For several decades, no one knew about the gypsorkaton. Now the situation is completely different - this material is used everywhere in many branches of economic activity. Taking into account such a demand for it, it is quite obvious that business in this area can flourish. So, the idea is formed, it remains only to buy a machine for the production of drywall, find a room, work out the technology and start making money.

Our business valuation:

Initial investments - from 2,000,000 rubles.

Market saturation is medium.

Difficulty starting a business - 7/10.

A drywall business plan plays an important role in starting a business. The project pages will display: technology development, technical equipment and upcoming costs. And this stage should not be ignored, especially if it is planned to attract third-party investments.

What types of drywall can be produced within the walls of the workshop?

A drywall business will generate consistently high profits when an entrepreneur provides potential consumers with a full range of products. And despite all the simplicity of the products, some options are possible here:

• Standard drywall. It is widely used for finishing rooms with humidity indicators not exceeding 70%.
• Waterproof plasterboard. Withstands humidity up to 90%.
• Fire resistant drywall. Can withstand high temperatures without catching fire.

In addition to the technological properties of the material, its dimensions can also vary. And virtually every drywall production line can produce sheets of different geometries. The most popular option among consumers is sheets with a size of 2500 * 1300 * 15 mm.

What raw materials will you need to purchase for the production process?

This line of business is good because the technology for the production of drywall is relatively simple, and everyone can master it. Thanks to this, it is so profitable today to start a home business, where a mini-workshop is based in your own garage or on a suburban area.

In general, the production steps can be described as follows:

• Formation of a gypsum mixture by mixing raw materials.
• Forming a sheet of a certain thickness while gluing cardboard to it.
• Drying of finished sheets.
• Product packaging and storage.

Almost each of the indicated processes is carried out by means of automated equipment. And the manufacture of drywall with your own hands is carried out only in the case of a home business, when an entrepreneur buys hand-held machines.

As for the necessary components, the workshop uses a wide variety of raw materials, the main of which are gypsum, cardboard, glue. And in order to supply customers with quality material, it is important to ensure that the components supplied to production are of the proper quality.

A standard drywall has the following composition: gypsum - 90-95%, cardboard - 4-7%, additional components - 1-3%.

Mini gypsum board production can also process some auxiliary components to give the finished product certain properties - fiberglass, silicone granules, foaming agent, starch, cellulose, caustic soda,

What equipment to equip the workshop with?

Having worked out the range and technology, you can already buy equipment for the production of drywall. The material is extremely popular in the consumer market, and therefore the machines for its production are represented quite widely.

What machines and devices does a fully equipped automated line for the production of drywall?

• Mixers and intermediate tanks.
• Machine for continuous feeding of cardboard into the former.
• Drywall sheet molding machine.
• Cutting machine.
• Dryer.
• Conveyors.

The financial issue will become an important issue in equipping the workshop. Automatic equipment costs today, given the rise in price of the dollar, quite expensive - about 5,000,000-9,000,000 rubles. (depending on power). More affordable option for many newcomers to this field - semi-automatic machines, where many operations will be carried out manually. The average price of equipment for the production of drywall of such a plan was established in the region - 900,000-2000000 rubles.

The equipment is quite cumbersome, so a spacious room will have to be found for a mini-workshop - at least 200 m 2. Here it is also important to provide for all communications - electricity, water supply, ventilation. Special requirements are put forward for the indicators of temperature and humidity in production and storage facilities.

It is clear that not everyone has the amount required for equipping. Therefore, there are 2 options - either to attract third-party investments, or to buy a supported line.

Features of the sales market

According to experts, it is profitable to open a mini-plant for the production of drywall in Russia only in those regions where the competition is not above average. Otherwise, you will most likely have to reduce the final price of the product or organize sales in other regions. The second option entails certain expenses that may be simply unaffordable for a novice entrepreneur.

As for potential drywall consumers, here you can choose one of many options:

• Wholesale sales to large construction companies.
• Retail sales to private customers.
• Opening your own warehouse store.

A large profit can be obtained by selling the released drywall in large batches. If you find regular customers, all costs will pay off soon. But here it is important to weigh your capabilities - and whether a low-power enterprise can fully satisfy the needs of a particular customer in material.

What funds will be invested in the business?

Considering how high the price of a drywall machine is, you need to be prepared for the fact that the investment in the business will be quite impressive. This includes spending under the following items:

• Technical equipment of the workshop.
• Registration of the company.
• Providing a raw material base.
• Preparing the premises for work.

By the most conservative estimate, the launch of a mini-workshop with a production capacity of 30-50 sheets / hour will require at least 2,000,000 rubles. Investments will literally quadruple if we talk about purchasing a more powerful line (up to 200 sheets / day).

The potential profit can be calculated based on the sales figures and the established prices for the finished material. On average, facing cardboard for drywall (standard type) costs 130-250 rubles / sheet on the wholesale market. It turns out that with 8-hour workshop work 30 days a month, you can get an income of ≈1,000,000 rubles. Net income is calculated by subtracting variable costs from their total monthly revenue.

