Gypsum Board Production Line China Factory

Gypsum Board Production Line

transforms raw gypsum and ancillary materials into flat panels used for interior walls, ceilings, and partition systems. The process is continuous and highly automated, ensuring consistent board dimensions, uniform density, and controlled surface quality. An overview of the main stages follows:

1. Raw Material Preparation
Gypsum board begins with calcium sulfate dihydrate (gypsum) powder. This material is often supplemented by additives such as starch (for paper adhesion), foaming agents (to adjust core density), and small amounts of performance enhancers like setting retarders or accelerators. Raw gypsum is first stored in silos and then carefully metered into a mixing system, where water and additives are introduced according to a precise recipe. Accurate weighing and proportioning are critical to maintaining board consistency and mechanical properties.

2. Slurry Mixing
In the mixer, gypsum powder and water form a fluid slurry. Paddle or ribbon agitators ensure that all components are evenly distributed. The slurry viscosity must be controlled to allow it to flow smoothly onto the forming line without separation or air entrapment. Automated sensors monitor parameters such as slurry density, temperature, and pH, feeding back to dosing units that adjust water or additive flow in real time. Proper mixing prevents defects such as core voids or surface unevenness.

3. Forming and Cutting
Once mixed, the slurry is deposited onto a continuous lower paper sheet transported by conveyor belts. An upper paper sheet is applied on top, sandwiching the slurry between the two paper liners. The combined “sandwich” moves forward, and a series of rollers guides it to the cutting station. Rotary knives slice the moving board to the desired lengths—typically 2400 mm or 3000 mm, though custom sizes are possible. Accurate cutting ensures that panel edges remain square and that length tolerances are maintained.

4. Setting and Drying
Cut boards enter a pre-drying tunnel to initiate the gypsum’s hydration reaction, allowing the core to harden sufficiently for handling. From there, panels pass through a multi-zone drying oven heated by gas, steam, or electric sources. Controlled temperature and humidity profiles remove free water without causing surface cracking or core delamination. Drying profiles are optimized to balance energy use against throughput: too rapid a profile may degrade quality, while too slow a profile reduces production capacity.

5. Finishing and Stacking
After exiting the dryer, boards cool to ambient temperature. Edge and face trimming units may remove minor irregularities, and surface inspection systems detect chips, warping, or paper defects. Finished panels are then stacked in bundles, often with protective corner guards and strapping. Automated stackers align boards in neat piles, ready for palletizing and shipment.

6. Quality Control and Environmental Considerations
Throughout the line, inline gauges measure board thickness, density, moisture content, and flatness. Data is logged to support batch traceability and to trigger adjustments when parameters drift outside set limits. Dust extraction systems capture airborne gypsum particles at mixing and cutting points, protecting worker health and reducing material loss. Waste water from cleaning processes can be treated to recover fine gypsum for reuse, minimizing environmental impact.

A well-designed gypsum board production line strikes a balance between throughput, energy efficiency, and product consistency. By integrating precise metering, closed-loop controls, and automated inspection, modern installations can achieve high output rates—often several thousand square meters per hour—while maintaining reliable performance over long production campaigns.