In this article:
Once upon a time, gloomy builders, accustomed to tinkering with heavy reinforced concrete and long-drying cement, looked askance at drywall, not trusting “foreign dummies.” Today, gypsum board is an indispensable material in the construction and decoration of buildings. Its unlimited possibilities allow you to implement the most original projects and developments, including the creation of suspended ceilings, internal partitions, shelves and racks, bar counters and wall cladding.
The elasticity of gypsum sheets makes it possible to model and obtain the necessary configurations and any arched surfaces.
The properties of plasterboard make it an ideal material for equipping residential and office premises:
- environmental friendliness, non-toxic and environmentally friendly;
- ability to save energy and keep warm;
- inactivation of sounds from neighboring apartments and street noise;
- incombustibility and fire resistance;
- ability to "breathe", that is, absorb excess moisture from the air;
- light weight;
- belonging to “dry technologies”: unlike “wet” ones, which include traditional plaster with its inevitable construction debris and dirt, plasterboard sheets or panels provide quick, easy and “clean” installation, which can significantly increase labor productivity (saving time , labor costs and the absence of downtime and smoke breaks while the “cement dries”).
Why drywall?
The explosive growth of construction in Russia and neighboring countries has led to a huge demand for drywall, which increases annually by an average of 20%. Over the past 2011, the volume of the Russian market for plasterboard profiles amounted to about 350 million square meters. m. However, even such an impressive number of meters does not cover the needs of the ever-growing “construction fever”.
The main supplier of drywall in Russia- German company Knauf is loaded to capacity with orders and will be glad for any “help” from Russian manufacturers. The second largest supplier of irreplaceable building materials is the French concern Compagnie de Saint-Gobain SA is also on the verge of a nervous breakdown due to the inability to embrace the immensity. That is why today and now is the best moment to grab the bull by the horns and launch your own drywall production.
Moreover, domestic figures speak for themselves: Russia produces only 4% of the world volume of this raw material. Who knows, maybe in a couple of years you will outshine the main plasterboard manufacturer - America (oh, those Americans!), which today produces 42% of the world's plasterboard market.
With minimal costs, you will have a unique opportunity to create your own and quite profitable business.
Stable and fast-paying production of plasterboard has great prospects and in the near future will significantly improve (and strengthen!) your economic situation.
True, to start an enterprise you will have to reduce your bank account by 5-6 million rubles, which will cover the costs of renting premises, purchasing equipment, raw materials and directly producing drywall.
To become a millionaire, you don’t have to fork out money for a mega-concern. On the contrary, you will quickly approach Rockefeller status if you open a small factory producing only 200 thousand square meters. meters per year (200 plasterboard sheets per day).
What are the advantages of such mini-production?
Firstly, in his high profitability due to low power consumption and fewer workers. Due to these factors, the cost of drywall with low productivity will be the same as with giant power lines of 2 million square meters. meters per year. A sheet of gypsum 1.2 m x 2.5 m long and wide, 9.5 mm thick and costing $3.05 has a wholesale price of $4.86, which means $1.81 profit per sheet!
Secondly, the average cost of such a mini-factory does not exceed 160 thousand dollars, which is more than acceptable for a successful business start. If you issue 200 sheets per day and make $1.81 profit from each of them, your monthly revenue will be $10,860, and your annual revenue will be $130,320. This means that within one and a half to two years you will have a real chance to recoup all the costs of the equipment. In the case of a larger plant - an area of 1000 square meters. m, with a productivity of 800 thousand sq. m. m (about 888 sheets per day) and the same profit per piece - you will earn $1,500 per day, or $450 thousand per month!
From words to action! Premises and equipment
So, have you decided? Then go ahead! Please keep in mind that the minimum production area is 600 sq. m, since your brand new equipment simply won’t fit into smaller volumes. The minimum ceiling height is 4.5 meters.
Required conditions: An industrial electrical network, gas and water supply must be installed in the workshop. Of course, tested and working. Make sure that the air temperature in the room is at least 15 ºС: this is necessary to comply with the process technology.