As practice shows, even expensive equipment, in the presence of constant demand for the produced drywall, pays off no later than 2 years later.

Hello dear readers! I often talk about repairs, because I like to make my own hands, and I make good money on objects. But, constantly dealing with building materials, it would be strange not to think about the business of producing them. Practice has shown that working with a metal profile does not bring benefits: if you open a small enterprise, the production cost will be almost equal to the price offered by huge factories. The production of drywall turns out to be more profitable, but even here difficulties await a novice entrepreneur. Let's figure out all the intricacies together.

But such a business must have a clear plan in order to be profitable. This article will discuss the main points of the production of drywall in bulk, as well as the conditions for business development in Russia.

Drywall: material features

Drywall is a material consisting of cardboard sheets glued using a gypsum mixture. Such a sheet (GCR) has a reinforcement that gives it strength due to reinforcing additives.

What should be the structure of drywall

Thanks to this structure, gypsum boards have the following advantages:

• ease and ease of do-it-yourself installation;
• environmental friendliness;
• moisture resistance and fire resistance;
• mechanical strength;
• good thermal insulation performance;
• the ability to "breathe", which allows the material to absorb excess moisture in the air;
• plastic.

Because of these advantages, drywall took first place in popularity as a finishing material for do-it-yourself interior work.

Drywall application: why production is profitable

Due to its advantages, gypsum board is today used everywhere for wall cladding, creating multi-level ceiling structures, columns, partitions, arches, niches and other furniture options with your own hands. In addition, with the help of GCR, you can easily hide communications or surface defects with your own hands.

Thus, the consumers of gypsum board are a wide variety of construction companies, of which there are a great many in Russia. Therefore, this kind of business has every chance of being successful in Russia if the plan was drawn up correctly and taking into account all the nuances.

The prospect of a drywall business

Today the German company Knauf is the undisputed leader in the manufacture of plasterboard sheets in bulk. It accounts for about 70% of the goods of the entire construction market in Russia. Knauf firm produces wholesale not only drywall, but also all materials necessary for working with it: putty, glue, profiles, fastening systems, etc.

If you develop the correct production plan, as well as conduct a market assessment, then the wholesale drywall business in Russia will be profitable and quickly pay off. Of course, such a business in terms of sales cannot be compared with the income of Knauf, but it will also be quite profitable and will occupy its own niche in Russia.

The building materials market is so huge and in demand that help to such a giant as Knauf in Russia is simply necessary, since the production of drywall is continuous and the number of consumers continues to increase every year. Therefore, Knauf and its drywall plant cannot cope with the demand on the market and other manufacturers enter it.

A business plan correctly drawn up with your own hands and brains, high-quality and qualified personnel will help you open a profitable and promising business for the manufacture of this building material in bulk.

Where to start the production of drywall

To open a drywall production in Russia and achieve a positive result here, you must go through the following stages:

• collect start-up capital. According to rough estimates, 5-6 million rubles are needed;
• create a business plan;
• rent a room for a business;
• buy equipment for the production of drywall;

Drywall Production Line

• purchase raw materials;
• take into account production costs - payment of utility bills, employee salaries, etc.

The most important requirement here is a well-written business plan. If you do not have sufficient skills and do not understand business plans, you can always turn to specialists for help. They will quickly develop a business plan that will bring you the expected returns.

Note! For a business to be successful and profitable, there is no need to open a mega concern. You can get a pretty good income with a production that produces about 200 sheets per day.

A small drywall wholesale business has the following advantages:

• low power consumption;
• high profitability;
• low costs of paying workers' wages;
• relatively small start-up capital required to start production.

Remember that with low productivity, the cost of drywall will be the same as with a powerful production. And from each sheet you will receive about 1.5-2 dollars! In such a situation, the monthly profit will be about 10,860 dollars and in 1-2 years the manufacturer will fully recoup its costs.

Premises and equipment for the production of drywall

The most important point for a wholesale drywall manufacturer at the start of a business is the choice of premises to launch a production line. The minimum size of the premises is 600 sq.m. In this case, the ceiling height should be 4.5 m. A smaller room simply cannot fit everything necessary equipment.

In addition to the size of the room, there are the following conditions for starting the manufacture of drywall sheets:

• the presence of an industrial power grid;
• the presence of a water supply and gas;
• appropriate temperature regime... The room temperature should not fall below 15 ºС, otherwise it will lead to disruption of the technological process;
• hiring only qualified specialistswith experience in this kind of production.

One of the most important points in this enterprise is the purchase of equipment. With it, the drywall production line will be fully formed. This is the most expensive item in the entire enterprise.

Note! The choice of equipment must be very careful, since production volumes directly depend on this. It is not worth saving here, as cheap equipment will break down more often. Therefore, it is better to immediately buy high-quality equipment that will definitely last a long time and in the long term will cost much less than frequent repairs of cheap equipment.

