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Sustainable Ytong and Multipor production at Turkey’s only “hybrid plant”

The Ytong plant in Çatalca, about 55 kilometers from the center of Istanbul, was commissioned by Türk Ytong in August 2015. In 2018 the production of Multipor was increased from 25,000 m³ to 50,000 m³.

17 February, 2022

Always a significant location

Çatalca is a settlement characterized by its large agricultural and forest areas, nature parks, beaches, and camping spaces in the surrounding area. However, it is also important from an economical perspective as it holds the most important water resources for Istanbul.The plant here is one of the latest additions to Ytong's long-standing production facilities in Turkey. AAC has a longer history in Turkey than one might think. Cooperation between Sweden's Ytong International AB and Turkish licensees began as early as 1963, and Türk Ytong, the brand under which the plants are still operated today, started production in 1965 at its first plant in Istanbul-Pendik with a capacity of 50,000 m³. Today, a total of six plants with a production capacity of up to 2.5 million m³ of Ytong and 50,000 m³ of Multipor operate in Turkey in a 25 percent partnership with the Xella Group.

 
Modern equipment in hybrid use
In Çatalca, 85 employees work in 4 shifts and deliver around 1,350 m³ of autoclaved aerated concrete per day. The plant is equipped with the latest technological and safety standards. Safety fences and machinery are supported by state-of-the-art automation, and employees receive regular training in occupational safety. In addition, the factory has a quality control laboratory with equipment and devices that meet international standards.
What is unique about the plant: It is the first in Turkey to produce Ytong and Multipor at the same time. The equipment for casting and cutting as well as the autoclaves can be used in the production process of both products, making the use of both product lines as efficient as possible. Other robots include the unloading unit of Multipor, which is separately used and robots and microwave ovens, that are used in the Multipor discharge line to increase efficiency and provide full automation.
 

World's first Green Building certificate for a Ytong plant
The plant is not only a positive example in terms of robotization, but also in terms of sustainability: Thanks to its vapor recovery systems, gas consumption is kept very low (65 kWh/m³). Ytong breakage, which is unavoidable in the production process, is immediately reused in the production of new products. In mechanical systems and lighting, energy consumption and CO2 emissions have been reduced by using highly efficient equipment in accordance with international standards. The energy consumption of all types of systems such as heating, cooling, ventilation and lighting is monitored by energy analyzers and a smart building system. This makes it possible to constantly monitor the level at which energy efficiency targets are being met.
All these features have made Çatalca the world's first Green Building certified Ytong plant and the first ever factory building in Turkey to receive a certificate in this category.

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