The selection of personnel with qualifications and experience is also of fundamental importance, since it is with their input that your products will be produced. By hiring professionals, you will not only save time and money on their training, but also insure the quality of the future product. Drywall production equipment- an expensive pleasure, so be careful when purchasing it. In this case, savings are not the best guide, since cheap machines will cost you more in the long run due to their constant repairs.
Structure of the new production line It starts with a sheet forming system, continues with an automatic conveyor, a dryer and ends with a sheet cutting installation (guillotine). The cycle ends with the packaging of drywall and its shipment to retail outlets. To get started, you will need production blocks, which are presented in detail in the following diagram.
- device for unwinding and feeding cardboard;
- sheet forming module, glue machine;
- belt conveyor;
- roller conveyor;
- conveyor with running acceleration;
- guillotine;
- transfer conveyor;
- reverse conveyor and distributor (cantilever conveyor 8.1);
- “six-tier” drying conveyor;
- sheet output conveyor;
- conveyor belt;
- cross conveyor belt;
- automatic machine for quick cutting of ends;
- surface for exiting finished products;
- bake;
- Dryer;
- heat exchange device;
- dosing machine for dry raw materials;
- starch and water mixer;
- gypsum mixer.
Don't be intimidated by the long list of unfamiliar names! Everything is much simpler than it looks on paper! After commissioning and installation work, the line can be put into operation.
To do this, you will need raw materials, which include the following components:
- Natural 85% gypsum in powder form
- Cladding cardboard with roll widths of 1180 mm and 1250 mm, thickness 0.3 - 0.46 mm, specific gravity from 170 to 220 g/sq. m, horizontal tensile strength - at least 3.5 kN/m, horizontal load resistance limit - from 12.5 kN/m.
- 70% starch with 11-13% water content, alkaline pH level 6.5 - 7.5, protein - 3%, dust - maximum 2%. The solubility of starch in water should be between 73 and 78%.
- Synthetic foaming agent with a concentration of mineral salts of no more than 2.5%.
Even before starting the line, make sure that it is fully grounded, that the gas pressure is stable, that the smoke exhauster is working perfectly and that there is a continuous supply of current, since any malfunction can lead to poisoning of workers and emergency situations. To avoid contamination of the eyes and respiratory tract with gypsum powder, all personnel are required to work in safety glasses and a respirator.
Drywall production lines are as reliable and automated as possible, which can significantly reduce material consumption, labor costs and work process time. Most functions - feeding cardboard, forming sheets, applying glue, entering the dryer, maintaining a constant temperature in the oven, feeding gypsum powder and water into the mixer, final cutting of sheets - are carried out automatically.
For smooth and cost-effective production, you will need 12 operators, one of whom will be responsible for supplying gypsum powder, two for heating and supplying water to the gypsum mixer, two more for molding gypsum sheets, one for moving the web on a conveyor belt, two for feeding of cardboard, another one for the entry of sheets into the dryer, another for their exit from there, and, finally, the last two for removing finished products from the line. To periodically check electrical equipment, you will need an electrician, and to monitor the work process, a master technologist.
Drywall production technology
The devil is not as scary as he is painted, and in practice you will see for yourself how simple the technology for producing drywall is. The first step towards your cherished goal will be preparing a mixture of water and gypsum powder. This is done in gypsum mixer. Moreover, the finer the gypsum grind, the better the quality of the final product.
When the mixture is ready, the top and bottom cardboard sheets are fed onto the line. In the molding module, the gypsum mixture falls from the gypsum mixer onto the bottom layer of cardboard. Afterwards it is leveled and covered with a top layer of cardboard, pre-lubricated with glue.
Using a special device, the bottom sheet is given the required shape and width, after which both layers are rolled with a pressure drum.
Thus, a finished cardboard profile with a gypsum filling is obtained, which is then conveyed through a conveyor into the guillotine for cutting. From there, sheets of the required size come out.
After that, they are sent by conveyor to a 6-tier dryer and remain there for about an hour.
