Finishing material is in demand in the construction and repair of many facilities, the technology for manufacturing drywall is quite simple, and the demand for it is steadily growing, so there are no difficulties with the sale of products.

This sheet material necessary for the construction of wall partitions, leveling walls, mounting ceilings, creating niches, shelves, arches and other decorative and functional elements.

The sale of FCL is carried out by many companies, and several types of drywall sheets (GKL):

1. Suitable for use in rooms with humidity up to 70%.
2. Moisture resistant. The gypsum structure includes silicone granules, so the sheets can withstand 80-85 percent humidity.
3. Fire resistant. Due to the fiberglass included in the composition, they do not collapse under the influence of high temperatures.
4. Moisture resistant. Combine the characteristics of the two above-mentioned types of GKL.

Drywall production technology allows you to get sheets of certain sizes, but for convenience, all manufacturers adhere to standards:

• length 250 or 300 cm;
• width 120 or 130 cm;
• thickness from 0.8 to 2.4 cm.

Documents for the production of drywall

To start your own drywall mini-factory, it is better to register a legal entity in the form OOO.

Individual entrepreneurs also have the right to work in this direction, but activities are limited.

To register an LLC, you need to prepare a package of documents:

• an application for registration and a decision of shareholders to establish an LLC;
• charter of the company with a legal address;
• photocopies of passports of the director and chief accountant.

All this must be submitted to the registration authority and additionally open a bank account.

For the manufacture of GKL, you must specify the appropriate OKVED. We are interested in section C and code 23.62 , involving the production plaster products for the construction industries.

We select a room

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Drywall production is profitable business. This material is in great demand, as it is used in construction. It consists of sheets with reinforcing additives made of cardboard, which are glued together. gypsum mixture.

Drywall has the following qualities:

• easy
• retains moisture
• does not pass noise
• fire resistant
• lasting
• environmentally friendly
• plastic

Product range

There are four types of drywall:

• Ordinary. It is suitable for decoration and construction of premises with a humidity level of not more than 70%.
• Moisture resistant. Used in places where the humidity is below 85%.
• Fire resistant. It retains its performance characteristics in hot conditions.
• Moisture resistant. It combines the features of two types of material: moisture resistant and fire resistant.

Application

Drywall is used for construction purposes:

• build partitions, arches, bearing walls, columns;
• repair walls;
• erect multi-level ceilings and mount them;
• make decorations, shelving and cabinets;
• separate communication cavities.

What room is needed for the production of drywall

The room in which the workshop for the manufacture of drywall will be located must be at least 500 square meters. meters. This area will be required for the installation of equipment. The temperature inside the production hall should be no more than 15 degrees above zero.

It is also worth paying attention to the water supply, sewerage, gas and electricity. All this must be carried out to the working area. If it is not possible to supply gas, then solid fuel can be used instead.

What equipment to choose for the production of drywall

The entire production process of the material takes place using automated installations. Equipment for the production of drywall:

• mixer;
• conveyor;
• unwinder;
• gypsum sheet former, gypsum and cardboard sheets;
• conveyors various kinds(tape, roller table, console, drying);
• rack.

Before selling products, the conveyors on which they were manufactured are tested. To do this, select three sheets (longitudinal and transverse) and perform an examination. Russia has its own regulations regarding drywall. If the sheets correspond to them, then they can be made on this equipment and subsequently sold.

A line for the manufacture of drywall will cost no less than 1.5 - 2 million rubles.

Purchase of raw materials

For the manufacture of drywall, you need to purchase a lot of components that make it up.

Gypsum	The manufacturer has the right to choose the type of gypsum from which he will make his products. He can use natural or artificial gypsum, or one that is obtained from chemical waste.
Cardboard	This material is placed on both sides of the drywall blank
Fiberglass	It gives the finished product fire resistance.
silicone granules	This is a filler that makes drywall moisture resistant.
Soap made from chemicals	It helps to foam the necessary parts during the production process.
Lignosulfonates	This chemical substances, which are added to the drywall construction to lower the water level
Modified starch, foaming agent, water, table salt, caustic soda, casein, cellulose	With the help of these components, sludge is made (a mixture for pouring drywall)

Drywall production technology

The business organization plan should contain a clause relating to the stages of product manufacturing. Drywall production technology is not difficult. She takes a few steps.

