In 2007, Hess AAC Systems installed a Keen-Crete^® – KBT plant at NUH Yapi in Türkiye, which continues to operate in excellent condition over 17 years later. This longevity underscores Hess AAC Systems’ commitment to delivering solutions that stand the test of time.

NUH Yapi’s plant was the first to incorporate the Tilting/Back Tilting method combination (Keen-Crete - KBT), significantly reducing but not entirely eliminating sticking during AAC production.

Initially operating with white separation, NUH Yapi transitioned to the innovative Green Separator based on experiences from other Hess AAC plants. This retrofitting significantly enhanced product quality, eliminating sticking and minimizing the reject rate.

NUH Yapi utilizes the Lathi mixing concept, complemented by peripheral mixers, as an additional purchase to achieve a homogeneous, fully automated, standard-compliant mixture. A special characteristic is the aeration concept for lime/cement, where built-in pads inflate with air during dosing, facilitating a unique level of dosing accuracy. Hammer strikes on the cone of the storage bins are not visible on the Hess AAC Systems’ mixing tower.

NUH Yapi’s packaging line is tailored to local requirements and operates fully automatically to streamline processes.

By diligently implementing Hess AAC’s Keen-Crete - KBT technology, NUH Yapi achieves minimal reject rates. Remarkably, after 17 years of operation, the factory consistently surpasses production quotas with outstanding quality.

Despite being 17 years in operation, the plant operates fully automatically, with operators overseeing monitoring and maintenance tasks in a steady, machine-friendly manner.

Aligned with Hess AAC Systems’ KBT plant versions, NUH Yapi can produce AAC blocks and panels in various raw densities (DIN AAC density classes 300 – 600/>120 – ≤600 kg/m³) meeting requirements, ensuring versatility in construction applications.

NUH Yapi’s success story exemplifies the enduring impact of innovative AAC production technologies. Through strategic adaption and continuous improvement, the company remains at the forefront of quality and efficiency in the construction materials industry.

Statement on a long-term partnership

“We are frequently asked why we chose Hess AAC Systems as our partner, which AAC products we produce, and what the quality is like. We have been working with Hess AAC Systems since 2007. The Hess AAC system is smartly designed to make simple movements with well-equipped automation that makes it easy to operate and guarantees quality. Maintenance durations and costs are lower because of the high-quality machinery manufacturing.

We are Hess AAC Systems’s first reference AAC plant with the Green Separator. All Hess AAC customers visited or knew us to witness the performance of the Hess AAC plant with experienced project details. On the maintenance side, we can quickly get the correct response and develop the solution online or on-site supervision.

We produce AAC blocks according to EN 771 with sizes from 50 mm to 400 mm, with thickness of 600 x 250 mm, and length and height. Furthermore, we produce lintels and panels, according to market demand. We can also produce AAC-based thermal insulation plate Termoküp™ with a lambda value of 0.045. We sell our AAC blocks to European countries, the Middle East, Africa, and even South America. The AAC-based thermal insulation plate Termoküp is mostly sold to European countries. However, we are open to selling our AAC-based thermal insulation plate with new partners all around the world, especially in EU countries where thermal energy efficiency at buildings is motivated by Green Deal targets.”

Bilder bitte horizontal nebeneinander anordnen.

Quality and efficiency – the most important assets

“We often receive inquiries about the quality of the chosen production method, damages during AAC production, and the reject rate. We have one AAC Plant. We decided to work with Hess AAC Systems in 2006 and still produce with increasing expertise, developing new products, and improving our profit margin. Our reject product rate is only 0.5 %.

The Green Separator is necessary for AAC production; we had a white separator in our old plants where the white product reject rates were around 2%. At this advanced AAC plant, we started with a white separator in 2008, and after some years, Hess AAC Systems developed the new Green Separator, which we have used since 2012. This has enabled us to increase production by 20%, i.e. by around 80,000 m³/year, which paid back its cost in a short period.

We have been in the AAC business since 1997; we already have an experienced production and maintenance team, which is our value to be in the AAC market with block, lintels, and the thermal insulation plate Termoküp. The Hess AAC plant performed very well in the last 15 years to support our AAC business performance.”  

Bilder bitte horizontal nebeneinander anordnen

Sustainability aspects

"We are a part of Nuh Cement Group, Türkiye’s biggest cement plant, where sustainable production is one of our primary targets. We have waste heat recovery and hydropower plants for renewable energy production. Besides those, we have ongoing investment projects for Wind Power Plants and Solar Power Plants to be in operation. Our AAC Plant has had an exhaust steam accumulation system in operation for ten years. We have a project planning biomass combustion at our circulating fluidized bed steam boiler. Our Research and Development Center focuses on AAC and the sustainable production capability of various raw materials. Nuh Yapi is a lime producer, too. The company developes and produces aluminum paste for the AAC process at our own plant. This way in our AAC products, the cement, lime and aluminum paste are produced by our own company. I think we are the only AAC producer in the world with these three central raw material production capabilities. As the producer of cement, lime, and aluminum paste, we are working on lowering the carbon footprint of these raw materials to produce the most sustainable AAC products in the world.”

Long-term cooperation

“On the question of how our cooperation with Hess AAC Systems has developed and how we see our long-term strategy regarding using AAC technologies in our company, I can say that we are the first plant of Hess AAC KBT-System with later integration of the Green Separation system in 2012. So we developed the system altogether. NUH Yapi and Hess AAC cooperated perfectly. If there is a better solution, it is applied in Nuh Yapi, or any process development requested/done by Nuh Yapi is saved as a modernization of Hess AAC Systems.

We now have one AAC plant in operation; we are more focused on value-added AAC products like Thermal insulation plate Termoküp, lintels, and panels than standard blocks. We have a patent application on Termoküp, and we are studying more projects to develop Termoküp and lambda 0.06 – 0.07 blocks.

Autoclaved aerated concrete will be a leading wall material with the help of the net zero road map of the European Autoclaved Aerated Concrete Association. AAC is always preferred because of its natural raw materials and fireproof structure. And no wall product recovers CO₂ back on its life cycle better than AAC.”