What you need to start a drywall production line

The list of equipment required to launch the line includes:

• device for producing gypsum mixture;
• apparatus for continuous supply to the cardboard former;
• the former itself, which provides the formation of the gypsum sheet;
• belt conveyor. It must be equipped with additional shapers for the thickness of the web and profile;
• roller conveyor for web cutting;
• conveyor for transporting sheets;
• cantilever conveyor;
• dryer conveyor;
• additional roller conveyor for final cutting of sheets.

All this must necessarily contain a production plan, which you draw up with your own hands or order from specialists.

Necessary

Like any production, the wholesale production of gypsum plasterboards requires the purchase of raw materials. For such production, the following types of raw materials are needed:

• gypsum (natural - 85% and artificial);
• facing cardboard. The roll width is 1180 mm and 1250 mm, and the thickness is 0.3-0.46 mm;
• 70% modified starch with 11-13% water content. Its alkaline level should be pH 6.5 - 7.5, dust - maximum 2% and protein - 3%. The water solubility of starch should be in the range 73 to 78%;
• synthetic foaming agent with a concentration of mineral salts of not more than 2.5%.

In addition, you will need borohypsum and phosphogypsum. Since both materials are wastes from the chemical industry, additional purification from impurities is required.

The list of impurities according to the established technology includes:

• salt;
• cellulose;
• caustic soda, etc.

All of these raw materials are essential for the production of plasterboard that meets international quality standards.

Technology plasterboard production

Drywall manufacturing technology consists of the following stages:

• preparation of a mixture, which includes water and gypsum powder, in a gypsum mixer;
• supply of cardboard sheets to the line;
• hitting the cardboard of the mixture in the molding module;
• leveling the mixture with a top layer of cardboard greased with glue;
• giving the canvas the desired shape.

As a result, we get a finished canvas, which is then cut into sheets of the desired size. The sheets are then dried and ready for sale.

As you can see, knowing the main nuances and stages of starting a business for the wholesale production of drywall, you can easily cope with the task with your own hands and your skills.

Drywall is currently the most common construction material, which is used in construction and interior decoration. Various structures are made of it: multi-level suspended ceilings, boxes on ceilings and walls, partitions, it is used to level surfaces. Drywall makes it possible not to use more time-consuming finishing methods, such as plastering and subsequent leveling. It is very easy to operate with it, and all work can be done by hand.

Plasterboard production in Russia

Drywall is a composite material that comes in the form of gypsum sheets.

To increase the strength of the sheets, they are pasted over with cardboard. Gypsum is additionally reinforced with reinforcing additives. Cardboard also performs a reinforcing function, in addition, it becomes a good basis for finishing work: applying putty, paint, wallpaper or ceramic tiles, which can be done by hand. Due to the plasticity of the material, you can make any curved structure from it with your own hands, for example, an arch. To do this, you just need to prepare the appropriate frame. These properties are widely used by interior designers who use drywall to make systems of different levels of complexity out of it.

This material has high flame retardant characteristics and is electrically neutral. In its composition there are no toxic components that could have a harmful effect on humans. Plasterboard production is an environmentally friendly process that does not pose a threat to the environment.

It is impossible to make drywall with your own hands at home. This requires a conveyor. Its production can be a profitable business that is not difficult to organize. At first, you can purchase a mini-line that will make it possible to make drywall. To start work, you need to prepare special units:

• neck or pneumatic conveyor;
• bunker;
• mixer;
• forming table;
• forming rolls;
• guillotine for cutting.

Materials will be needed:

• building plaster;
• special waterproof cardboard;
• modified starch;
• synthetic foaming agent;
• adhesive additives (polyvinyl acetate emulsion).

The composition of drywall can include fiberglass, cellulose and other additives that regulate the speed of solidification of the mixture, give the finished product moisture-resistant and fire-resistant characteristics. In the work, it is better to use natural gypsum that has been fired. It is fed into the supply hopper. This will be done by a screw or pneumatic conveyor. Then the mixture is sent to the mixer in order to add the necessary additives to it: dry components, chemical substances, fiberglass. It should be understood that if you mix the ingredients with your own hands, then lumps may remain in the mixture, and as a result, the drywall will turn out to be of poor quality.

The fortified mixture must be placed in a permanent mixer, where pulp and foam are added. Gypsum for the production of the core must have special technical and physical properties so that the finished material has the ability to "breathe", absorb excess moisture and, if necessary, give it away. To increase the density and strength of the gypsum layer, special components must be added to the mixture that will increase its performance.

Drywall sheet molding

The prepared foam gypsum mass is fed to the forming table, on which a sheet of cardboard is already laid out. The edges of the sheet should be curved. This process cannot be done by hand, everything happens automatically. The plaster mass is evenly distributed over the sheet. The top sheet of cardboard is laid on top. The cardboard used for production has special properties, it is moisture and vapor proof.