The moisture content of the sheets when leaving the drying chamber should not be higher than 7%. Then the dry slabs enter the device for high-speed (finishing) edge trimming, after which they end up on the finished product table. From there they are removed by workers and placed on pallets.
Finished products
So, your first batch of drywall is ready. It will be better if by this time you have already concluded supply contracts with trading companies or construction organizations.
Don't forget about advertising your product and keep in mind that modesty is not appropriate here. This should be extensive PR, designed not only for your city, but also for the entire region (at least!). In such cases, it is better not to skimp and immediately hire advertising business professionals. As a rule, successful advertising more than pays off in high sales.
Another tip that might make you your first million: try incorporating phase reversible materials (RPMs) into your technology. These include salt hydrates, paraffin and others. They increase the ability of drywall to accumulate heat, which helps save up to 40% of energy consumption in buildings, offices, apartments, etc.
Drywall is a universal, multifunctional finishing material consisting of cardboard sheets and a gypsum mixture placed between them, strengthened with reinforcing additives.
GKL meets all the requirements that modern construction technologies impose on building materials: it is environmentally friendly, lightweight, non-flammable, moisture resistant, has high mechanical strength and excellent sound-absorbing qualities, and is easy to install and process. The absence of harmful impurities in its composition makes it absolutely non-toxic, and in terms of plasticity, no building material made from natural raw materials can compare with it.
Drywall as a product
Let's consider the product characteristics of the product in question.
Plasterboard sheets are used for:
- creating partitions that do not bear load;
- construction of suspended ceilings (including multi-tiered ceiling structures);
- wall decoration;
- creating niches, shelves and recesses;
- construction of columns and arched unloaded systems;
- construction of furniture (cabinets, racks, bar counters);
- creating cavities for laying communications (telephone, computer, security systems, etc.);
- construction of theatrical scenery.
Main consumers
Consumers of the products include both individuals purchasing material for personal needs, as well as enterprises in the construction industry that carry out repairs and finishing of premises, as well as retail chains and stores selling building materials.
Range
Depending on the requirements of use, plasterboard is divided into the following categories:
- normal - used in rooms with humidity up to 70%;
- moisture-resistant - has a gypsum structure with silicone granules (designed for use in rooms with air humidity of 82-85%, with exposure to it for no more than 10 hours per day);
- fire-resistant - its structure contains fiberglass, which protects the layers of gypsum from destruction by high temperatures;
- moisture-resistant - is a combination of fire-resistant and moisture-resistant plasterboard and has the qualities of both types of materials.
As for the dimensions, gypsum boards are produced using technology that does not limit their size. But in practice, in order to facilitate the work of installers and designers, the material is produced in the form of standard sheets not exceeding 2.5 meters in length with a width of 1.2 - 1.3 m. The thickness usually ranges from 8 mm to 24 mm.
Necessary raw materials and equipment for the production of plasterboard
The main raw materials for the production of plasterboard are: natural or artificial gypsum, facing cardboard, modified starch and synthetic foaming agent. Chemical industry wastes such as borogypsum and phosphogypsum are sometimes used as raw materials. However, their use requires additional costs aimed at purifying a large number of impurities. The molding mixture may also contain table salt, cellulose, casein, caustic soda and some other components that affect the weight of the finished sheet, its flexibility and other indicators.
Drywall production is a high-tech, fully automated process. The production line is represented by the following equipment:
- A machine for making gypsum mixture, in which the formation of gypsum mass is carried out.
- A machine that continuously supplies cardboard to the former.
- A former, on which the process of molding the gypsum sheet and subsequent gluing of cardboard leaves together takes place.
- Belt conveyor equipped with additional profile and web thickness formers. Provides a product that exactly matches the required dimensions.
- A roller conveyor, on which the gypsum sheet is cut into sheets using a guillotine.
- A sheet transport conveyor that moves sheets from a roller conveyor to a cantilever conveyor.
- A cantilever conveyor that lays out gypsum boards onto the dryer conveyor.
