What Is the Production Process of Gypsum Board Machinery

What Is the Production Process of Gypsum Board Machinery?

Introduction

Producing gypsum board is a continuous, multi-stage manufacturing process that converts raw gypsum and paper liners into finished boards used for wall and ceiling systems. The production flow combines thermal, mechanical and chemical operations with precise timing and material control. The following narrative explains the typical end-to-end process in detail, suitable for plant planners, operations staff and procurement specialists. Hengshui Decheng Machinery& Equipment Co.,Ltd supplies turnkey machinery and control systems that support each stage described here.

1. Raw material supply and preparation

The process begins with the reliable supply of raw gypsum materials: natural gypsum rock, flue gas desulfurization (FGD) gypsum or recycled gypsum board. Materials are inspected, sampled and stored in designated yards or silos. Crushing and screening reduce large lumps and remove tramp metal or contaminants. If raw gypsum contains excessive moisture, dryers or preconditioning steps are used.

2.Calcination (stucco production)一 if plant includes this stage

If the plant produces its own stucco, raw gypsum is fed to a calciner where controlled heating removes crystal water, converting dihydrate gypsum to hemihydrate (stucco). The calcination step is critical: precise temperature and residence time determine the reactivity (setting characteristics) of the stucco. After calcination, the material is cooled and conveyed to storage silos where it is aerated to remain free-flowing.

3. Milling and classification

Calcinated gypsum (stucco) is milled to a specified fineness that influences slurry rheology and board strength. Closed-circuit mills with air classifiers enable control of particle size distribution.The finished stucco is stored and metered for mixing.

4. Paper feed and forming

Two continuous paper webs (facer and backer) are unwound, prepared (splicing, edge trimming, tensioning) and guided through the forming area. At the headbox, the slurry is deposited onto the lower facer paper; the backer is applied on top, and the continuous sandwich enters the forming conveyor. The forming belts and tables control board thickness and surface profile.Initial dewatering occurs through gravity and the wetted paper’s absorption.

5. Setting and initial curing

As the continuous board traverses the forming line, a chemical setting reaction gradually converts the hemihydrate back toward dihydrate, giving the board mechanical integrity. Line speed and setting time are balanced so that boards reach sufficient strength for cutting. During setting, foamed cores or special additives control density and flexural strength.

Conclusion

The production process of gypsum board machinery is a continuous, interdependent sequence: material preparation, stucco production, precise slurry mixing, continuous forming and setting, controlled drying and finishing, followed by automated stacking and packing. Each step must be engineered and controlled to achieve consistent product performance. Hengshui Decheng Machinery & Equipment Co.,Ltd provides equipment and integrated control solutions for every stage of this process, enabling reliable production of a wide range of gypsum board products.