Production of gypsum sheets	This First stage in the manufacture of drywall, which is carried out using a conveyor that forms the desired shape of gypsum strips. If you add impurities to the gypsum mixture (depending on the purpose of the material), you can get a more durable finished product
Sheet cutting	For this stage, a conveyor (roller table) is used, which cuts drywall sheets
Distribution	This process is carried out using console pipelines. They send finished products to dryers
Drying	It takes less than an hour
pruning	The roller conveyor is involved in giving the desired shape to drywall sheets
stacking	These stages are carried out with the help of employees who pack the finished products.
Package

Markets

It is not difficult to sell these products, since there are a lot of consumers:

• construction stores
• contractors
• construction firms
• individuals

In Russia, the demand for drywall is growing every year, as this material has a wide range of applications. Therefore, even a small plant within a small business will be able to find buyers and customers.

How much money do you need to start a drywall business

Starting capital is approximately 7.5 million rubles. This is a fairly large amount. The main costs are divided into the following:

• purchase of equipment (5 million rubles)
• delivery and installation of equipment (500 thousand rubles)
• repair of the premises for the workshop (600 thousand rubles)
• purchase of raw materials (600 thousand rubles)
• rent and other payments (500 thousand rubles)

How much can you earn in the production of drywall

The price of one sheet of drywall is about 150 rubles, if you sell products in bulk. With well-established production, it is possible to manufacture and sell goods for 1 million rubles. per month.

The payback period is 1.5 - 2 years.

The production of drywall will bring high income if the manager competently organizes the activities of the enterprise. For the plant to function, initially large investments and a clear plan are needed.

How to start a business

To start the production of drywall in your region, you need to analyze the market, determine the demand for the product, as well as with competitors. After that:

• registration and rental of premises;
• purchase of equipment and related material;
• hiring employees and concluding contracts;
• advertising company, etc.

How much can you earn

The profitability of this area of ​​activity, with properly established production, can reach 65%. With good production volumes, monthly revenue can reach one million rubles. Nested cash, in this case, fully pay off within 1 - 2 years.

What OKVED must be specified for the production of drywall

Section "C" - manufacturing production, this is where code 23.62 is located, which includes the manufacture of gypsum products that are used in construction industry activities.

What documents are needed to open

The best option for the production of drywall is registration legal entity in the form of a limited liability company. Individual entrepreneurs also have the right to engage in this area of ​​activity, but compared to an LLC, their activities are greatly curtailed. To register as a limited liability company, you must collect and submit to the registration authority:

• an application for registration of an LLC and a decision of the meeting of shareholders on the establishment of a limited liability company;
• The charter of the company and the legal address (the address of the location of the production facilities is quite often used);
• information about the director of the LLC and the chief accountant - photocopies of passports.

In addition to the above, you will need to register with the relevant state authorities and open a bank account.

What taxation system to choose for the production of drywall

For this line of business, several systems are suitable for paying tax. However, among them it is best to focus on the simplified one, it provides some benefits. In particular, when providing documents that confirm the expenses incurred by the company during the reporting period, a tax of 15% of net profit is paid. In the event that such documents are not provided, the LLC pays 6% tax on the income received.

Do I need permission to open

For the production of drywall, it will be necessary to apply for the appropriate permits to the fire inspection and the sanitary and epidemiological station.

In the production of drywall, the following main materials are used:

* Natural gypsum (CaSO4.2H2O).

* Covering cardboard, the roll width of which is 1250 mm and 1180 mm. Dimensional deviations can be accepted if they do not change the dimensions of the finished product, and do not weaken the adhesive bond of the cardboard layers to each other along the edge.

* Modified starch, with a starch content of at least 70%.

* Foaming agent.

Drywall production technology

The first step in the drywall manufacturing process is the preparation of the gypsum mass. It is used subsequently in the formation of a gypsum tape. Gypsum has excellent technical and physical properties, and to improve its performance properties, certain components are added to it. The technological process for obtaining drywall sheets is as follows:

1. A continuous flat strip is formed on the conveyor, with a section of a given shape. It happens in the following way. From the carton feeding machine, the bottom and top sheets of cardboard are fed to the shaper. In it, a pre-prepared gypsum mixture is laid between the canvases. The glue machine lubricates the top layer of cardboard along the edges with glue, and the edges are hardened at the bottom layer. Then both layers are rolled and a drywall sheet with a gypsum core inside is obtained, which is formed into the required profile.

