Detailed Project Report (DPR) on gypsum board

GYPSUM BOARD

[CODE NO.4232]  

The global gypsum board market size was estimated at USD 40.87 billion in 2019 and is expected to expand at a CAGR of 11.9% in terms of revenue, from 2020 to 2027. Growing demand from the residential construction sector coupled with increasing consumer spending on advanced construction materials is expected to drive the growth. Accelerating growth of construction industry across the major economies, such as China, India, Brazil, Mexico, South Africa, and Russia is expected to support the market growth. In addition, growing innovative construction applications of gypsum board are likely to provide growth opportunities.

Pradhan Mantri Awas Yojana (PMAY) is an initiative in which affordable housing will be provided to the urban poor with a target of building 20 million affordable houses by 31 March 2022. Such initiative by governments towards economical and affordable housing is all set to stroke the gypsum board market with abundant demand.

In the recent years, Gypsum Association member companies are producing specialty products for targeting industrial application segment. Some of the products are exterior gypsum sheathing, abuse-resistant and impact-resistant gypsum panels, mold and moisture resistant panels and, gypsum shaft liner. Due to such immense credibility along with easy and fast installation compared to the traditional plasters, gypsum boards are employed globally in various heavy operational facilities.

Gypsum Material Characteristics

Whether raw, natural, synthetic, or even recycled, it is often desirable to further process gypsum before use, particularly in the case of agricultural applications. When processing any material, it is important to recognize key characteristics that will affect manufacturing operations and the final product generated. Even commonly processed minerals such as gypsum require testing on a case-by-case basis to ensure quality results. 

The following list outlines key material characteristics that affect gypsum processing.

Abrasive

Mined gypsum is a somewhat abrasive material. As a result, robust equipment must be used when processing gypsum. Rotary dryers are an ideal solution for many types of ore, as they are rugged pieces of equipment, easily customized with heavy-duty linings that defend against erosion. Customizations can be made to other processing equipment as well, in order to protect against abrasion, and prolong equipment life. No matter what the equipment, keeping gypsum’s abrasive nature in mind during design is a must.

Dust and Clumps

When granulated properly, pelletized gypsum is much easier to handle than its raw, powdered counterpart. However, clumping and dusting issues may occur when drying and pelletizing powdered gypsum. In order to avoid such problems, processing equipment should be customized to accommodate.

Raw Material Description 

Gypsum has been known for centuries and is one of the oldest building materials in the world. The earliest use of gypsum discovered was in Anatolia around 6000 B.C. Later, in about 3700 B.C., gypsum was used on the interiors of the great pyramids in Egypt. One of the early uses of gypsum in building construction appears to have occurred in 3700 B.C. when the Egyptians used gypsum blocks and plaster applied over woven straw lath in the building of the pyramid of Cheops. 

As a testimony to the strength and durability of gypsum, some of this construction is still intact and viewable, including walls decorated with murals composed of tinted plaster. For centuries now, gypsum has played a crucial role in construction. American settlers recognized gypsum’s potential use as plaster and as a soil amendment. Modern gypsum board has as its predecessor a product called “Sackett Board,” a composite material that was made of layers of thin plaster placed between four plies of wool felt paper. Sackett Board was patented in 1894 by Augustine Sackett, the man generally considered to be the grandfather of the gypsum board manufacturing industry. 

The wallboard is approximately 92% gypsum (calcium sulfate dihydrate CaSO4 2H2O), 7% paper, and 1% impurities and additives. Gypsum is found in every continent of the world and is one of the most widely used minerals.

Gypsum board – a part replacement to wood

Due to obvious reasons, wood has been extensively used in the construction of buildings in Bhutan for flooring, paneling, insulation and various other purposes. In the today’s context, wood is increasingly becoming scarce and costly. Some of the applications of wood viz for insulation, ceiling, partition, paneling, etc need to be replaced by alternative materials. Gypsum board offers an alternative to wood for applications like ceiling, insulation and partition. Besides, gypsum board is a modern material of construction used extensively in the construction and finishing of the buildings. Gypsum board is often called drywall, wallboard, or plasterboard.

? It consist of a noncombustible core, composed primarily of gypsum, and a thick paper surfacing on the face, back and long edges.

? They can be faced with a variety of different materials, including paper and fiberglass mats.

? It differs from other panel building products, such as plywood, hardboard, and fiberboard, because of its noncombustible core and paper facers.

? Gypsum wall board creates a continuous surface suitable for most types of interior decoration.

COST ESTIMATION

Plant Capacity                                    240 Ton/Day

Land & Building (4500 sq.mt.)  Rs. 4.08 Cr

Plant & Machinery                              Rs. 6.93 Cr

Working Capital for 3 Months    Rs. 23.50 Cr

Total Capital Investment                   Rs. 35.10 Cr

Rate of Return                                     65%

Break Even Point                               27%

• INTRODUCTION
• GYPSUM MATERIAL CHARACTERISTICS
• ABRASIVE
• DUST AND CLUMPS
• RAW MATERIAL DESCRIPTION
• GYPSUM BOARD-A PART REPLACEMENT TO WOOD
• CHEMISTRY OF GYPSUM BOARD
• TYPES OF GYPSUM BOARD
• CONSTRUCTION MATERIAL
• DEFINITION AND CATEGORIES OF GYPSUM BOARD
• ADVANTAGES OF GYPSUM BOARD
• AREAS OF APPLICATIONS
• GYPSUM BOARD – STANDARDS & QUALITY CONTROL
• CHEMICAL COMPOSITION - GYPSUM
• PLANT & MACHINERY REQUIREMENTS
• MARKET OVERVIEW
• MANUFACTURING TECHNOLOGY FOR GYPSUM BOARD
• PROCESS FLOW DIAGRAM
• COMPARISON OF PRODUCTS / MANUFACTURING TECHNOLOGIES
• PRODUCT SPECIFICATION
• MACHINERY LIST
• SUPPLIERS OF RAW MATERIALS
• LIST OF GYPSUM BOARD DEALERS
• SUPPLIERS OF PLANT AND MACHINERY
• MACHINERY PHOTOGRAPHS
• RAW MATERIAL PHOTOGRAPHS
• PRODUCT PHOTOGRAPHS
• GENERATION AND MANAGEMENT OF WASTES
• ANTICIPATED ENVIRONMENTAL IMPACTS
• MITIGATION MEASURES (PROPOSED)
• HEALTH SAFETY & ENVIRONMENT
• SAFETY & OCCUPATIONAL MEASURE

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)