Before attaching the cardboard to the gypsum core, it must be covered with a special adhesive. This can be done with a special sheet former. After the sheets and the core are fastened together, the side edges of the sheet must be rolled up. This can be done with the face layer of the cardboard edge.

The gypsum mass is pulled through the forming rolls, which are set at such a distance from each other, what thickness the finished drywall should have. Moving along the conveyor, the mass dries up and is cut into sheets of the required length. This can be done using a guillotine. The prepared sheets are sent to the drying chamber. Already dry drywall is laid face to face, leveled, and the ends are cut to make the sheets even. Then they must be folded; production workers must do this with their own hands.

Drywall characteristic: high production standards

The production technology makes it possible to make drywall with any characteristics and different sizes. As a rule, sheets are made no more than 2.5 m long.The width can be 1.2-1.3 m and a thickness of 0.8-2.4 cm.It is most convenient to work with sheets of this size for professional builders and those who want do it yourself.

According to the characteristics of the produced material, drywall can be divided into several main categories. Plasterboard, which can be used if the humidity does not exceed 70%. Moisture resistant - which contains silicone granules. Due to this, it can withstand 82-85% humidity. The next type is fire-resistant, not destructive at high temperatures due to the fact that it contains fiberglass. And moisture-resistant drywall, which combines the characteristics of moisture-resistant and fire-resistant materials.

Manufacturing tools that help fulfill renovation work quickly and efficiently, is gaining momentum. The production of drywall was no exception.

Will there be a demand for drywall during its production

This sheet material in finishing works used for a long time. It gained its popularity due to its practicality and environmental friendliness. Also, the types of HA play an important role in its demand.

According to the technical characteristics, drywall can be as follows:

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

With regard to the field of application, the material is classified as wall and ceiling. Sheets have various parameters and bearing capacities.

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

Increasingly, drywall is pushing other materials into the background 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 stages:

• Construction of the frame from metal profiles or wooden planks.
• Thermal insulation and waterproofing (the latter will be a mandatory action in rooms with high air humidity).
• Installation of sheets.
• Preparation of the surface of the material for subsequent lining (priming and plastering).

Despite such a number of actions, the use of gypsum board will be much more effective than leveling the surface using plaster mixtures.

The frameless method of fastening the material is less popular. This is due to the fact that the rough base for fixing the sheets must be flat. It remains to prime it.

Raw materials for the production of drywall

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

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

A prerequisite for production quality material is a check of all components for compliance with established standards (GOST).

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

Also in the technological process, the following types of basic additives are used:

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

In addition, modified starch and lignosulfonates (technical and powder mixtures) are used. They are designed to provide a good bond between the gypsum core and the cardboard.

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

Equipment for the production of drywall

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.

Plasterboard production equipment:

• Machine for making gypsum mix.
• Shaper - used for joining cardboard sheets and shaping a gypsum-based composition.
• Special apparatus for continuous feeding of cardboard to the former.
• Belt conveyor - designed to form the parameters of the future product.
• The roller conveyor is a guillotine that cuts the gypsum sheet.
• Transport Conveyor - Used to feed sheets to cantilever and roller conveyors.
• Cantilever conveyor - designed for placing sheets of HA on the dryer.

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

Plasterboard production stages

The material manufacturing process 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 gypsum plasterboard 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 product drying. It is in it, with the help of specialized equipment, that excess moisture is removed from the product. Thanks to this, the sheets acquire the required strength and density of the internal structure.

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

The storage area is used to properly store the material and package it before transportation.

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

Plasterboard production process

Plasterboard manufacturing is quite complex. Initially, a plaster 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 in dry form. 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, pressed on special equipment and dried.

Initially, long flat strips with a dense structure are made from the gypsum composition. For this, conveyors are intended, which set certain sections of the mixture.

The next stage is the formation of sheets of material. Pressed cardboard is installed in a special machine - bottom and top former. After that, the plaster mixture is served.

Cardboard sheets are pretreated with special glue, which fixes gypsum on them.

On the sides, drywall sheets are also treated with an adhesive solution so that the ends of the product are not destroyed in the further production process. Then the material is cut to 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 out under the influence of a certain temperature regime. Then they can be transported to the warehouse.

Production areas for the manufacture of drywall

Today, the most popular material is drywall, the production of which requires certain characteristics of the workshop. The room should not have high humidity. Such impact can negatively affect the quality of the manufactured products. To avoid an increase in humidity, additional types of ventilation are installed in the production workshop.

It is necessary to constantly maintain one temperature regime. The 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 board must have big sizes... This is the only way to install the necessary equipment in it, which will allow efficient use of the production line.

