Gypsum Board Manufacturing Process

Gypsum Board Manufacturing Process: From Raw Materials to Finished Panel

The gypsum board manufacturing process involves a series of well-coordinated steps to transform raw materials into durable, construction-grade panels. Hengshui Decheng Machinery & Equipment Co., Ltd. has developed systems that streamline each stage, ensuring consistent output and minimal downtime.

Raw Material Handling
The process begins with the preparation of raw gypsum. Natural or synthetic gypsum is crushed and ground into a fine powder. This powder is then mixed with water and various additives, such as starch, foaming agents, and setting regulators. Paper rolls for the face and back layers are prepared for feeding.

Slurry Mixing and Forming
In a high-speed mixer, gypsum slurry is created and deposited onto a continuously moving sheet of face paper. A second sheet of paper is applied on top, enclosing the slurry. This sandwich structure forms the initial board shape.

Shaping and Pre-Setting
As the board progresses along the forming conveyor, it begins to set. Shaping tools and edge rollers define the final width and thickness. Proper control during this stage is critical for product consistency.

Cutting and Transfer
Before the board hardens completely, it is cut to the required length. The cut boards are transferred to a belt system that conveys them into the drying section. A gentle pre-curing period ensures the boards retain their shape before drying.

Drying and Finishing
Drying is conducted in multi-zone kilns where hot air circulates around the boards. Moisture is evaporated slowly to prevent surface cracking. Once dry, boards are cooled, trimmed, and inspected before stacking and packaging.

Environmental Management
The process includes dust filtration systems and water recycling loops to reduce environmental impact. Energy recovery systems may also be employed to utilize waste heat from the kiln.