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

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

GKL is sold by many companies, and several companies enter the market. types of gypsum plasterboards (gypsum plasterboard):

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 moisture.
3. Fire resistant. Due to the fiberglass included in the composition, they are not destroyed under the influence high temperatures.
4. Moisture resistant. Combines the characteristics of the above two types of GCR.

The technology for the production of drywall allows you to obtain 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.

Plasterboard production documents

To launch your own mini drywall plant, it is better to register a legal entity in the form Ltd.

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

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

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

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

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

We select a room

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Drywall production is profitable business... There is a great demand for this material, as it is used in construction. It consists of sheets of cardboard with reinforcing additives, which are glued together plaster mix.

Drywall has the following qualities:

• light
• retains moisture
• does not pass noise
• fireproof
• lasting
• environmentally friendly
• plastic

Range of products

There are four types of drywall:

• Usual. It is suitable for decoration and construction of premises with a humidity level not exceeding 70%.
• Moisture resistant. Used in places where the humidity is below 85%.
• Flame retardant. It maintains its performance 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, load-bearing walls, columns;
• repairing walls;
• erect multi-level ceilings and mount them;
• make decorations, shelves and cabinets;
• finishing the 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 sq. meters. This area is required to install the equipment. The temperature inside the production hall should be no more than 15 degrees above zero.

Also pay attention to water supply, sewerage, gas and electricity. All of this must be conducted 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. Plasterboard production equipment:

• mixer;
• conveyor;
• decoiler;
• former for gypsum sheets, gypsum and cardboard sheets;
• conveyors different types (belt, roller table, cantilever, 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 standards for drywall. If the sheets correspond to them, then they can be produced on this equipment and subsequently sold.

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

Purchase of raw materials

For the manufacture of drywall, it is necessary to purchase a lot of components of which it consists.

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	It is a filler that makes drywall moisture resistant
Soap made from chemical materials	It helps to foam the required parts during production
Lignosulfonates	it chemical substancesthat 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 (mixture for pouring drywall)

Plasterboard production technology

The business organization plan should contain a clause regarding the stages of product manufacturing. Drywall production technology is not complicated. It takes several steps.

Production of gypsum sheets	it first stage in the manufacture of drywall, which is carried out using a conveyor that forms the desired shape of plaster strips. If you add impurities to the gypsum mixture (depending on the purpose of the material), you can get a more durable finished product
Cutting sheets	For this stage, a conveyor (roller conveyor) is used, which cuts drywall sheets
Distribution	This process is carried out using cantilever conveyors. They send finished products to dryers
Drying	It takes at least an hour
Pruning	The roller conveyor is involved in shaping the plasterboard sheets
Stacking	These steps are carried out with the help of staff who pack the finished products
Packaging

Sales markets

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

• construction stores
• contractors
• construction firms
• private persons

In Russia, the demand for drywall is growing every year, since 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 is needed to start a drywall business

The start-up capital is approximately 7.5 million rubles.This is a fairly large amount. The main costs are allocated to 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 an established production, it is possible to manufacture and sell goods for 1 million rubles. per month.

The payback period is 1.5 - 2 years.

Plasterboard production 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.

Where 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 line of business, 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 industry, 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 to register a legal entity in the form of a limited liability company. Individual entrepreneurs also have the right to engage in this area of \u200b\u200bactivity, but in comparison with LLCs, their activities are greatly curtailed. To register as a limited liability company, you must collect and submit to the registration authority:

• application for registration of LLC and the decision of the meeting of shareholders on the creation of a limited liability company;
• Company charter and legal address (quite often the address of the location of production facilities is 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 government authorities and open a current account with the bank.

What taxation system to choose for the production of drywall

Several systems are suitable for this line of business, according to which tax can be paid. However, among them it is best to dwell on the simplification, it provides some benefits. In particular, upon the submission of documents that confirm the expenses incurred by the company for the reporting period, tax is paid in the amount of 15% of net profit. 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, you will need to apply for the appropriate permits to the fire inspection and sanitary and epidemiological station.

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.

Plasterboard 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 increase its performance properties. The technological process for obtaining gypsum plasterboard 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. A previously 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 and get a drywall sheet with a gypsum core inside, which is formed into the required profile.

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

3. The web then goes onto the roller conveyor at rapid speed. It is cut into sheets using a guillotine. Further, the drywall sheets are removed by the transition conveyor and transferred to the console conveyor (dispenser). The dispenser distributes the sheets to the six conveyors of 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 device 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, wasted 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 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, 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 solid 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 greatly contribute to the creation of a harmonious atmosphere. Each of these properties can be enhanced if you need to design a drywall sheet 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 platesin 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 fixed to a timber 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 always bend lengthwise, not width, and 60mm 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: wood, aluminum, steel, plastic.

Plates of drywall not only bend well, but are also perfectly cut with a boot knife and sawn. Using special tools, the panel can be cut to the desired length and width and, if necessary, drilled through it.

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

Why is GCR popular?

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.
By technical specifications 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.

More and more, 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:

• Frame construction from metal profiles or wooden planks.
• Insulation and waterproofing (the latter will be a mandatory action in rooms with high 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 production

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 technological process these 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 HA 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.

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.
• Roller conveyor - 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.

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.

Technological 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 together, 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 for 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 do not collapse in the future. 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 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 gypsum boards

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 rising humidity, production workshop equip additional types of ventilation.

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 in it necessary equipment, which will allow efficient use of the production line.

Today, the production of drywall is one of the most promising businesses, because this material is widely used in decoration and construction of premises. Here we will look at the technology and equipment for the production of drywall.

If you are not yet familiar with this material, then we will briefly tell you about it. Drywall is a kind building material, which is a cardboard sheets glued with a gypsum mixture, additionally reinforced with reinforcing additives. The characteristics of drywall are as follows: lightness, moisture resistance, environmental friendliness, anti-noise, 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 diverse:

• erection of partitions, columns, arches, not bearing 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 (shelves, cabinets, etc.).

Main consumers

Consumers include various construction organizations involved in the renovation of premises, specialty stores, and ordinary citizens who use drywall for domestic needs.

Assortment of goods

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

• normal - used at humidity no more than 70%;
• moisture resistant - due to the gypsum structure with silicone granules, it withstands air humidity of 82-85% for 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 gypsum boards 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 waste - phosphogypsum and borogypsum - is associated with additional costs for their purification from impurities. Variations in sheet weight and flexibility are achieved by adding cellulose, table salt, caustic soda, etc. to the molding mixture.

Equipment for the production of

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

• a device for the formation and production of a gypsum mixture;
• device for continuous supply of cardboard to the former;
• shaper - provides the formation of the gypsum sheet and the connection of sheets of cardboard to each other;
• belt conveyor, which is equipped with additional shapers of the thickness of the web and profile 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 gypsum plasterboard sheets - it transfers them from the roller conveyor to the console conveyor;
• cantilever conveyor - places sheets on the dryer conveyor;
• dryer conveyor - gradually moves the sheets until they dry;
• an additional roller conveyor for the final trimming of the drywall sheet and its transfer for packing and stacking.

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

The whole process looks like this - video:

Premises

To organize the production of drywall, a building with an area of \u200b\u200b600 m2 is required with a temperature not lower than 15 ° C and supplied with electricity, gas, water and wastewater.

Expenses

When choosing a production line GKL-0.2, you will need the following financial resources:

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

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

Revenue and business profitability

Today, the average wholesale price of a leaf 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.