It is difficult today to find an apartment where, as a rough interior decoration drywall would not be used. He is able not only to quickly level the wall, but also to mount a partition, column, niche, arch, bar counter, suspended ceiling and many other functional or decorative coatings. The high popularity of this material is associated with its versatile capabilities and characteristics: heat and sound insulation, fire resistance, vapor tightness, breathable effect, low weight, environmental friendliness. But not many people know how this material is produced in Russia.

The situation with the production of drywall in Russia

The production of gypsum board, which can be seen on store shelves in Russia, Kazakhstan, Ukraine, is mainly owned by Knauf, British Plaster Board and Lafarge Group.

The business of domestic manufacturers is distinguished by a more modest volume of production, nomenclature and prices of drywall. The largest Russian manufacturer is the Volgograd gypsum plant, which produces gypsum plasterboards under the Volma trademark. Another popular brand is Magma. IN different regions the plasterboard business is also being developed by their own local producers, so in Kazan Arakchinsky gypsum LLC produces several types of gypsum plasterboard under the Abdullingips brand.

How drywall is made (video)

Raw materials for the production of drywall

Judging by the name of the building material, drywall is made from gypsum and cardboard. But for the formation of the board, glue and additives are needed to improve the characteristics of dry plaster.

The main ingredients of GCR:

• natural gypsum powder – 85%;
• facing cardboard sheets - 1180x1250 mm;
• starch – 70%;
• glue- polyvinyl acetate emulsion;
• synthetic foaming agent.

In addition to the main components, the composition of drywall can be supplemented with fiberglass, cellulose, and other additives to control the rate of hardening of the gypsum mixture and impart various properties to the drywall (moisture resistance, fire resistance).

Drywall production technology

The gypsum mass is kneaded by adding fillers necessary for a particular type of gypsum board. Continuous sheet webs are formed on a conveyor using a special shaping technique. Automatically, the gypsum dough is poured between the sheets of cardboard supplied by the installation, the layers are glued, the edges are rolled.

As it moves along the conveyor, the compressed belt dries up and falls under the machine, which cuts the web into separate pieces. Then the sheets are passed through a drying unit, the finished products are stacked and packaged.

Equipment for the production of drywall

For the production of gypsum boards, not one or two machines are needed, but a whole automated line of equipment, consisting of machines kneading gypsum, equipment that dispenses and feeds the mixture, glue, cardboard and other additives in accordance with a specific technology.

The list is supplemented by sheet forming machines, dryers and conveyors, trimming and finishing machines, automatic packaging machines and other equipment.

The production is equipped with systems for controlling humidity, temperature, for forming a certain type of plates, measuring a fixed value for cutting gypsum boards, feeding a mixture, etc.

Such equipment is offered by different manufacturers, most often China. The starting price of a small complex is $ 120,000.

Guide production as a business

Drywall profile - steel fasteners that form the frame for the gypsum board. Strong bases allow you to securely fix partitions, sheathe walls, etc ... The metal profile is easy to cut and easy to attach. It is more durable than wood.

The frame for the gypsum board is a lengthy element made of thin steel tape. Cold rolled products and special grades of steel provide the necessary rigidity and durability, the galvanized coating protects the profile surface from corrosion.

For convenient installation, a wide range of profiles for different areas of application are produced:

• Rack- for the racks of the frame of partitions and facings.
• Ceiling- for the frame of ceilings and wall claddings, suspensions are attached to the supporting base. The edges are bent inward for support when placing crabs.
• Guide- for post and ceiling profiles, as well as for the installation of jumpers.
• Guideceiling - for PP-profile guides when installing the ceiling frame and cladding.

Equipment for the production of profiles for gypsum plasterboard

The plasterboard industry is not only the production of gypsum boards, but also the manufacture of rack and guide profiles, including suspensions and other components, without which the installation of plates is impossible. Large manufacturers, such as Knauf, produce a complete set for drywalls, including suspensions, putties and other finishing materials.

Profile making machines are:

• roll forming module;
• stationary or flying cut pneumatic guillotine for cutting after profiling;
• automatic control system.

An optional touchscreen operator panel simplifies parameter entry and control, and allows 10 modes to be entered into memory. When working from a roll, one operator is needed to fill the strip and set the ACS operation mode.

You can see the full cycle of production of drywall and components in Russia in this video clip.

Plasterboard production (video)

Drywall business plan

The construction fever in Russia has caused a huge demand for drywall, which is growing by 20% annually. The leaders of the domestic construction market, the German company Knauf and the French concern Compagnie de Saint-Gobain SA, are loaded with orders, so the time to calculate the plan to launch their own production is the most favorable. Russia produces only 4% of the world's drywall, while America produces 42%.

The plan for the budget of the mini-project is 5-6 million rubles required for the rental of premises, the purchase of raw materials and equipment, for the production of gypsum board for the production of 200,000 m² / year (200 GCR / day).

Gypsum board is a universal, multifunctional finishing material, consisting of cardboard sheets and a gypsum mixture placed between them, reinforced with reinforcing additives.

