The plant's journey
The AAC Deva plant stands as a testament to continuous improvement, combining efficiency with sustainability. Over the years, the plant’s production capacity has increased by more than 40% compared to its initial design.
The challenges for production shifted in the last years: until 2021, the Romanian market experienced steady growth, prompting the plant to focus on maximizing output. However, starting in 2022, the energy crisis and the first signs of a market decline necessitated a strategic pivot. The plant shifted its focus toward enhancing production efficiency, prioritizing safety and quality above all.
Thus, three main focus points were established:
- Optimization of the product portfolio (including new products) and shifts work system
- Improvement of the product recipes
- Improvement of energy efficiency and sustainability.
Keeping these targets in mind, with the involvement, effort, and dedication of the plant team and strong support received from both the regional and group level, the Deva plant managed to improve its efficiency managing to reduce specific consumptions such as binders, sand, gas and freshwater, which also contributed to a positive impact on the environment. Regarding the reuse of AAC leftovers, the plant has taken important steps, in 2024 the reuse rate was 89%, being prepared for full reuse starting this year.
Real transformation in safety
Since Xella took over the plant in 2018, it has gone through a constant and intense process of transformation in terms of safety. The approach moved from a level of compliance with legal requirements, to ensuring real protection for our colleagues. During this period, over 50 health & safety projects have been implemented that have substantially improved workplace safety. Through the Total Safety Leadership program, which has been a strong support in the transformation, managers and coordinators shifted their focus from technical aspects to the mindset and behavior that underpin a safe workplace. This shift in approach has strengthened the journey towards a true safety culture, where safety isn’t simply a policy but a core value.
“Keeping the focus on our core principles of safety, quality, efficiency, environmental responsibility and team spirit, I am confident that our plant will continue its successful course.” says Alin Nicula, plant manager.