Gypsum Board Manufacturing Factory

What Are the Key Stages in Gypsum Board Manufacturing?

Gypsum board manufacturing is a structured sequence of interrelated stages designed to convert raw materials into finished construction panels. At Hengshui Decheng Machinery & Equipment Co.,Ltd, the process is optimized for both precision and scalability, allowing for large-scale production with minimal variation.

Stage 1: Material Storage and Handling
The process begins with the delivery and storage of raw gypsum, paper, and additives. Gypsum is kept in silos while paper rolls are stored in a climate-controlled area to prevent moisture absorption. The additives, such as starch and foam agents, are stored in separate tanks and handled with metering systems.

Stage 2: Slurry Preparation
Using automated batching systems, gypsum is mixed with water and additives to form a homogenous slurry. This mixture is crucial for the board’s strength, setting time, and resistance to sagging. High-speed mixers ensure consistency and uniformity.

Stage 3: Paper Feeding and Forming
Unwinding stations feed top and bottom paper into the forming line. The slurry is poured onto the bottom paper, and the top paper is pressed down to form the board. The forming table and roller setup determines the thickness and width of the board.

Stage 4: Initial Setting
The continuous wet board passes along the conveyor belt, allowing the gypsum to hydrate and set partially. This setting zone can be adjusted in length to accommodate different board formulations or thicknesses.

Stage 5: Cutting
After the initial set, the board is cut into predefined lengths using a synchronized cutting system. The cut boards are transferred to the dryer entrance in precise intervals to avoid overlap or stacking during drying.

Stage 6: Drying
Boards pass through a kiln with multiple temperature zones. Early zones remove surface moisture gently, while middle and final zones apply higher temperatures to fully dry the core. The drying cycle is designed to prevent warping and maintain strength.

Stage 7: Finishing
Once dried, the boards are cooled, edge-trimmed, and inspected. Some lines include surface coating or lamination stations to apply additional finishes or water-resistant layers.

Stage 8: Stacking and Packaging
Boards are automatically stacked in uniform bundles. Strapping and labeling machines prepare them for storage and shipping.

Every stage is monitored and controlled to maintain quality standards and production consistency. This structured approach ensures that gypsum boards produced are suitable for various interior construction applications.