GYPSUM PLASTER BOARD

[EIRI/EDPR/3858] J.C.: 1968

INTRODUCTION

Gypsum Material Characteristics

Whether raw, natural, synthetic, or even recycled, it is often desirable to further

process gypsum before use, particularly in the case of agricultural applications.
When processing any material, it is important to recognize key characteristics that
will affect manufacturing operations and the final product generated. Even
commonly processed minerals such as gypsum require testing on a case-by-case
basis to ensure quality results.

The following list outlines key material characteristics that affect gypsum
processing.

Abrasive

Mined gypsum is a somewhat abrasive material. As a result, robust equipment

must be used when processing gypsum. Rotary dryers are an ideal solution for
many types of ore, as they are rugged pieces of equipment, easily customized with
heavy-duty linings that defend against erosion. Customizations can be made to
other processing equipment as well, in order to protect against abrasion, and
prolong equipment life. No matter what the equipment, keeping gypsum’s abrasive
nature in mind during design is a must.

Dust and Clumps

When granulated properly, pelletized gypsum is much easier to handle than its
raw, powdered counterpart. However, clumping and dusting issues may occur
when drying and pelletizing powdered gypsum. In order to avoid such problems,
processing equipment should be customized to accommodate.

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Raw Material Description

Gypsum has been known for centuries and is one of the oldest building materials
in the world. The earliest use of gypsum discovered was in Anatolia around 6000
B.C. Later, in about 3700 B.C., gypsum was used on the interiors of the great
pyramids in Egypt. One of the early uses of gypsum in building construction
appears to have occurred in 3700 B.C. when the Egyptians used gypsum blocks
and plaster applied over woven straw lath in the building of the pyramid of
Cheops. As a testimony to the strength and durability of gypsum, some of this
construction is still intact and viewable, including walls decorated with murals
composed of tinted plaster. For centuries now, gypsum has played a crucial role in
construction. American settlers recognized gypsum’s potential use as plaster and
as a soil amendment. Modern gypsum board has as its predecessor a product
called “Sackett Board,” a composite material that was made of layers of thin
plaster placed between four plies of wool felt paper. Sackett Board was patented in
1894 by Augustine Sackett, the man generally considered to be the grandfather of
the gypsum board manufacturing industry.

The wallboard is approximately 92% gypsum (calcium sulfate dihydrate CaSO4

2H2O), 7% paper, and 1% impurities and additives. Gypsum is found in every
continent of the world and is one of the most widely used minerals.

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 CONTENTS

INTRODUCTION
GYPSUM MATERIAL CHARACTERISTICS
ABRASIVE
DUST AND CLUMPS
RAW MATERIAL DESCRIPTION
GYPSUM BOARD – A PART REPLACEMENT TO WOOD
THE CHEMISTRY OF GYPSUM BOARD
PLANT LOCATION AND INFRASTRUCTURE
POTENTIAL LOCATIONS
"THE CROWN OF KERALA"
HOW TO REACH:-
BY FLIGHT
BY TRAIN
BY BUS
TYPES OF GYPSUM BOARD
TYPES OF GYPSUM BOARD (BASED ON MATERIAL STRENGTH)
GYPSUM LINER BOARD –
GYPSUM SHEATHING –
CONSTRUCTION MATERIAL – BASED ON INDIGENOUS
RAW MATERIALS
GYPSUM BOARD – ENVIRONMENT FRIENDLY MATERIAL OF CONSTRUCTION
PRODUCT RANGE
GYPSUM PANEL PRODUCTS
ADVANTAGES OF GYPSUM BOARD
EASE OF INSTALLATION:
FIRE RESISTANCE
SOUND INSULATION:
DURABILITY:
ECONOMY:
AREAS OF APPLICATIONS
GYPSUM BOARD FOR ACOUSTIC APPLICATIONS
GYPSUM BOARD FOR CEILING APPLICATION
GYPSUM BOARD – STANDARDS AND QUALITY CONTROL
ASTM STANDARDS
BIS STANDARDS
CHEMICAL COMPOSITION GYPSUM
PLANT & MACHINERY REQUIREMENTS
RAW MATERIALS AND CONSUMABLES

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GYPSUM PANEL
GYPSUM BOARD
MARKET SURVEY
GYPSUM BOARDS MARKET: DRIVERS AND RESTRAINTS
GYPSUM BOARDS MARKET: SEGMENTATION
THE GYPSUM BOARDS MARKET CAN BE SEGMENTED ON THE BASIS
OF PRODUCT TYPE:
THE GYPSUM BOARDS MARKET CAN BE SEGMENTED ON THE BASIS
OF APPLICATION:
EXAMPLES OF SOME OF THE MARKET PARTICIPANTS IN THE GYPSUM
BOARDS MARKET, IDENTIFIED ACROSS THE VALUE CHAIN ARE
MENTIONED BELOW:
INDUSTRY INSIGHTS
PRODUCT INSIGHTS
APPLICATION INSIGHTS
REGIONAL INSIGHTS
MANUFACTURING TECHNOLOGY FOR GYPSUM BOARD
MACHINES AND EQUIPMENT
MANUFACTURING PROCESS
PROCESS FLOW DIAGRAM
COMPARISON OF PRODUCTS / MANUFACTURING TECHNOLOGIES
PRODUCT SPECIFICATION
MACHINERY LIST
SUPPLIERS OF RAW MATERIALS
GYPSUM MINERALS
GLASS FIBRE
LIST OF GYPSUM BOARD DEALERS
SUPPLIERS OF PLAND AND MACHINERY
MACHINERY PHOTOGRAPHS
PAPER SUPPLY SYSTEM
AUTOMATIC POSITION ADJUSTER
AUTOMATIC GLUE-COATING DEVICE
SILO
FOAMING SYSTEM
FORMING SYSTEM
FORMING DEVICE
CONVEY SYSTEM
DRYING SYSTEM
RAW MATERIAL PHOTOGRAPHS
GYPSUM MINERAL
MINERAL FIBRE
PRODUCT PHOTOGRAPHS

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APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)

COST ESTIMATION

Plant Capacity 6800 sq.mt/Day

Land & Building (2700 sq.mt.) Rs. 1.96 Cr
Plant & Machinery Rs. 2.25 Cr
Working Capital for 1 Month Rs. 1.40 Cr
Total Capital Investment Rs. 6.22 Cr
Rate of Return 63%
Break Even Point 35%

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