- A dryer conveyor that slowly advances the sheet to ensure complete drying.
- An additional roller conveyor, which ensures final cutting of the sheet and its delivery for packaging and stacking.
A similar mini-line of the GKL-0.2 brand with a capacity of 200,000 sq.m of plasterboard per year (which corresponds to the production of 200 sheets per day) will cost approximately $160,000 - $170,000.
Room
To accommodate a small plant, a premises of 600 square meters is required. m, which must meet the following requirements:
- temperature regime not lower than 15 ° WITH;
- availability of electricity supply, natural gas (or solid fuel), water and wastewater.
Estimating the costs required for production
Subject to the acquisition of the GKL-0.2 production line, the following capital costs will be required:
- The cost of the mini production line is 5 million rubles.
- Delivery of the line - 500 thousand rubles.
- Repair and preparation of premises (600 sq. m) - 600 thousand rubles.
- Creation of inventory for one month - 600 thousand rubles.
- Other expenses - 500 thousand rubles.
Thus, to start a business project, an initial investment of 7.2 million rubles is required.
Revenue and profitability
The average selling wholesale price of a plasterboard sheet is 160 rubles. Thus, the monthly revenue of the GKL-0.2 mini-production will be about 1 million rubles, and the profitability will be about 60-70%. Under these conditions, investments made in production will pay off in approximately 18 months.
Today, the production of drywall is one of the most promising businesses, because... This material is widely used in the decoration and construction of premises. Here we will look at the technology and equipment for the production of plasterboard.
If you are not yet familiar with this material, we will briefly talk about it. Drywall is a type of building material that consists of cardboard sheets glued together with a gypsum mixture, additionally reinforced with reinforcing additives. The characteristics of plasterboard are as follows: lightness, moisture resistance, environmental friendliness, noise reduction, fire resistance, mechanical strength, ease of installation. Gypsum plasterboard sheets (GKL) are more plastic than any natural material and do not contain toxic additives.
Application
It is very diverse:
- construction of partitions, columns, arches that do not bear loads;
- wall corrections;
- finishing of communication cavities (security systems, telephone facilities, etc.);
- installation of ceilings at various levels;
- construction of shelves and niches;
- creation of theatrical scenery, furniture (racks, cabinets, etc.).
Main consumers
Consumers include various construction organizations involved in the renovation of premises, specialized stores, as well as ordinary citizens who use drywall for household needs.
Product range
Requirements for the use of drywall allow us to distinguish it into categories:
- regular – used at humidity not more than 70%;
- moisture resistant - due to the gypsum structure with silicone granules, it can withstand air humidity of 82-85% for up to 10 hours a day;
- fire-resistant – not subject to destruction under the influence of high temperatures due to the fiberglass content;
- moisture- and fire-resistant - combines the properties of moisture-resistant and fire-resistant plasterboard.
The production technology of this material makes it possible to obtain gypsum boards of any size. However, for the convenience of builders and designers, sheets are produced with a length of no more than 2.5 m, a width of 1.2-1.3 m and a thickness of 0.8-2.4 cm.
Raw materials for production
For the manufacture of drywall, the following raw materials are used: facing cardboard, gypsum (both natural and artificial), synthetic foaming agent, modified starch. The use of chemical industry waste - phosphogypsum and borogypsum - is associated with additional costs for their purification from impurities. Variations in the weight and flexibility of the sheets are achieved by adding cellulose, table salt, caustic soda, etc. to the molding mixture.
Equipment for the production of
Its manufacturing technology is fully automated. We list the necessary equipment for the production of drywall:
- device for forming and producing gypsum mixture;
- apparatus for continuous supply of cardboard to the former;
- former – ensures the molding of the gypsum sheet and the connection of sheets of cardboard with each other;
- belt conveyor, which is equipped with additional web and profile thickness formers to ensure exact compliance of the product with the stated dimensions;
- roller conveyor – cuts the gypsum sheet into sheets using a guillotine;
- conveyor for transporting plasterboard sheets - it transfers them from the roller conveyor to the cantilever conveyor;
- cantilever conveyor – places sheets on the dryer conveyor;
- dryer conveyor – gradually moves sheets until they dry;
- additional roller conveyor designed for final cutting of the plasterboard sheet and its transfer for packaging and stacking.
