mould surfaces, including edges and corners.

The mould surface is divided into eight independently programmable oiling zones. Each zone can be configured individually via the operator panel, allowing the oil quantity to be adapted to specific mould geometries, product types, or production requirements. This zoned approach enables high precision and repeatability across different AAC formats.

Oil is applied using oil pressure spraying, rather than compressed air. This method provides accurate deposition of oil onto the mould surface while avoiding excessive mist formation. The result is a cleaner oiling process with improved control over film thickness and reduced oil losses. The oil supply system includes an integrated 24-liter buffer tank with controlled heating and continuous circulation. This ensures that the oil remains at a stable operating temperature, maintaining a kinematic viscosity of 135–150 cSt (mm²/s), typically measured at 40 °C. Consistent viscosity is essential for reliable spray characteristics and uniform surface coverage.

During operation, the oiling area is enclosed by a steel cover incorporating an air circulation and filtration system. Oil particles generated during spraying are captured, filtered, and returned to the system. This closed-loop concept significantly reduces environmental impact and keeps the surrounding production area clean. Excess oil is collected through an integrated drip collection system, allowing residual oil to be recovered and reused. In combination with the filtration unit, this design contributes to reduced operating costs and improved sustainability of the mould preparation process.

Oil consumption is continuously monitored by an integrated flow meter, providing accurate measurement and transparency for production control. With a typical oil consumption of 0.7–0.9 liters per mould and a mould volume of 5.4 m³, the resulting consumption is approximately 0.13–0.17 L per cubic meter of AAC, supporting efficient and predictable operation.

The Closed Mould Oiling Machine operates with a stand-alone control system based on a dedicated Siemens PLC and touchscreen operator panel. The interface allows operators to manage oiling parameters, monitor system status, and adjust zone settings with clarity and precision. Signal exchange is prepared for integration into the customer’s existing factory automation system.

Mechanical features include a centering device to ensure accurate mould positioning and a dedicated maintenance platform with stairs to provide safe and easy access for inspection and servicing. These elements support reliable long-term operation and simplified maintenance routines.

The complete oiling cycle is performed in less than three minutes, enabling the machine to operate efficiently within high-capacity AAC production lines. The system is suitable for both open and closed mould configurations, and in Tilt-Cake factories with closed moulds, the cutting platform can be oiled separately if required.

The machine is prepared for connection to external oil storage, such as standard 1,000-liter IBC tanks or larger bulk oil tanks. Installation and commissioning are typically completed within 4–5 days, allowing rapid integration into existing plants. The Closed Mould Oiling Machine provides a robust, precise, and scalable solution for modern AAC manufacturing.