2. During the movement of the drywall sheet along the conveyor belt, the gypsum core is pre-hardened to a density that will be necessary for the subsequent cutting process.

3. The web is then fed onto a high speed roller conveyor. It is cut into sheets using a guillotine. Next, drywall sheets are removed by the transition conveyor and transferred to the cantilever conveyor (distributor). The distributor distributes the sheets to the dryer's six conveyors. The speed of movement of the sheet inside the dryer is reduced and the drywall sheet remains there for about an hour.

4. On the exit conveyor, the already dried sheets descend one by one onto one roller conveyor. On it, the ends of the sheets are cut off by a special machine. The cut-to-size sheets end up on the table, where they are manually stacked and packaged.

To achieve the required performance of the gypsum core, special components are added to it that increase the performance properties. It turns out the main material of dry construction - gypsum board (gypsum board).

Drywall is indispensable in the production of construction and finishing works: construction interior partitions, wall cladding and device suspended ceilings in buildings with dry and normal humidity conditions. And, finally, a drywall sheet is an excellent tool for creating decorative interior elements. The distinctive properties of drywall are its ability to bend, which allows you to give walls, partitions or ceilings any shape, for example, make walls wavy or decorate a doorway with an arch.

The cost of drywall is low, but this material will save you from wet processes that carry with them a lot of labor, wasted time, a lot of dirt and debris.

In addition, drywall is excellent sound quality. The basis of this modern material- gypsum, the one that was used in the fine arts and orthopedics. The same gypsum that has the ability to "breathe", that is, let air through, while maintaining a constant humidity regime in the room. One of the most important properties of gypsum is its environmental friendliness, it does not contain toxic substances. Complete systems made of drywall (gypsum plasterboard) are non-flammable, do not contain toxic elements and have an acidity similar to human skin. In addition, gypsum is not radioactive, provides high sound and thermal insulation, is completely odorless and thermally neutral. A gypsum core, glued on both sides with special cardboard (for greater strength and a smoother surface) forms a gypsum panel or slab, which is simply called drywall. Gypsum panels of different brands are produced by construction companies in Russia, Germany, Great Britain, Greece, France, the USA and other countries.

Cardboard plays the role of both a reinforcing frame and an excellent basis for applying any finishing material(plaster, wallpaper, paint, ceramic tiles). So the material is both flexible and hard. It has an acidity similar to that of human skin.

The last two properties allow drywall to regulate the microclimate of the premises in a natural way and to a large extent contribute to the creation of a harmonious atmosphere. Each of the listed properties can be enhanced if you need to assign a drywall sheet for specific purposes.

Fire-resistant are used for finishing all kinds of air ducts and communication shafts. And there are also so-called tongue-and-groove slabs in which gypsum is fired. Their strength increases so much that they can be used as interior partitions, painted, wallpapered or veneered without any preparation. ceramic tiles. Such partitions are one-, two- and three-layer. The latter are applicable in seismically hazardous areas, for residential, civil and industrial buildings of all degrees of fire resistance. In their cavities it is possible to lay electric and telephone cables, dust removal systems, heating and plumbing communications.

The use of this material allows you to create any type of ceiling: ordinary, suspended, multi-level, etc. The plasterboard ceiling is also mounted on a wooden or steel frame. Gypsum panels with a thickness of 9.5 and 12.5 mm, due to their plasticity in the wet state and high resistance to bending in the dry state, with appropriate processing, can turn into convex or concave building elements and building parts of any configuration, including complex molded surfaces: domes , vaults, cylindrical structures. In this sense, with the help of drywall, any designer's idea can be realized, no matter how daring it may be.

Panels are always bent in length, not in width, and 60 mm wide gypsum panels are best suited for this. Their concave side can be both front and back surfaces. In plasterboard walls, you can install any door and window frames: wooden, aluminum, steel, plastic.

Drywall slabs not only bend well, but are also perfectly cut with a cobbler's knife and sawn. Using special tools, you can cut the panel to the desired length and width and, if necessary, make a hole in it.

Making tools to help you complete repair work quickly and efficiently, gaining momentum. The production of drywall was no exception.

Why is GKL popular?

This sheet material finishing works has been used for a long time. He gained his popularity due to practicality and environmental friendliness. Also, types of HAs play an important role in its demand.
By technical specifications drywall can be as follows:

• moisture resistant;
• fire resistant;
• moisture and fire resistant;

As for the scope, the material is classified as wall and ceiling. Sheets have various parameters and bearing capacities.