Such a production line (machine), for example, GKL-0.2 brand, produces 200 sheets per day and its price ranges from 160 to 170 thousand dollars.
The whole process looks like this - video:
Room
To organize the production of plasterboard, you need a building with an area of 600 m2 with a temperature maintained at no lower than 15 ° C and supplied with electricity, gas, water and wastewater.
Expenses
When choosing a GKL-0.2 production line, you will need the following financial resources:
- the cost of the mini-line itself;
- line delivery;
- formation of a monthly inventory of drywall;
- preparation and repair of the building;
- other expenses.
The initial capital for launching a business project will be approximately 7 million rubles.
Revenue and business profitability
Today, the average wholesale selling price for sheets is 150 rubles. Consequently, the revenue from such drywall production will be about 1 million rubles per month. With a profitability of 60-70%, the payback of the project will occur in a year and a half.
The production of products that help carry out repair work quickly and efficiently is gaining momentum. The production of drywall was no exception.
Why is gypsum board popular?
This sheet material has been used in finishing work for a long time. It gained its popularity due to its practicality and environmental friendliness. Also, types of HA play a big role in its demand.
According to technical characteristics, drywall can be as follows:
- moisture resistant;
- fire resistant;
- moisture- and fire-resistant;
Regarding the area of application, the material is classified as wall and ceiling. Sheets have different parameters and load-bearing capacities.
The product is quite easy to install. For installation, two methods are used - frame and frameless.
Drywall is increasingly pushing other materials into the background, because it is environmentally friendly, easy to install, and also economical.
The first type of installation is difficult to perform, since the surface must first be prepared. The work process includes the following stages:
- Construction of a frame from metal profiles or wooden planks.
- Carrying out insulation and waterproofing (the latter will be a mandatory action in rooms with high air humidity).
- Installation of sheets.
- Preparing the surface of the material for subsequent cladding (priming and plastering).
Despite this number of steps, the use of gypsum plasterboard will be much more effective than leveling the surface using plaster mixtures.
The frameless method of fastening the material is less popular. This is due to the fact that the rough base for fastening the sheets must be level. All that remains is to prime it.
Raw materials for production
Making drywall is impossible without special components. The following raw materials are used:
- gypsum astringent;
- facing cardboard;
- vapor-forming additives;
- substances for quick setting of the mixture;
- components that increase the adhesion rate of the base and gypsum mortar;
- hydrophobic additives;
- dispersed reinforcing substances and much more.
A prerequisite for the production of high-quality material is to check all components for compliance with established standards (GOSTs).
During the production of drywall, all components are checked for compliance with established standards.
The following types of basic additives are also used in the technological process:
- technical foam - allows you to reduce the density of the gypsum core;
- fiberglass trimmings - increase the bending strength of sheets;
- paper fiber - increases strength.
In addition, modified starch and lignosulfonates (technical and powder mixtures) are used. They are designed to provide high-quality adhesion between the gypsum core and cardboard.
The surface of the HA sheets is covered with latex so that dust does not settle on them and they do not absorb moisture.
Equipment for making material
To produce drywall, specialized machines are needed. Together they form a continuous production cycle. It is better to purchase them from trusted manufacturers to avoid negative consequences in the technological process.
Equipment for the production of plasterboard:
- Machine for making gypsum mixture.
- Shaper - used to join cardboard sheets and give shape to a gypsum-based compound.
- A special apparatus for continuous supply of cardboard to the former.
- Belt conveyor – designed to form the parameters of a future product.
- A roller conveyor is a guillotine that cuts the gypsum sheet.
- Transport conveyor – used to feed sheets onto cantilever and roller conveyors.
- Cantilever conveyor – designed for placing HA sheets on the dryer.
