Complete gypsum board manufacturing solutions — from gypsum rock or FGD gypsum calcination through forming, drying, cutting, and packing. Turnkey lines producing 2 to 30 million m² of wallboard per year.
Overview
Gypsum board (drywall / plasterboard) is the world's most widely used interior wall and ceiling material — lightweight, fire-resistant, sound-insulating, and fast to install. A complete production line converts raw gypsum into finished board in a continuous, automated process.
A gypsum board production line converts gypsum rock or industrial by-product gypsum (such as FGD gypsum from power plants) into a flat sandwich panel: a gypsum core encased between two sheets of special paper liner. The core is formed by mixing calcined gypsum (stucco) with water and additives, spreading it between the moving paper liners, and letting it set in a continuous flat belt before drying, cutting, and stacking.
Modern gypsum board plants are highly automated and continuous — a single line can run for days producing board at 10 to 60 meters per minute. The key engineering challenge is precision control of slurry rheology, setting time, board thickness, and dryer energy use. LIMING Machinery supplies complete lines from raw gypsum intake to finished board stacking, with capacities from 2 to 30 million m² per year.
Besides standard wallboard, the same line (with minor additive and thickness adjustments) can produce moisture-resistant board, fire-resistant board (with glass fiber and vermiculite), sound-insulation board, and decorative ceiling tiles — giving a single plant access to multiple market segments.
Production Process
Six continuous stages turn raw gypsum into finished, stacked board ready for the warehouse.
Core Equipment
Six equipment groups form the backbone of a gypsum board plant. LIMING supplies, installs, and commissions them all under one contract.
Reduces raw gypsum rock to calciner feed size and grinds calcined stucco to the required fineness (100-200μm).
Rotary kiln, kettle, or hot-oil-conveyor calciner that converts dihydrate gypsum into hemi-hydrate stucco.
High-shear foam mixer that blends stucco, water, and additives into a homogeneous fluid slurry at line speed.
Continuous flat belt conveyor that lays the slurry between paper liners and holds board shape through the setting period.
Multi-zone convection dryer (gas, steam, or oil-heated) that removes free moisture to the target level.
Synchronized cut-to-length saw, edge profiler, and automatic stacker/wrap machine for finished board handling.
Plant Capacities
Gypsum board line capacity is defined by board width and line speed. LIMING offers three standard tiers.
| Line Tier | Annual Output | Board Width | Line Speed | Typical Market |
|---|---|---|---|---|
| Entry Line | 2-8 million m²/year | 1200mm | 10-20 m/min | Regional wallboard supply |
| Mid Line | 8-20 million m²/year | 1200-1300mm | 20-45 m/min | National market, multi-product |
| Large Line | 20-30 million m²/year | 1300-1500mm | 45-60 m/min | Export-grade, high-volume |
Key Advantages
Built for low-energy, high-yield, multi-product production with long continuous campaigns.
Optimized multi-zone dryer with heat recovery keeps steam consumption per m² among the lowest in the industry.
Servo-controlled forming plate and belt tracking hold board thickness tolerance to ±0.2mm for premium-grade output.
One line produces standard, moisture-resistant, fire-rated, and ceiling boards with recipe-based changeover.
Designed to run on FGD and phosphogypsum — turning industrial waste into a profitable building product.