GKL meets all the requirements that modern building technologies impose on building materials: it is environmentally friendly, lightweight, non-combustible, moisture resistant, has high mechanical strength and excellent sound-absorbing qualities, is easy to install and process. The absence of harmful impurities in the composition makes it absolutely non-toxic, and in terms of plasticity, no building material made from natural raw materials can be compared with it.

Drywall as a product

Consider the product characteristics of the product in question.

Plasterboard sheets are used for:

• creating partitions that do not carry the load;
• constructions false ceilings (including multi-tiered ceiling structures);
• wall decoration;
• creating niches, shelves and recesses;
• erection of columns and arched unloaded systems;
• construction of furniture items (cabinets, shelves, bar counters);
• creating cavities for laying communications (telephone, computer, security systems, etc.);
• construction of theatrical scenery.

Main consumers

The consumers of the products are both individuals who purchase material for personal needs, and enterprises of the construction industry that repair and decorate premises, as well as retail chains and stores selling building materials.

Range

Depending on the requirements of use, drywall is divided into the following categories:

• normal - used in rooms with humidity up to 70%;
• moisture resistant - has a gypsum structure with silicone granules (designed for use in rooms with an air humidity of 82-85%, when exposed to no more than 10 hours per day);
• fire-resistant - its structure contains fiberglass, which protects gypsum layers from destruction by high temperatures;
• moisture-resistant - is a combination of fire-resistant and moisture-resistant drywall and has the qualities of both types of materials.

As for the dimensions, gypsum boards are produced using technology that does not limit their size. But in practice, in order to facilitate the work of installers and designers, the material is produced in the form of standard sheets, not exceeding 2.5 meters in length with a width of 1.2 - 1.3 m.The thickness usually ranges from 8 mm to 24 mm.

Required raw materials and equipment for the production of drywall

The main raw materials for the production of gypsum plasterboard are: natural or artificial gypsum, facing cardboard, modified starch and synthetic foaming agent. Wastes of the chemical industry are sometimes used as raw materials - borohypsum and phosphogypsum. However, their use requires additional costs aimed at cleaning from a large amount of impurities. The composition of the molding mixture can also contain sodium chloride, cellulose, casein, caustic soda and some other components that affect the weight of the finished sheet, its flexibility and other indicators.

Plasterboard production is a high-tech, fully automated process. The production line is represented by the following equipment:

• Machine for the production of gypsum mixture, in which the formation of the gypsum mass is carried out.
• A machine that continuously feeds the cardboard to the former.
• A shaper, on which the process of forming a gypsum sheet and subsequent gluing together of cardboard leaves takes place.
• Belt conveyor equipped with additional formers of profile and web thickness. Provides a product that exactly matches the required dimensions.
• A roller conveyor on which the gypsum sheet is cut into sheets with the help of a guillotine.
• A conveyor for transporting sheets, which transfers sheets from a roller conveyor to a cantilever one.
• Conveyor cantilever, making the layout of the gypsum board on the conveyor of the dryer.
• Dryer conveyor, which slowly advances the sheet to ensure complete drying.
• Additional roller conveyor, providing the final cutting of the sheet and its supply for packaging and stacking.

A similar mini-line of the GKL-0.2 brand with a capacity of 200,000 square meters of plasterboard per year (which corresponds to the production of 200 sheets per day) will cost approximately $ 160,000 - 170,000.

Premises

A small factory requires a 600 sq. m, which must meet the following requirements:

• temperature regime not lower than 15 ° FROM;
• the presence of a supply of electricity, natural gas (or solid fuel), water and wastewater.

Estimation of costs required for production

Subject to the purchase of the production line GKL-0.2, the following capital costs will be required:

• The cost of the production mini-line is 5 million rubles.
• Delivery of the line - 500 thousand rubles.
• Repair and preparation of premises (600 sq. M.) - 600 thousand rubles.
• Creation of a commodity stock for one month - 600 thousand rubles.
• Other expenses - 500 thousand rubles.

Thus, to start a business project, an initial investment of 7.2 million rubles is required.

Revenue and profitability

The average selling wholesale price of a plasterboard sheet is 160 rubles. Thus, the monthly proceeds of the mini-production of GKL-0.2 will be about 1 million rubles, and the profitability will be about 60-70%. Under these conditions, the investment made in production will pay off in about 18 months.

Drywall is a building material for wall decoration. Sheets made of this material are used for the repair of living and working premises. Recently, the consumption of gypsum board has dropped somewhat, but the product continues to be popular. It is bought by both construction organizations and ordinary people.

There is a demand on the market for inexpensive building materials, so the production of drywall is a promising business. In this material, we will tell you in more detail how to open a small factory for the production of gypsum boards, and give approximate calculations of the payback of the case.

GKL market overview

Due to the stagnation in the Russian economy, the volume of the drywall market is shrinking. According to the latest research, there has been a drop over the past 3 years. Consumption of gypsum plasterboard (gypsum plasterboards) fell back to the level of 10 years ago.

