Gypsum board, as a widely used material in modern architectural decoration, relies on efficient and advanced gypsum board equipment for its production. The following will elaborate on the complete production process of gypsum board equipment from raw material preparation to finished product packaging.
1、 Raw material preparation stage
The main raw materials for gypsum board include gypsum, protective paper, and various additives. Firstly, gypsum raw materials need to undergo strict screening and crushing treatment to ensure uniform particle size and meet production requirements. Usually, natural gypsum ore is crushed into small particles by a grinder and further refined by grinding equipment to improve the reactivity of gypsum and the uniformity of mixing with other raw materials.
The selection of protective paper is crucial, as it needs to have certain strength and toughness to ensure good bonding with gypsum core material in the subsequent production process. Before entering the production line, the protective paper needs to be cleaned and pre treated to remove surface impurities and moisture, in order to prevent adverse effects on the quality of gypsum board in subsequent processes. In addition, additives such as starch and coagulants also need to be accurately measured and prepared in a certain proportion. They will play a role in bonding the protective paper and gypsum core material, adjusting the setting time of gypsum, and so on.
2、 Ingredients and Mixing
According to the specific formula requirements of gypsum board, the prepared gypsum, treated slurry of protective paper (some production processes use pre prepared slurry of protective paper), and additives are transported to the batching system. The ingredient system uses high-precision measuring devices to accurately weigh various raw materials according to preset proportions, ensuring the accuracy of the formula. The measured raw materials are sent into the mixing and stirring equipment, and under the strong action of the high-speed mixer, various raw materials are thoroughly mixed and uniform. The mixing time, speed and other parameters are precisely controlled according to production requirements and raw material characteristics to achieve the best mixing effect. The fully mixed slurry has good fluidity and uniformity, providing a good foundation for subsequent molding processes.
3、 Forming process
The fully mixed gypsum slurry is evenly distributed on the continuously running protective paper tape through a dedicated slurry box. The gypsum slurry gradually forms a certain thickness of gypsum layer on the protective paper tape, and then covers another layer of protective paper. Through the compaction and extrusion of multiple layers of rollers, the two layers of protective paper are tightly combined with the gypsum core material, forming a preliminary gypsum slab. During the molding process, precise control is required for parameters such as the flow rate of the slurry box, the running speed of the protective paper, and the pressure of the rollers. The flow rate of the slurry box determines the uniformity of the distribution of gypsum slurry, which directly affects the density and strength of gypsum board; The running speed of the protective paper matches the production line speed to ensure consistent thickness of each part of the gypsum board; The pressure of the roller affects the compactness of the gypsum slab. Excessive pressure may cause cracking of the gypsum board, while insufficient pressure may result in insufficient strength of the gypsum board.
4、 Cutting process
The gypsum slab with initial shape will be cut longitudinally and transversely by cutting equipment during transportation. The cutting equipment adopts high-precision cutting tools and advanced cutting technology, which can accurately cut the gypsum slab into the required length and width according to the preset size specifications. During the longitudinal cutting process, the cutting tool moves along the length direction of the gypsum board to cut the longer slab into the specified length; Horizontal cutting is carried out in the width direction of the gypsum board, cutting the gypsum slab into the desired width. The edges of the cut gypsum board should be flat and smooth, without burrs or cracks. In order to ensure cutting accuracy, the cutting equipment is equipped with advanced positioning and detection devices, which can monitor the cutting process in real time, adjust the position and cutting speed of the cutting tools in a timely manner, and ensure that each gypsum board meets the size requirements.
5、 Drying process
The cut gypsum board is transported into a drying kiln through a conveying device for drying treatment. The drying kiln adopts a hot air circulation heating system, which gradually evaporates the moisture in the gypsum board through reasonable temperature and humidity control. In the early stage of drying, the temperature inside the kiln gradually increases, accelerating the evaporation of surface moisture on the gypsum board; As the drying process progresses, the temperature and humidity inside the kiln are precisely adjusted according to the changes in moisture content of the gypsum board to ensure that the moisture inside the gypsum board can be evenly discharged. The drying process requires strict control of time and temperature. If the time is too short, it will cause excessive moisture residue in the gypsum board, affecting its strength and durability; If the time is too long, it may cause problems such as cracking and deformation of the gypsum board. At the same time, the dried gypsum board also needs to be cooled to gradually reduce its surface temperature and avoid internal stress caused by large temperature differences, which may affect product quality.
6、 Quality inspection process
The dried and cooled gypsum board enters the quality inspection process. Quality inspectors will conduct comprehensive inspections on the appearance quality, dimensional accuracy, physical properties, and other aspects of gypsum boards. The appearance quality inspection mainly checks whether the surface of the gypsum board is flat, whether there are defects such as rough surface, bubbles, cracks, etc; The dimensional accuracy testing uses professional measuring tools to measure whether the length, width, thickness and other dimensions of the gypsum board meet the standard requirements. Physical performance testing includes but is not limited to indicators such as strength, hardness, water absorption, and fire resistance of gypsum board, which directly affect the performance of gypsum board in practical applications. For products that fail the inspection, they will be marked and isolated. After analyzing the reasons, corresponding measures will be taken to ensure that every gypsum board leaving the factory meets high quality requirements.
7、 Packaging process
The gypsum board that has passed strict quality inspection will enter the packaging process. The packaging process first arranges the gypsum boards in a certain quantity and order, and then wraps them with packaging materials such as plastic film and cardboard to prevent damage and contamination of the gypsum boards during transportation and storage. The labeling on the packaging should be clear and explicit, including product specifications, models, production dates, batch numbers, and other information, to facilitate product traceability and management. The packaged gypsum boards are transported to the warehouse for storage by forklift or conveyor belt. In the warehouse, the gypsum boards are classified and stored according to different specifications and types to ensure accurate and fast delivery to meet customer needs.
8、 Finished product storage and transportation
In terms of storage, the warehouse needs to have good ventilation and moisture-proof conditions to ensure stable quality of gypsum boards during storage. Different specifications and batches of gypsum boards should be stored separately, and a comprehensive management system should be established for easy access and allocation at any time. In the transportation process, choose the appropriate transportation method and packaging reinforcement measures based on the customer's needs and transportation distance. For long-distance transportation or easily damaged gypsum boards, stronger packaging methods will be used, and attention will be paid to preventing collisions and squeezing during transportation to ensure that the gypsum boards can be safely and intact delivered to customers.
The production process of gypsum board equipment is a highly integrated and refined process, and each link is crucial. From the careful preparation of raw materials, to the strict control of each process, to the quality inspection and packaging transportation of the final product, professional technology and strict operating standards are required to ensure the production of high-quality gypsum board products that meet the widespread application needs of the building decoration industry. With the continuous advancement of technology and changes in market demand, the production process of gypsum board equipment will also be continuously optimized and innovated to provide customers with higher quality and more efficient products and services.