A machine is also needed for drying the material and its further processing - cutting sheets to the desired size and laying them.
Production stages
The material manufacturing process includes several stages. It is for this reason that there are three main sections in the production line.
These include the following:
- procurement;
- molding;
- drying
At the first stage of gypsum board production, a gypsum mixture is prepared. The second section is intended for filling the space between the cardboard sheets with a gypsum-based solution. The final stage is drying the product. It is here that excess moisture is removed from the product using specialized equipment. Thanks to this, the sheets acquire the required strength and density of the internal structure.
During production, plasterboard goes through three main stages: blanking, molding and drying.
The storage area is used to properly store the material and package it before transportation.
It is not recommended to store drywall in a room with high humidity. Its structure absorbs moisture and begins to collapse. This negatively affects the quality of the product and its further operation.
Technological process
The production of drywall is quite complex. Initially, a gypsum mixture is prepared. In order for it to acquire the necessary technical properties, various components are added. Everything is thoroughly mixed using special equipment.
Gypsum powder and additives are pre-mixed dry. After this, a certain amount of liquid is added to them (according to GOST).
While the gypsum composition is being prepared, the production of the cardboard base is underway. For this purpose, paper or other similar raw materials are used. Elements of the future cardboard web are glued together, pressed using special equipment and dried.
Initially, long flat strips with a dense structure are made from gypsum composition. Conveyors are designed for this purpose, which set specific sections for the mixture.
The next stage is the formation of sheets of material. The pressed cardboard is installed in a special machine - lower and upper former. After this, the gypsum mixture is served.
Cardboard sheets are pre-treated with a special glue, which fixes the plaster on them.
The sides of the plasterboard sheets are also treated with an adhesive solution so that the ends of the product are not destroyed in the further production process. Then the material is cut into the required sizes - depending on the parameters of the finished product established by GOST.
The final stage is drying. Plasterboard sheets are placed in a special machine in which they dry under a certain temperature regime. After this, they can be transported to the warehouse.
Production facilities for the production of gypsum boards
Today, the most popular material is plasterboard, the production of which requires certain workshop characteristics. There should not be high air humidity in the room. Such exposure may negatively affect the quality of manufactured products. To avoid increased humidity, additional types of ventilation are installed in the production workshop.
It is necessary to constantly maintain one temperature regime. The slightest change will lead to the appearance of excess moisture or dry air. The latter also violates the technical properties of the finished product.
It is worth considering that the workshop for the production of gypsum boards must be large. This is the only way to install the necessary equipment in it, which will allow you to effectively use the production line.
If we consider the modern production of plasterboard, then this material is the most popular and one of the most environmentally friendly materials used in construction. It is produced in the form of fireproof gypsum plates. A special feature is that all planes of the plate, except for the end edges, are lined with cardboard, which is firmly glued to the base of the material.
A sheet of finished gypsum board consists of 93% gypsum and 6% cardboard, located along the side bases of the sheet. Another 1% consists of various organic substances used in manufacturing technology, humectants. Despite the fact that cardboard is used in drywall, it is fire resistant and not flammable. This can be explained by the complete absence of air between all layers of the cardboard sheet and the plaster layer.
Kinds
Modern plasterboard production offers several main types of this building material. They vary depending on the basic properties of the sheet. It can be standard, moisture resistant, fire resistant, moisture resistant, vinyl, flexible, perforated and laminated.
Standard drywall is used in rooms where humidity is up to 70%.
Moisture-resistant has a special structure and structure; the technology involves the use of silicone granules in gypsum. This drywall is intended for use in rooms where humidity ranges from 82-85%. It is necessary to pay attention to the fact that the average exposure to moisture should not exceed ten hours per day on drywall.
The production technology of fire-resistant plasterboard involves the use of fiberglass. It protects all layers of gypsum from possible destruction when exposed to high temperatures. Also moisture- and fire-resistant plasterboard, it combines all the characteristics and qualities of the previously discussed types of materials for construction.