In 2016, consumption decreased by 6% compared to the previous year, amounting to 220 million sq. m, the volume of drywall production - by 4%. At the same time, the dynamics is such that against the background of a decrease in consumption in the Russian Federation, exports to other countries are increasing.

This situation is associated with a decrease in construction volumes in the country. It is the construction companies that are the main consumer of the material.

Nevertheless, there is an unmet demand - especially in regions where there is no open production drywall sheets. It is definitely advisable to start a business here.

Applications of building material

Drywall is most often used in finishing works. GKL is a building material that allows simple repairs, it is suitable for leveling any surface. With the help of drywall sheets, you can flawlessly finish the walls in any room - residential or office.

Wallpaper can be glued to this building material without any preliminary processing, pipes, cables and wiring can be hidden under it. Laminated and non-laminated (painted) drywall are used in interior design.

Other areas of application of the material:

• creation of multi-tiered ceiling structures (suspended ceilings);
• production of non-load bearing partitions, columns and arches;
• creating niches and recesses.

Types of drywall

The production technology allows you to create sheets of any size and area. As a rule, sheets are used with the following dimensions: length - no more than 2500 mm, thickness - 1200-1300 mm, thickness - 8-24 mm.

Table 1. Types of drywall.

	Main characteristic	Marking
Normal (GCR)	Retains properties at humidity up to 70%	Grey colour, blue marking
Moisture resistant (GKLV)	Withstands humidity levels up to 85%, contains silicone granules and antifungal components	Green color with blue marking
Fire resistant (GKLO)	Has increased resistance to open flames, which is achieved through fiberglass reinforcement	Gray with red markings
Moisture-resistant (GKLVO)	Combines the properties of GKLV and GKLO	Green with red markings

Initial costs

The main expense item when organizing the production of conventional drywall is the purchase of a production line. In order for the enterprise not to stand, it should be provided with raw materials. The drywall plant must store sufficient raw materials.

Table 2. The sum of the initial costs for the production of drywall.

The calculations are relevant for a city with a population of up to 1 million people. Additional costs include spending on utility bills, advertising, cosmetic repairs.

Documents

An entrepreneur can conduct business in the form of a natural or legal person. However, an individual entrepreneur will not be able to build a large sales network, cooperate with wholesalers and construction companies. Therefore, it is best to open an LLC - the simplest form of legal entity. faces.

The documents indicate the OKVED code 23.62 "Production of gypsum products for use in construction".

Although it is not necessary to obtain a mandatory quality certificate for drywall, it is still recommended to undergo voluntary certification according to the GOST R system. 98% of Russian manufacturers have such a document that guarantees the proper quality of the goods. The certificate will help you to quickly negotiate with supply intermediaries and improve sales.

Drywall production technology

The production of conventional drywall consists of the following steps:

1. A mixture of the desired composition is created. Various impurities are added to the solution to improve the characteristics of the building material.
2. On the conveyor, gypsum sheets are created, which are fed into a special former, where the sheets are glued and the web is formed.
3. The "semi-finished product" is fed to a belt conveyor, where the web is formed according to the program and the dimensions of the profiles.
4. On a roller table, the web is cut using guillotines.
5. The resulting sheets are transported by the device to a cantilever conveyor, which puts them on drying.
6. In the dryer, the gypsum boards are processed for at least 1 hour until completely dry.
7. Sheets are fed to an additional roller conveyor, where they are cut.
8. The finished product is stacked and packed.

The production technology can be seen in the following video:

Premises

To organize a plant for the production of gypsum plasterboards, a fairly large area will be required - at least 500 sq. m. Most of the territory will be occupied by a work shop and warehouses. It is necessary to equip a room for employees, a bathroom, an administrative office.

It is necessary to carry out industrial electricity, water supply and sewerage, as well as heating. The air temperature in the workshop should not fall below 15 ° C.

Near the plant, it is necessary to equip an entrance for trucks and a place for loading and unloading operations.

The premises for the production of drywall are best located in an industrial area or on the outskirts of the city - that is, in accordance with the requirements of the norms and close enough to the sales market.

Raw materials

The main raw material is gypsum. It can be both natural and artificial. But it should be borne in mind that artificial gypsum - boron or phosphogypsum - is obtained from chemical waste. It will need to be additionally cleaned of impurities, which implies additional costs.

Cardboard is needed for cladding, placed on 2 sides of the sheet blank.

Materials of the next group are needed to create slurry, a mixture for pouring. We are talking about a synthetic foaming agent, modified starch, casein, cellulose, table salt, caustic soda and water.

A number of impurities can be added to the mixture to improve the characteristics of the product - glass fiber, silicone granules, lignosulfonates.

Equipment for the production of drywall

Using production lines such as GKL-0.2, the production of gypsum plasterboard sheets will be fully automated. Personnel are only needed to maintain production equipment.

