Industry Overview
Gypsum wallboard, also known as drywall or plasterboard, is one of the most widely used indoor building materials. It is available in various standard sizes and is valued for its relatively low cost, ease of installation, smooth finishing, ready availability, non-toxicity, and sound attenuation properties. Gypsum board is commonly used in residential, commercial, and other building applications to create interior walls, ceilings, firewalls, and shaft enclosures.
Gypsum board consists of a non-combustible gypsum core with paper surfacing on its face, back, and long edges. The production process is based on gypsum hydration technology, with fibres, plasticizers, foaming agents, and other additives incorporated into certain products to improve specific performance characteristics, including water resistance, mildew resistance, and fire performance.
Manufacturers use both natural and synthetic gypsum. Synthetic gypsum can be recovered from processes that remove pollutants from exhaust gases generated by fuel combustion for power generation. Its use in gypsum panel manufacturing also provides an alternative to landfill disposal. The paper facing commonly incorporates recycled materials such as cardboard, newsprint, and other post-consumer waste, while recycled gypsum in board products is often derived from post-industrial sources.
Gypsum boards are available in several varieties, including standard, fire-resistant, moisture-resistant, impact-resistant, foil-backed, liner, and sheathing boards. Edge profiles include square, tapered, bevelled, rounded, and tongue-and-groove designs, with square-edged and tapered boards being common. Since gypsum board is vulnerable to moisture, selecting the appropriate product for the intended environment is important for maintaining performance and durability.
Cost Estimation
| Particulars | Details |
|---|---|
| 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% |
Content Index
- 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
- 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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