Drywall production technology + video on how to do it
The technology itself is not complicated. In industry, plasterboard is produced in the form of standard sheets. The industrial machine produces a rectangular sheet shape. Sheet sizes may vary. The length on average ranges from 2000 to 4000 mm in increments of 50 mm, and the width is 600 or 1200 mm. The thickness of the drywall can be 6.5; 8; 9.5; 12.5. Also 14; 16; 18; 20 or 24 mm, the price and cost formation also depend on this. The standard front side of the finished plasterboard sheet has a smooth surface, the back side has seams for gluing the material.
If we consider global production, the world leader has long been the German company Knauf. The products of this company have over 80% of the entire Russian market and are in high demand. The share of the products of the mentioned German concern on the European market is much smaller, it is only 40%. Also, the remaining 10% of the Russian market is occupied by other Western manufacturing companies, and another 10% can only be provided by domestic enterprises. It is quite difficult for Russian manufacturers to compete with powerful and larger foreign manufacturers. This is manifested both in cost and in product quality. Most foreign companies have production facilities in Russia, thus, the domestic manufacturer is completely displaced both as a commodity producer and in the retail market of construction and finishing materials.
Let's take a closer look at the process of making drywall so that you can develop your own business plan for organizing the work. You can install the machine even at home and thus provide a mini business, or develop a large enterprise. The technology used cannot be called complex. But, it requires the provision of equipment; you will have to buy a machine to organize the work of a mini business and provide manufacturing technology. First, you need to select equipment for the production of drywall that allows you to start the manufacturing process. The production of drywall can be divided into several main stages. Considering the process from the beginning, the main stage is the extraction of gypsum and its primary processing. But intensive production does not involve independent extraction; raw materials are purchased, and enterprises are located as close as possible to the place of gypsum extraction and processing. This allows you to save money spent on transporting material. By origin, gypsum is a natural material. It has valuable qualities for construction, while manufacturers always improve the quality of gypsum by adding additional components to the gypsum mass. All this is performed by one line of the workshop. In industrial conditions, the extracted material is thoroughly mixed with water, chemical soap is added and the material is enriched with minerals. Then, everything is placed in a previously prepared container, and the catalyst is added to the mixture. This helps the gypsum harden quickly. Thus, primary material is obtained, the production line produces sludge.
The sludge is then used to make a continuous layer of gypsum in a sheet. Everything looks like large flat continuous stripes. They serve as the basis for the manufacture of future drywall. Such strips are produced on high-tech conveyors that specify the cross-section of the required shape. The design of the production equipment includes a sheet former. The bottom and top sheets of cardboard are formed in the former. Cardboard sheets are slowly laid onto the pre-prepared layer of gypsum mixture from a cardboard feeding machine. Then, their edges are tightly lubricated with a layer of glue. This procedure occurs automatically; everything is performed by the machine without the use of manual labor. The finished product acquires the required density, this makes it possible to perform high-quality and correct cutting.
Finished sheets are cut into standard sizes using a roller conveyor. Sheet sizes can be set depending on the need to set parameters for the finished product. The slow movement of sheets along the conveyor helps them dry; at the secondary stage, the movement accelerates. The sheets are cut into even pieces; after cutting, the sheets are transferred to the dispensing area. For further drying, plasterboard sheets are distributed among the dryers of the enterprise. For high-quality drying of one canvas, it takes no more than one hour, for this reason the conveyor belt moves quite slowly, ensuring the drying of the material on the conveyor belt itself and in the drying chamber. After forced drying, the plasterboard sheet is transferred to a roller conveyor. Here the final formation and giving of size and shape already takes place. In production, this stage is called trimming. Trimming is followed by the final stage of production. This is stacking and then packaging of finished products. At this stage, direct manual labor of workers will be required.
When the drywall is ready, it must undergo the necessary testing. It is carried out by experts who evaluate the quality according to certain parameters. You can consider the standards that are used in our country and those that are adopted in the countries that produce equipment. The assessment criteria themselves may vary, this must be taken into account during the assessment.
