Detailed project report on gypsum boards manufacturing

GYPSUM BOARDS MANUFACTURING [3521]

Gypsum Wall Board (Drywall or Plasterboard) is known to be the most common indoor building material. This dry wall is known to be available in a variety of standard sizes. The gypsum wall is a benign substance and is known to have several environmental impacts and is known to be used on a vast scale.

The advantages of gypsum board include low cost, finishing and low cost, easy availability, non-toxicity, sound attenuation, and few more. The manufacturers of gypsum board rely much on synthetic gypsum as an alternative to natural gypsum. Natural gypsum and synthetic gypsum are normally used to remove pollutants from exhaust created by burning of fuels for power generation. Also, it is understood well that if synthetic gypsum is not used in manufacturing gypsum panel products, then these would eventually end up being accumulated in landfills.

The face paper used for gypsum board is 100% recycled from cardboard, newsprint and other postconsumer waste streams. Most of the recycled gypsum in all board products in post-industrial in nature. The gypsum boards are typical materials used in building light walls. The production process of gypsum boards is based on gypsum hydration technology.

It is understood well that the home-building and remodelling industry witnesses a variety of construction materials used to enhance the attractive appeal as well as functionality of the building. Gypsum board is a generic name that is for a family of panel products. The gypsum board comprises of a non-combustible core made of gypsum as well as a paper surfacing are on the face, back and long edges.

The gypsum boards can be used for the surface layer of ceilings as well as interior walls, between rooms, area separation firewalls, elevator and other shaft enclosures, and other aspects. The gypsum board being attached on horizontal wall and vertical wall are depicted in the figure below. The gypsum boards used in construction and building are named as ‘gypsum panel products’. The gypsum board is known to be mixed with fibre, plasticizer, foaming agent and various other forms of additives that can reduce water absorption, mildew as well as flammability.

There are different types of gypsum boards based on edges – and these are normally rounded, tapered, bevelled, square-edged and tongue and groove (V-edge). The most commonly available gypsum boards are square and taper-edged boards.

The common types of gypsum board are mentioned below along with their pictures.

1. Regular / Standard Gypsum Board

2. Fire-Resistance Gypsum Board

3. Moisture-Resistant Gypsum Board

4. Fire-and Moisture Resistant Gypsum Board

5. Abuse-Resistant Gypsum Panels

6. Exterior Gypsum Soffit Board

7. Foil Backed Gypsum Board

8. Gypsum Liner Board

9. Gypsum Sheathing

10. Impact Resistant Gypsum Panels

11. Sag Resistant Board

12. Proprietary Type X Gypsum Board

13. Water Resistant Gypsum Board

The gypsum board is known to be highly vulnerable to moisture due to various inherent properties of the materials that comprise it.

COST ESTIMATION

Plant Capacity                                                50 Lacs sq.ft/Day
Land & Building (4000 sq.mt)        Rs. 2.65 Cr
Plant & Machinery                                         Rs. 3.43 Cr
Working Capital for 2 Months        Rs. 60 Lacs
Total Capital Investment                            Rs. 6.84 Cr
Rate of Return                                             23%
Break Even Point                       64%

INTRODUCTION
SPECIFICATIONS
MANUFACTURE
MAIN CONFIGURATION
PROCESSING CHART
GYPSUM BOARD PRODUCTION LINE PICTURES
B. I. S. SPECIFICATIONS
BASIS
MARKET SURVEY
RAW MATERIALS
CHEMISTRY OF THE PROCESS & PHYSICAL PROPERTIES
PRESENT MANUFACTURERS/EXPORTERS OF GYPSUM BOARD
MANUFACTURING PROCESS
PROCESS FLOW SHEET
LIGHTWEIGHT GYPSUM BOARD
CONTINUOUS PRODUCTION OF GYPSUM BOARD
PRINCIPLES OF PLANT LAYOUT
PLANT LOCATION FACTORS
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
PROJECT IMPLEMENTATION SCHEDULES
PLANT LAYOUT
SUPPLIERS OF RAW MATERIALS
COMPLETE PLANT SUPPLIERS ON TURNKEY BASIS
SUPPLIERS OF MACHINERY & EQUIPMENTS

APPENDIX – A:

1.     COST OF PLANT ECONOMICS
2.     LAND & BUILDING
3.     PLANT AND MACHINERY
4.     FIXED CAPITAL INVESTMENT
5.     RAW MATERIAL
6.     SALARY AND WAGES
7.     UTILITIES AND OVERHEADS
8.     TOTAL WORKING CAPITAL
9.     COST OF PRODUCTION
10.     PROFITABILITY ANALYSIS
11.     BREAK EVEN POINT
12.     RESOURCES OF FINANCE
13.     INTEREST CHART
14.     DEPRECIATION CHART
15.     CASH FLOW STATEMENT
16.     PROJECTED BALANCE SHEET

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