Apr. 29, 2024
Machinery
Gypsum can be a difficult material to process, from its variability, to its tendency to harden into a cement-like form, and its abrasive nature. For this reason, choosing processing solutions that are heavy-duty and designed around the unique characteristics of the gypsum sample to be processed will offer the best results.
FEECO has been providing the best in high-quality, custom gypsum equipment and process solutions for decades. We frequently help our customers with pelletizing gypsum for use as a soil amendment, drying gypsum ore, processing FGD gypsum (synthetic gypsum), and more.
When it comes to agglomeration, FEECO’s expertise is second to none. In addition to complete pelletizing systems, we can provide you with individual, custom-engineered pieces of agglomeration equipment.
Our pin mixers and disc pelletizers are frequently used to process gypsum into a premium pellet product. Pin mixers are also ideal for use in de-dusting applications, as well as a means of pre-conditioning gypsum for pelletization on a disc pelletizer. When utilized as a pre-conditioning step in a disc pelletizer setup, pin mixers can yield increased production; the majority of the required moisture can be added during the pre-conditioning step, avoiding the sometimes lengthy process of adding it gradually on the disc pelletizer. Furthermore, binder costs are often reduced as well, because the pin mixer uses motion to densify the product instead of binder.
When pelletizing gypsum, our robust hammer mills are an ideal size reduction device for crushing oversize granules for reintroduction to the process as recycle.
FEECO rotary dryers are widely used throughout the gypsum processing industry. Whether you’re looking to dry gypsum ore, prepare gypsum for wallboard processing, or ensure your pelletized gypsum product meets desired moisture content, our custom rotary dryers offer a reliable drying solution.
We offer a complete line of bulk material handling equipment both as stand-alone systems, as well as a complement to our processing equipment.
Belt conveyors, bucket elevators, steep incline conveyors, and reversing shuttle conveyors, can all be used to bring seamless fluidity and automation to your gypsum processing operation.
Additional equipment such as trippers and plows and belt feeders are available for increasing the flexibility of your system.
With challenging characteristics and wide variability, testing is often a critical component in the success of a gypsum processing operation. The FEECO Innovation Center is a unique testing facility where we can test your material at both batch and pilot scale in order to work out process variables and design commercial-scale units, as well as scale up the process.
The FEECO Innovation Center is well-equipped to suit a wide range of testing needs, from de-dusting to pelletizing and even drying. We can test on a single piece of equipment, or a continuous process loop.
We offer comprehensive testing services in four categories:
Feasibility/Proof of Concept: An initial, non-witnessed batch testing phase in which the possibility of creating a product is explored.
Proof of Product: A more in-depth batch testing phase in which more time is spent determining whether a product can be made to desired specifications.
Proof of Process: A continuous testing phase that aims to establish the equipment setup and parameters required for continuous production of your specific material.
Process/Product Optimization: An in-depth study to optimize your specific material’s characteristics and/or production parameters in an industrial setting.
Learn more about the Innovation Center >>
FEECO provides a comprehensive offering of parts and service to keep your equipment running its best for years to come. This includes a variety of field services, process and equipment audits, spare parts, and more.
Drywall manufacturers are definitely on the rise. Since drywall seems hard to beat thanks to a wide range of advantages such as low cost, this modern alternative to old good wall plaster has become the most popular material that is used for construction. It is produced primarily of gypsum – a soft mineral containing large amounts of water. This chemical property allows drywall to provide a certain measure of fire protection.
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Related links:The thing about drywall is that gypsum gets sandwiched between two layers of heavy paper which helps to prevent the board from breaking. However, plasterboards are composed not only of gypsum: even though manufacturers balance between 70 to 95% gypsum, cellulose and additional substances may comprise up to 30% of the material’s composition. In spite of having fire-resistant properties, the paper content makes it difficult to refer to drywall as to ‘100% fireproof’, though.
To put it simply, drywall is needed everywhere. Being an essential material for either remodeling or construction, it is applied in interior walls – if you look around, you’d notice that most commercial establishments use gypsum boards. In recent years, it has been widely used for home décor, too, owing to its sound absorbing properties and fire retardancy. It’s so prevalent and even, to some extent, indispensable but there’s a reason for that: drywall is extremely easy to install. Even if it gets damaged, you’ll be able to repair the thing quite quickly.
You can also fix any wall you want before painting it to get a smooth finish. Besides, the material’s structure allows to create unusual (read: curved) shapes that is especially important when decoration comes into play – drywall can add some interesting textures to your place.
There are different types of drywall in the American and Canadian market, each tailored to a specific purpose or project:
Drywall panels are industrially manufactured according to size standards. Depending on the size, panels vary in their prices and production costs. Though there are international size charts setting a standard for each type, some countries produce wider or thicker boards varying in length.
