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Gypsum Board POP Plant
Gypsum Board POP Plant
Typical Process of Manufacturing Gypsum Board
Raw materials: Gypsum rock is mined at quarries or mines near plants or transported by railway,cargo ship or truck.
Crusher: It crushes large rocks into small pieces of rocks. At some plants, the crushed rock pieces are given a surface drying treatment before sending them to the grinding mill.
Grinding Mill: The mill for grinding small rocks into a very fine, chalk-like powder called land plaster.
Calcine system: The land plaster is heated in large kettles for removing most of the water from the plaster.
Stucco Holding Tank: Stucco, calcined land plaster is fed from a holding bin to the mixer by a screw conveyor.
Mixer: Water is added back to the calcined land plaster to form a slurry. Then foam is added to the slurry for making the wallboard more light in weight.
Forming Station: The board forming line initiates with two large rolls of recycled paper or fiberglass mats. The slurry is added on to the bottom sheet and is quickly covered by the facing sheet from another roll. The 'sandwich' passes through a forming plates/ rolls pair that determines the board thickness.
Boardline: The board passes a long conveyor line in a single continuous piece. During this travel, water makes the stucco rehydrated and causes it to harden.
Cut-off knife: A blade cuts the hardened board in to several lengths at the end of the line.
Transfer Table: The cut hardened board are turned face-side.
Kiln: The board kiln completes the drying process and leaves the gypsum board virtually moisture-free.
Bundler and Stacker: The bundler works to 'book' the gypsum board by keeping two pieces cooperatively with the face on the inside. The pieces are trimmed to exact length. The boards pair is taped for further board face protection. The stacking of bundles is performed to transfer to the warehouse for shipping to customers. Computerized process control systems, visual inspection and periodical lab testing throughout the day ensures the product quality throughout the gypsum board manufacturing process.
Capacity: 2 to 30 million sq.mtr/annum
Size: length-2400 to 3600mm/ width-900 to 1200mm/ thickness-9 to 15mm