The product is quite easy to install. For installation, two methods are used - frame and frameless.

Increasingly, drywall is overshadowing other materials because it is environmentally friendly, easy to install, and also economical.

The first type of installation is difficult to perform, since the surface must first be prepared. The work process includes the following steps:

• Frame construction from metal profiles or wooden planks.
• Performing insulation and waterproofing (the latter will be a mandatory action in rooms with high humidity).
• Installing sheets.
• Preparation of the surface of the material for subsequent cladding (priming and plastering).

Despite such a number of actions, the use of GKL will be much more effective than leveling the surface with plaster mixes.

The frameless method of fastening the material is less popular. This is due to the fact that the draft base for fixing the sheets must be even. It remains to be primed.

Raw materials for production

Drywall production is impossible without special components. The following are used as raw materials:

• astringent gypsum;
• facing cardboard;
• vaporizing additives;
• substances for quick setting of the mixture;
• components that increase the adhesion index of the base and gypsum mortar;
• hydrophobic additives;
• dispersion-reinforcing substances and much more.

Mandatory condition for production quality material is to check all components for compliance with established standards (GOSTs).

In the production of drywall, all components are checked for compliance with established standards.

also in technological process the following types of additives are used:

• technical foam - allows you to reduce the density of the gypsum core;
• fiberglass trimmings - increase the bending strength of sheets;
• paper fiber - increases the strength indicator.

In addition, modified starch and lignosulfonates (technical and powder mixtures) are used. They are designed to provide high-quality adhesion of the gypsum core and cardboard.

The surface of the GK sheets is covered with latex so that dust does not settle on them and they do not absorb moisture.

Material Making Equipment

To produce drywall, specialized machines are needed. Together, they form a continuous production cycle. It is better to buy them from trusted manufacturers in order to avoid negative consequences in the technological process.

Equipment for the production of drywall:

• Machine for the production of gypsum mixture.
• Former - used to connect cardboard sheets and give shape to the gypsum-based composition.
• Special device for continuous supply of cardboard to the shaper.
• Belt conveyor - designed to form the parameters of the future product.
• A roller conveyor is a guillotine that cuts the gypsum sheet.
• The transport conveyor is used to feed sheets to the cantilever and roller conveyors.
• Cantilever conveyor - designed to place HA sheets on the dryer.

You also need a machine for drying the material and its further processing - cutting sheets to the desired size and stacking.

Production stages

The manufacturing process of the material includes several stages. It is for this reason that there are three main sections in the production line.

These include the following:

• procurement;
• molding;
• drying.

At the first stage of GKL production, a gypsum mixture is prepared. The second section is designed to fill the space between the cardboard sheets with a gypsum-based solution. The final stage is the drying of the product. It is in it that excess moisture is removed from the product with the help of specialized equipment. Thanks to this, the sheets acquire the desired strength and density of the internal structure.

In the production of drywall, there are three main stages: harvesting, molding and drying.

The storage area is used to properly store the material and pack it before transport.

It is not recommended to store drywall in a room with high humidity. Its structure absorbs moisture and begins to collapse. This negatively affects the quality of products and their further operation.

Technological process

The production of drywall is quite complex. Initially, a gypsum mixture is prepared. In order for it to acquire the necessary technical properties, various components are added. Everything is thoroughly mixed on special equipment.

Gypsum powder and additives are pre-mixed dry. After that, a certain amount of liquid is added to them (according to GOST).

While the gypsum composition is being prepared, the cardboard base is being produced. For this, paper or other similar raw materials are used. The elements of the future cardboard sheet are glued together, pressed on special equipment and dried.

Initially, long flat strips with a dense structure are made from the gypsum composition. Conveyors are designed for this purpose, which set certain sections of the mixture.

The next step is the formation of sheets of material. Pressed cardboard is installed in a special machine - the lower and upper shaper. After that, the gypsum mix is ​​​​served.

Cardboard sheets are pre-treated with a special glue that fixes gypsum on them.

On the sides, drywall sheets are also treated with an adhesive solution so that the ends of the product do not collapse in the future. manufacturing process. Then the material is cut into the required dimensions - depending on the parameters of the finished product established by GOST.