The line consists of:

• devices for forming a mixture of plaster;
• a conveyor that ensures the movement of the product through all stages of the production of plasterboard;
• a former necessary for forming the web and gluing the sheets;
• belt conveyor, which ensures the exact conformity of the sheet to the required dimensions;
• roller conveyor and additional roller conveyor for cutting and trimming the product;
• console and drying conveyor - for drying the gypsum board.

The cost of such a line with a capacity of up to 200 sheets per day is 8.5 million rubles. Taking into account the costs of delivery and installation - about 9 million rubles.

Sales of finished products, target audience

Plasterboard consumers are construction and repair organizations, specialized stores and individuals who need gypsum plasterboard for domestic needs.

Sales can be arranged both directly and through intermediaries. In the first case, it is supposed to work with construction companies and / or to open a retail store, in the second - to supply consignments of goods to wholesale and retail networks.

Negotiating with counterparties and concluding contracts can be done by a businessman or a sales manager.

The drywall market is filled with the products of several large firms (Knauf, Volma), so to attract buyers, you should first offer your product at low prices. Best option - conclude long-term contracts with one or more customers, to whom and sell most of their sheets.

Table 3. Business case for a business idea.

Business success will be affected economic conditions in the region where the activity will take place. The largest regions for the production of gypsum plasterboards are Moscow and Samara regions, Krasnodar and Perm regions. More than 55% of all drywall in Russia is produced here. You need to study your region well or choose one in which the competition will not be higher than average. Then it will be possible to quickly find buyers, regular customers, and the business will pay off in about 1.5 years.

Our business plan will help you figure out how to open a small drywall plant. The value of the initial costs for this business is quite large, therefore, it is extremely risky to approach the manufacture of gypsum board without a clear plan.

The following basic materials are used in the production of drywall:

* Natural gypsum (CaSO4.2H2O).

* Facing cardboard, roll widths of 1250mm and 1180mm. Dimensional deviations can be accepted if they do not change the dimensions of the finished product, and do not weaken the adhesive bond between the cardboard layers at 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 subsequently used in the formation of a gypsum tape. Gypsum has excellent technical and physical properties, and certain components are added to improve its performance properties. Technological process 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. The bottom and top webs of the board are fed from the board feeding machine to the former. In it, a pre-prepared gypsum mixture is placed between the canvases. The glue machine lubricates the top layer of cardboard around the edges with glue, and at the bottom layer the edges are rolled. Then both layers are rolled in and a drywall sheet with a gypsum core inside is obtained, which is formed into the required profile.

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

3. The web then goes onto the roller conveyor at rapid speed. On it, it is cut into sheets using a guillotine. Next, the drywall sheets are removed by the transition conveyor and transferred to the console conveyor (dispenser). A dispenser distributes sheets to six conveyor belts in the dryer. The speed of movement of the sheet inside the dryer is reduced and the drywall sheet remains there for about an hour.

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

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

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

The cost of drywall is low, but this material will save you from wet processes, which carry great labor costs, loss of time, a lot of dirt and debris.

Plus, drywall is excellent sound quality. The basis of this modern material - gypsum, the one that was used in the visual arts and orthopedics. The very same gypsum that has the ability to "breathe", that is, to 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 gypsum plasterboard (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 absolutely odorless and thermally neutral. A gypsum core, pasted over on both sides with a special cardboard (for greater strength and a smoother surface), forms a gypsum board or slab, which is simply called gypsum board. Gypsum panels of various brands are produced by construction companies in Russia, Germany, Great Britain, Greece, France, the USA and other countries.

Cardboard serves as both a reinforcing frame and an excellent base for applying any finishing material (plaster, wallpaper, paint, ceramic tiles). So the material is flexible and rigid at the same time. It has an acidity similar to that of human skin.

The last two properties allow plasterboard to regulate the microclimate of the premises in a natural way and contribute significantly to the creation of a harmonious atmosphere. Each of the listed properties can be enhanced if the gypsum plasterboard needs to be designed for specific purposes.

Fire-resistant is used for finishing all kinds of air ducts and communication shafts. And there are also the so-called tongue-and-groove slabs, in which the gypsum is fired. Their strength increases so much that they can be used as interior partitions, without any preparation, paint, wallpaper or revet 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, you can lay electrical and telephone cables, dust removal systems, heating and water supply lines.

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 wood or steel frame. Gypsum panels with a thickness of 9.5 and 12.5 mm, due to their plasticity in a wet state and high resistance to bending in a dry state, with appropriate processing, can turn into convex or concave building elements and into building parts of any configuration, including complex curved 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 folded lengthwise, not widthwise, and 60 mm wide gypsum panels are best suited for this. Their concave side can be both front and back surfaces. Any door and window frames can be installed in plasterboard walls: wooden, aluminum, steel, plastic.

Plasterboard plates not only bend well, but are also perfectly cut with a boot 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.