Basically, drywall is divided according to appearance and compliance with the required dimensions into groups A and B. For drywall belonging to group A, some deviation is allowed. This is a line that allows deviation from a rectangular shape of no more than 3 mm. For group sheets, no more than 8 mm is allowed. All Group A products must be free of damaged edge corners. Products of group B may have some defects, these could be damage to corners or edges, but such damage should not exceed more than two of each type. The longitudinal edges of plasterboard sheets are straight, rounded, as well as thinned or semicircular on the front side and semicircular and thinned on the front side. The total mass of a sheet always depends on its type. Standard and moisture-resistant sheets have a general calculation formula by which the weight of the sheet is determined.
If the water absorption of moisture-resistant and moisture-fire-resistant drywall is considered, then it should not be higher than 10%. The product standard is considered to be moisture resistance above 25%. It is necessary to understand that any type of drywall belongs to group G1 in terms of flammability. This is regulated by GOST 30244. What does this mean? This is the main characteristic of fire resistance and means that during a fire, drywall will not ignite. Any line of drywall retains its fire resistance properties for twenty minutes. Then the drywall loses its properties and succumbs to fire. Guaranteeing certain qualities, moisture-resistant and fire-resistant drywall must withstand extreme exposure to fire for at least 55 minutes; a modern material that can be used without restrictions must meet this requirement.
Video how to do it:
It may also be noted that drywall is rated by the strength of the bond between the cardboard and the main gypsum core. The adhesion must be stronger than the adhesion of the layers of cardboard. It should be difficult to tear the cardboard from the base and the material should not come off easily. It should not tear or separate into layers. The specific permissible effective activity of natural radionuclides in drywall is not higher than 370 Bq/kg.
Equipment for the production of plasterboard
The production of plasterboard sheets is a high-tech and fully automated process. The line represents:
- a machine for mixing the mixture, which is responsible for the formation of gypsum.
- machines for feeding cardboard to a special former.
- a former that shapes the gypsum sheet and glues the sheets together.
- belt conveyor, has additional molding profiles and web thicknesses. This ensures that you get a product that exactly matches certain sizes.
- The conveyor is a roller conveyor; the web is cut using a guillotine.
- the transportation conveyor carries out the movement of sheets onto the cantilever conveyor.
- cantilever conveyor for laying out sheets for drying.
- The dryer advances the drywall sheets to ensure they dry completely.
- The roller conveyor additionally provides sheet cutting and feeding for stacking and packaging.
Video overview of the entire process:
A mini-line of gypsum board brand GKL-0.2 is capable of producing up to 200 thousand m² of products per year (about 200 sheets per day) and costs about 160 thousand dollars.
Sales of products
Constantly growing demand stimulates efficient production. Drywall is being used more and more often, which ensures high demand in the market. Unfortunately, Russian-made products are significantly inferior both in popularity and in sales volumes. The buyer chooses products from Western manufacturers. A new company needs to understand that it will have to compete with foreign brands and companies that have established a foothold in the domestic market. The network of retail chain bases is overflowing with high quality finished products. A new manufacturer will have to make its way even in the markets; this factor must also be taken into account.
Costs of organizing production
Time to sum it up. To organize your own production of small volumes of drywall, you will need a line costing 5-5.5 million rubles. Let's add 500 thousand rubles spent on delivery, installation and setup. Additional expenses will include renting a room; the amount will depend on the area, location and general condition. If you additionally order repairs, this will require an additional 100 thousand rubles per 100 sq. m. meters. You will also have to take care of creating a stock of raw materials for production. At a minimum, it is necessary to create reserves for a month. Let's add raw materials, the price of which will be about 500-550 thousand rubles and additional transport, unforeseen expenses of about half a million. In general, expenses will amount to about 8 million rubles.
On average, the wholesale cost of a sheet of drywall is close to 165-170 rubles. With the planned production volumes, the monthly revenue of the enterprise can reach one million. This ensures business profitability of 65%. Based on the above data, the costs of producing plasterboard can be recouped in approximately the first 1.5-2 years of operation of the enterprise.