Gypsum Board Production Technology
Gypsum board production sold in Russia, Ukraine, Kazakhstan is mainly owned by large foreign companies such as Knauf, British Plaster Board and Lafarge Group. Almost all of them have production facilities in post-Soviet space. For example, there are Knauf and Lafarge plants in Ukraine.
Gypsum Board Manufacturers
Gypsum board production sold in Russia, Ukraine, Kazakhstan is mainly owned by large foreign companies such as Knauf, British Plaster Board and Lafarge Group. Almost all of them have production facilities in post-Soviet space.
For example, there are Knauf and Lafarge plants in Ukraine. If you search for "buy gypsum board" on the internet in any large city, such as Novosibirsk or Donetsk, most offers will come from Knauf distributors.
Russian manufacturers differ by more modest production volumes, smaller product range and lower price of gypsum board. The largest among direct Russian manufacturers is the Volgograd Gypsum Plant producing gypsum board under the brand Volma. Another popular Russian brand of gypsum board is Magma.
In some regions, local manufacturers of this popular building material also exist. In Kazan, a small production of several sizes and types of gypsum board under the brand Abdullingips is produced by LLC "Arachinsky Gypsum".
Another company (LLC "Aksolit") recently opened a new complex for producing gypsum building materials in Tatarstan named "Fonika Gypsum".
Photo 1 — Standard Volma Gypsum Board Sheet
Raw Materials for Gypsum Board Production
As the name suggests, gypsum board is made from gypsum and cardboard. However, to form a board, a binding substance is also needed.
Besides that, there are additives that improve the technical characteristics of gypsum board. All these components must meet certain requirements to produce high-quality GKL. Main ingredients:
- gypsum – 85% powder;
- cardboard – sheets of 1180 x 1250 mm;
- starch – 70%;
- foam agent;
- polyvinyl acetate emulsion (glue).
In addition, depending on the technology, such fillers as glass fiber and cellulose may be included in the composition of gypsum board, and other additives that regulate the setting speed of the gypsum mixture, give moisture resistance and fire resistance to gypsum board, etc.
Photo 2 — Standard, Moisture-Resistant and Fire-Resistant Gypsum Board
Equipment for Gypsum Board Production
Producing gypsum board requires not just one machine, but an entire automated production line. It includes machines that mix, dose and feed gypsum, feed glue, cardboard and other components of gypsum board.
The machine forming GKL, conveyors, dryers, cutting and edge finishing units, packaging machines – this is not a full list of required equipment.
Production facilities also have systems that control temperature and humidity, form specific types of boards, measure fixed values for raw material feeding and board cutting, etc.
Gypsum board production equipment, with the price of a small unit starting at about $120,000, is offered by various manufacturers, including China.
Diagram 1 — Automated Production Line for Gypsum Board
Gypsum Board Production Technology
The gypsum mass is formed, and necessary additives and fillers are added.
On the conveyor, with the help of a special GKL former, continuous sheets of gypsum board are formed: in automatic mode, the gypsum mixture is laid between cardboard sheets supplied by a separate unit, layers are glued together, and edges are rolled.
The pressed sheet, which has dried as it moves along the conveyor, is sent to a machine for cutting into individual sheets.
Sheets pass through drying units.
Finished products are stacked and packed.
Photo 3 — Gypsum Board Production Room
Gypsum Board Production, Video
"Gypsum Board Industry" is not only GKL production, but also the production of guides and stud profiles, hangers and other components needed for subsequent gypsum board installation.
It is also impossible to do without gypsum putties and other finishing materials for work with gypsum board. Large manufacturers like Knauf produce a "complete set" for gypsum board installers.
Cost of Gypsum Board
Undoubtedly, it is most economical to buy gypsum board in bulk directly from the manufacturer.
- Knauf – Gypsum board from the manufacturer, price in Moscow – starting at 74 rubles per square meter;
- Knauf – Gypsum board from the manufacturer, price in Kiev – starting at 40 hryvnia per sheet.