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The forming section is where the gypsum board is created. Gypsum powder and additives are batched to a controlled ratio, mixed with water into slurry, spread between the bottom and top paper, and the continuous board sets on the setting belt before being cut to length. The section comprises a high speed mixer, a scraper type stainless steel mixer, a dynamic foaming system, a dropdown shaping machine, an automatic paper supply and joint system and a setting belt. Five of these are available as complete single machines, and spare parts including setting belts are supplied separately. Reference unit prices for the main machines are listed on this page. Output meets GB/T 9775-2008, from 7 to 20 mm thick.
The forming section is where the gypsum board is created. Gypsum powder and additives are batched and mixed with water into slurry, the slurry is spread onto the bottom paper and covered with the top paper, and the continuous board sets on the setting belt before being cut to length. DCI supplies the forming section as part of a complete gypsum board production line from 2 to 50 million m²/year, and the main machines can also be supplied separately for line upgrades.
The section carries out four stages in sequence.
Stage | What happens |
1. Batching | Gypsum powder, modified starch, foaming agent and glue are dosed to a controlled ratio |
2. Mixing and foaming | The dosed materials are mixed with water into slurry; a dynamic foaming system forms part of this stage |
3. Shaping | Slurry is spread onto the bottom paper and covered with the top paper |
4. Setting and cutting | The continuous board passes the setting belt and is cut to length |
Equipment | Function in the section |
High speed mixer | Mixes gypsum powder, water and additives into slurry |
Scraper type stainless steel mixer | Mixing and slurry preparation in stainless steel construction |
Dynamic foaming system | Foaming stage of the slurry preparation |
Dropdown shaping machine | Forms the continuous board between the bottom and top paper |
Automatic paper supply and joint system | Feeds the facing paper and joints a new roll, reducing paper-break shutdowns |
Setting belt | Carries the continuous board while it sets, before cutting to length |
All six items are supplied by DCI. The high speed mixer, scraper type mixer, dropdown shaping machine, dynamic foaming system and automatic paper supply and joint system are also available as complete single machines. Spare parts and wearing parts — including setting belts — are supplied separately for existing lines.
The section takes gypsum powder, modified starch, foaming agent, glue and facing paper, together with water. Formulation and additive changes are what allow one line to produce regular, moisture-resistant and fire-resistant board.
DCI also supplies the raw materials on a long-term basis. Specification of three of the key additives:
Additive | Specification |
Modified starch | Starch content >80% (dry basis); moisture ≤10%; ash ≤0.5%; protein ≤0.3%; pH 6–7; residue on 0.2 mm sieve ≤4.0%; bonding performance: dry heat I, wet heat |
Foaming agent | Active content ≥34% (surface active matter in liquid); pH 7–9; cloud point<10 °C; sodium sulfate ≤2.0%; sodium chloride ≥0.1%; foam stability ≥95% |
Silicone oil | Colourless and transparent; hydrogen content 1.50–1.65%; viscosity 15.00–40.00 mm²/s; volatile matter ≤4%; used for moisture-resistant board |
The forming section is set to the board dimensions of the line: thickness adjustable from 7 to 20 mm, width 1200 or 1220 mm, and length from 2400 to 3600 mm. Other dimensions can be designed on request. Output meets GB/T 9775-2008 or an equivalent international standard.
The forming section is the first section of the production line, running from raw material batching through to cutting the wet board to length. It feeds the wet board conveying and stacking section, which in turn feeds the drying system. Because the setting belt, the conveying section and the dryer are sized to the same line speed, the capacity tier of the line is fixed before the forming section is configured.
When supplied as part of a complete line, the forming section is carried in the line price rather than quoted separately. A complete gypsum board production line is quoted from USD 180,000 to USD 8,500,000 FOB China, depending on the capacity tier, the heating and drying system, the fuel type, the automation level and the scope of supply.
Individual machines are also supplied for line upgrades and replacements. Reference unit prices from our current catalogue:
Machine | Reference price (FOB) |
High speed mixer | USD 16,000 – 17,000 per unit |
Dropdown shaping machine | USD 11,000 – 13,000 per unit |
Scraper type stainless steel mixer | USD 7,500 – 8,500 per unit |
Prices depend on model, capacity and construction. Other single machines and spare parts are quoted against a specific machine list.
DCI engineers attend site for mechanical installation, electrical commissioning and trial production, and remain until the line reaches design capacity. Operator and maintenance training is carried out during commissioning. Installation takes about 4 to 6 months, and the line carries one year of warranty with remote technical support and long-term spare parts supply.
Country | Capacity |
Oman | 20 million m²/year |
Morocco | 15 million m²/year |
Russia | 15 million m²/year |
Iran | 10 million m²/year |
Kyrgyzstan | 10 million m²/year |
Kuwait | 5 million m²/year |
Q: What is the forming section of a gypsum board production line? A: The first section of the line. It batches and mixes the slurry, spreads it between the bottom and top paper, lets the board set on the setting belt and cuts it to length.
Q: Which machines make up the forming section? A: A high speed mixer, a scraper type stainless steel mixer, a dynamic foaming system, a dropdown shaping machine, an automatic paper supply and joint system and a setting belt.
Q: Can the forming machines be supplied for an existing line? A: Yes. The high speed mixer, scraper type mixer, dropdown shaping machine, dynamic foaming system and paper supply system are available as complete single machines. Spare parts and wearing parts, including setting belts, are supplied separately.
Q: What do the forming machines cost? A: Reference unit prices are shown in the Cost section. A firm price is issued against a specific machine list, because price depends on model, capacity and construction.
Q: What board types can the forming section produce? A: Regular, moisture-resistant and fire-resistant board, switched by formulation and additives — fibreglass for fire resistance and silicone oil for moisture resistance.
Q: What board thickness and dimensions does it produce? A: Thickness 7 to 20 mm, width 1200 or 1220 mm and length 2400 to 3600 mm, all adjustable. Other dimensions can be designed on request.
Send us your target capacity, raw material type and available fuel, and our engineering team will return a tailored configuration and quotation. Hengshui Decheng Machinery & Equipment Co., Ltd. (DCI) — Email: dci@chinagypsummachine.com | WhatsApp: +86 13930110827 / +86 18203235588
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