On the whole, gypsum business is gradually growing over recent years. The number one reason why the market continues to develop is a tendency among manufacturers to pursue aggressive pricing strategies. Regardless of what substitutes are offered, gypsum building blocks remain one of the cheapest materials available, and in comparison to their direct competitors – plywood, wooden panels or hardboard which tend to cause depletion of forest ecosystems – low-cost drywall improves overall ecological situation mostly because components used in the production can be easily recycled. So it goes without saying that gypsum plasterboards has a great market potential and might be quite a lucrative investment opportunity for vendors.
If you want to become ‘a gypsum entrepreneur’, first you will need to apply for various certificates and registrations – always check your state’s law before delving in the business. Right when the paper work is done, it is time to set up the machinery: production line, testing gear, hand tools, tables etc. The better your manufacturing equipment, the better products will roll off the line, so you should think about these details in advance. As for raw materials, two important compounds of any plasterboard are heavy paper sheets and gypsum powder. And do not forget that you always have to meet the standards or criteria of the state. That’s the key.
Small-scale production lines are of special interest because this is a powerful piece of equipment to start your own business. These manufacturing units have high production capacity and can produce up to 240 yd of gypsum boards per year. Speaking in equivalents, these metrics match 200 drywall panels per average working shift. Small-scale lines cost at a slightly lower figure than heavy machinery: approximately $150,000. The price, though, depends on characteristics and features coming within the machine.
In addition, your industrial premises have to meet fundamental requirements. The facility area must not be less than 785 yd³ while the temperature must not be lower than 15°С. Wallboard manufacturing facilities ought to maintain safe working environment for employees and, what’s more important, you should have enough supplies to keep going.
The main ‘element’ for drywall production is natural or synthetic gypsum. There are a few other materials that you will have to take care of: paper sheets, dry additives. But gypsum and plaster of Paris are your principal raw materials whereas others come more as modifiers to produce different types of plasterboards. Some manufacturers use recycled chemicals to improve the product quality: these are borogypsum and phosphogypsum. Slurry additives are also worth mentioning: these are pulpwood, sodium chloride and sodium hydroxide. Besides, you will have to buy casein used in drywall fillers.
Manufacturing can be divided into several primary stages.
Gypsum occurs underground, so the whole process starts with mining. But do not think that you’ll be supposed to source deposits of gypsum all over the country – there’s an option to buy materials from ‘gypsum retailers’. As long as most gypsum is harvested from quarries, manufacturers try to locate their factories close to these mines to avoid shipping expenses and to save money. Surprisingly, but this all is done within one production line. Gypsum rocks are crushed to turn it into a powder which is then mixed with other minerals, water, soap foam and starch. Once the mixture forms a thick paste, it is placed in a special tube with accelerators so that the material could set faster. That is the way of getting the primary material called a slurry which then goes onto the board forming line.
Then it is time to make the sandwich. The slurry is poured onto a sheet of paper that moves along a board machine and then another layer unrolls on top of the slurry. This sandwich travels through special rollers compacting the core to the right thickness. That’s why everyone says that gypsum ‘is sandwiched between two paper sheets – this is literally the process of making drywall. By the way, most of processes are automatic – everything is done by calibrated machines without any handmade. The final stage before cutting the panels is finishing the edges – another automated line forms the edges of some shape (there are various options).
Now the product actually looks like two endless flat stripes. Right after these sheets harden a little and edges get shaped, they continue their journey on a series of conveyors. A cutting machine chops this mega board into plasters. Of course, plasters size can be easily programmed. Sheets continue travelling down the conveying line: the first circle they move slowly, the second one goes a little faster. And then the drying process begins. The boards are conveyed on a line feeding them through a very long oven. As they enter the oven, the panels get exposed to decreasing levels of heat dropping little by little for about forty minutes. And when the process of drying is over, here comes the final stage – inspection.
How to make gypsum board:
The finished product is thoroughly inspected by experts who estimate the quality prescribed by certain criteria. Take your targeted market into consideration because from state to state the criteria may vary, so you should definitely pay attention to these details while inspecting the gypsum plasters.
North America is still a major regional market and a runway for freshmen. Even though building materials stores are overfull nowadays and it even seems that it would take some extra effort to grow business in this niche, there’s always a room for anyone. If you want to avoid too much competition, then online marketing comes in handy – statistic shows that this affordable method of growing a product turns out to be more welcoming than local marketing.
It’s time to sum it all up and answer the question ‘how to start a business in drywall manufacturing’. So, as you remember, you will need a production line worth $150.000-200.000. Add extra $15.000 to pay off equipment shipping and transportation, its installation and adjustment. Moreover, additional expenses would involve rental lease. The amount you pay would depend on the total area, location and overall condition of the premises. It will take $5.000 more per 120 yd2 if you would like to redecorate them. Besides, you will have to take care of raw materials which should be sufficient for a monthly-period production. Add another $15.000 for unexpected expenses or taxes. In total, your bankroll should be around $300,000, but a few more bucks wouldn’t go amiss.
The payback period for a drywall project to repay its initial investment is reasonable 1.5-2 years, but you can always generate more output.
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