The final stage is drying. Plasterboard sheets are placed in a special machine in which they dry under the influence of a certain temperature regime. After that, they can be transported to the warehouse.

Production area for the manufacture of drywall

Today, the most demanded material is drywall, the production of which requires certain characteristics of the workshop. The room should not have high humidity. Such an impact can adversely affect the quality of manufactured products. To avoid rising humidity, production shop equip additional types of ventilation.

It is necessary to constantly maintain one temperature regime. Its slightest change will lead to the appearance of excessive moisture or dry air. The latter also violates the technical properties of the finished product.

It is worth considering that the workshop for the production of gypsum boards must have big sizes. This is the only way to install necessary equipment, which will allow efficient use of the production line.

Today, the production of drywall is one of the most promising cases, because. This material is quite widely used in the decoration and construction of premises. Here we will consider the technology and equipment for the production of drywall.

If you are not yet familiar with this material, then we will briefly talk about it. Drywall is a type building material, which is cardboard sheets glued with a gypsum mixture, additionally reinforced with reinforcing additives. The characteristics of drywall are as follows: lightness, moisture resistance, environmental friendliness, noise reduction, fire resistance, mechanical strength, ease of installation. Plasterboard sheets (gypsum plasterboard) are more plastic than any natural material, do not contain toxic additives.

Application

It is very varied:

• erection of partitions, columns, arches that do not bear loads;
• wall fixes;
• finishing of communication cavities (security systems, telephone facilities, etc.);
• installation of ceilings of various levels;
• construction of shelves and niches;
• creation of theatrical scenery, furniture (racks, cabinets, etc.).

Main consumers

Consumers include various construction organizations involved in the repair of premises, specialized stores, as well as ordinary citizens who use drywall for domestic needs.

Product range

Requirements for the use of drywall allow you to distinguish it in the categories:

• normal - used at a humidity of not more than 70%;
• moisture resistant - due to the gypsum structure with silicone granules, it withstands air humidity of 82-85% up to 10 hours a day;
• fire-resistant - does not undergo destruction under the influence of high temperatures due to the content of fiberglass;
• moisture-resistant - combines the properties of moisture-resistant and fire-resistant drywall.

The production technology of this material makes it possible to obtain plasterboards of any size. However, for the convenience of builders and designers, sheets are produced no more than 2.5 m long, 1.2-1.3 m wide and 0.8-2.4 cm thick.

Raw materials for production

For the manufacture of drywall, the following raw materials are used: facing cardboard, gypsum (both natural and artificial), synthetic foaming agent, modified starch. The use of chemical industry wastes - phosphogypsum and borogypsum - is associated with additional costs for their purification from impurities. Variations in sheet weight and flexibility are achieved by adding cellulose, common salt, caustic soda, etc. to the sand.

Equipment for the production of

Its manufacturing technology is fully automated. We list the necessary equipment for the production of drywall:

• a device for forming and producing a gypsum mixture;
• apparatus for continuous supply of cardboard to the shaper;
• shaper - ensures the formation of a gypsum sheet and the connection of cardboard sheets to each other;
• a belt conveyor, which is equipped with additional web and profile thickness formers to accurately match the product to the declared dimensions;
• roller conveyor - cuts the gypsum sheet into sheets by means of a guillotine;
• conveyor for transporting drywall sheets - it transfers them from the roller conveyor to the console conveyor;
• cantilever conveyor - places sheets on the conveyor of the dryer;
• dryer conveyor - gradually moves the sheets until they dry;
• optional roller conveyor designed for the final cutting of the drywall sheet and its transfer for packaging and stacking.

Such a production line (machine), for example, of the GKL-0.2 brand, produces 200 sheets per day and its price is from 160 to 170 thousand dollars.

The whole process looks like this - video:

room

To organize the production of drywall, a building with an area of ​​600 m2 is required with a temperature of at least 15 ° C and supplied with electricity, gas, water and sewage.

Expenses

When choosing a GKL-0.2 production line, the following financial resources will be needed:

• the cost of the mini-line itself;
• delivery line;
• formation of a monthly commodity stock of drywall;
• preparation and repair of the building;
• other expenses.

The initial capital for launching a business project will be approximately 7 million rubles.

Revenue and business profitability

Today, the average wholesale selling price of a sheet is 150 rubles. Consequently, the proceeds from such production of drywall will be about 1 million rubles per month. With a profitability of 60-70%, the project will pay off in a year and a half.