Gypsum Board Manufacturing Process Manufacturer

Gypsum Board Manufacturing Process

The gypsum board manufacturing process at Hengshui Decheng Machinery & Equipment Co.,Ltd is engineered for consistency, efficiency, and adaptability. From raw material input to finished panel, each stage is optimized to maintain product integrity and minimize waste.

1. Raw Material Preparation

• Gypsum Powder Storage: Fine‑ground calcium sulfate is stored in sealed silos with aeration to prevent clogging.

• Paper Preparation: Face and backing paper rolls are aligned on unwinding shafts with tension control to ensure wrinkle‑free feeding.

2. Slurry Mixing
Gypsum powder is metered into a mixing tank where water and performance additives (e.g., retarders, foam agents, starch) are introduced. High‑shear impellers produce a homogenous slurry with target viscosity and setting time.

3. Board Forming
The slurry is deposited onto the lower paper layer via a calibrated headbox. The upper paper layer is applied immediately, forming a continuous “sandwich.” Shaping rollers set the thickness and edge profile.

4. Pre‑Setting
This initial stage allows the board to gain rigidity. As the wet panel travels on the forming conveyor (often many meters long), the gypsum begins its hydration reaction, transforming into a firm structure.

5. Cutting
Once the board reaches semi‑rigidity, synchronized cutting knives score or fully sever sheets at programmed intervals. The length can be adjusted on the fly.

6. Drying
The boards enter a multi‑zone kiln.

• Zone 1: Low‑temperature start (50–70 °C) to prevent surface cracking.

• Zones 2–4: Gradual ramp (up to 120–140 °C) to remove bound moisture.

• Exhaust Handling: Wet air is drawn off and routed through heat exchangers for energy recovery.

7. Trimming and Calibration
After drying, edge trimmers remove irregularities and bevel edges if required. Thickness calibration rollers ensure uniform board depth across the width.

8. Quality Inspection and Packaging
Automated scanners check board flatness, thickness variance, and surface defects. Conforming boards are stacked, strapped, and labeled before dispatch.

This process flow is continuously monitored and adjusted to maintain optimal throughput while ensuring each board meets defined performance criteria.