For several decades, no one knew about gypsorcatone. Now the situation is completely different - this material is used everywhere in many branches of economic activity. Given 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 earning.

Our business valuation:

Starting investments - from 2,000,000 rubles.

Market saturation is average.

The complexity of starting a business is 7/10.

A drywall business plan plays an important role when starting a business. The pages of the project 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?

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

• Standard drywall. It is widely used for interior decoration with humidity levels of not more than 70%.
• Waterproof drywall. Withstands humidity up to 90%.
• Fire resistant drywall. Can withstand high temperatures without flammable.

In addition to the technological properties of the material, its dimensions may also vary. And almost 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 need to be purchased 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.

Generally, production steps can be described like this:

• Formation gypsum mixture by mixing raw materials.
• Forming a sheet of a certain thickness with simultaneous pasting of cardboard on it.
• Drying finished sheets.
• Product packaging and storage.

Almost each of the designated 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 purchases manual machines.

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

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

Mini drywall 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?

Having worked out the assortment 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 manufacture are widely represented.

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

• Mixers and intermediate tanks.
• The car for continuous giving of a cardboard in former.
• Plasterboard sheet former.
• Cutting machine.
• Dryer.
• Conveyors.

An important issue in equipping the workshop will be the financial issue. Automatic equipment today, given the rise in price of the dollar, is quite expensive - about 5,000,000-9,000,000 rubles. (depending on power). More affordable option for many beginners in 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 - 900,000-2,000,000 rubles.

The equipment is rather bulky, so you will have to find a spacious room for a mini-workshop - at least 200 m 2. It is also important to provide for all communications - electricity, water supply, ventilation. Special requirements are put forward to indicators of temperature and humidity in industrial and warehouse premises.

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

Sales market features

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

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

• Wholesale sales to large construction companies.
• Retail sales to private customers.
• Opening of own warehouse-shop.

Big profits can be made by selling the released drywall in large quantities. If you find regular customers, all costs will pay off soon. But here it is important to weigh your capabilities - and whether it will be possible for a low-power enterprise to fully satisfy the needs of a particular customer in the 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 capital investment in the business will be quite impressive. This includes spending on the following items:

• Workshop equipment.
• Company registration.
• Providing a raw material base.
• Preparing the premises for work.

According to the most modest calculation, 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).

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

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

Hello dear readers! I often talk about repairs, because I like to make things with my own hands, and I make good money on the objects. But, constantly dealing with building materials, it would be strange not to think about the business of their production. Practice has shown that working with a metal profile does not bring benefits: if you open a small enterprise, the cost of production will almost be equal to the price offered by huge factories. The production of drywall turns out to be more profitable, but here, too, difficulties await the novice entrepreneur. Let's take a look at all the details 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 together with a gypsum mixture. Such a sheet (GKL) has a reinforcement that gives it strength due to reinforcing additives.

What should be the structure of drywall

Due to this structure, GKL have the following advantages:

• ease and simplicity 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 has taken first place in popularity as finishing material For internal works held by hand.

Scope of drywall: why production is profitable

Due to its advantages, drywall is now 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 GKL, you can easily hide communications or surface defects with your own hands.

Thus, the consumers of GKL 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 prospects for the drywall business

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

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

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

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

Drywall production line

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

Here the most important requirement 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 profit.

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

A small wholesale drywall business has the following benefits:

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

Remember that with a small 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, and in 1-2 years the manufacturer will fully recoup its costs.

Room and equipment for the production of drywall

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

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

• the presence of an industrial power grid;
• availability of water supply and gas;
• corresponding temperature regime. The temperature in the room should not fall below 15 ºС, otherwise this will lead to a violation of the technological process;
• hiring only qualified specialists with experience in this type of industry.

One of the most important moments 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! You need to choose equipment very carefully, since production volumes directly depend on it. 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 run will cost much less than frequent repairs of cheap equipment.

What you need to start a drywall production line

The list of necessary equipment for launching the line includes:

• a device for producing a gypsum mixture;
• apparatus for continuous supply to the cardboard former;
• the shaper itself, which provides the molding of the gypsum sheet;
• belt conveyor. It must be equipped with additional shapers in the thickness of the web and profile;
• roller conveyor for web cutting;
• sheet conveyor;
• console conveyor;
• dryer conveyor;
• an additional roller conveyor that makes the final cutting of the 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 drywall sheets 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 width of the roll is 1180mm and 1250mm, and the thickness is 0.3-0.46mm;
• 70% modified starch with 11-13% water content. Its alkaline level should be pH 6.5 - 7.5, dust - a maximum of 2% and protein - 3%. The water solubility of starch should be in the range of 73 to 78%;
• synthetic foaming agent having a concentration of mineral salts not higher than 2.5%.

In addition, you will need borogypsum and phosphogypsum. Since both materials are waste products of the chemical industry, their additional purification from impurities is necessary.

The list of impurities according to the established technology includes:

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

All these raw materials are necessary for the production of drywall, corresponding to the international level of quality.

Technology drywall production

Drywall manufacturing technology consists of the following steps:

• preparation of a mixture in a gypsum mixer, which includes water and gypsum powder;
• supply to the line of a cardboard web;
• hitting the mixture on the cardboard in the molding module;
• leveling the mixture with the top layer of cardboard smeared 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. Next, the sheets are dried and they are ready for sale.

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

Currently, drywall is the most common construction material, which is used in construction and for interior decoration. Various designs are made from it: multi-level suspended ceilings, boxes for 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 manage, and all the work can be done by hand.

Drywall 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 out of it, 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 various levels of complexity out of it.

This material has high fire-resistant characteristics, it is electrically neutral. It does not contain any toxic components that could have a harmful effect on humans. The production of drywall is an environmentally friendly process that does not pose a danger to the environment.

It is impossible to make drywall with your own hands at home. This requires a conveyor. Its production can become profitable business which is easy to organize. At first, you can purchase a mini-line, which will make it possible to make drywall. To start work, you need to prepare special units:

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

From the materials you will need:

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

The composition of drywall may 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 work, it is better to use natural gypsum that has been fired. It is fed into the feed bin. This will be done by a screw or pneumatic conveyor. Next, the mixture is sent to the mixer in order to add the necessary additives to it: dry ingredients, 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, drywall will turn out to be of poor quality.

The enriched mixture must be placed in a permanent mixer, where the 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, release it. To increase the density and strength of the gypsum layer, special components must be added to the mixture that will increase its performance.

Forming drywall sheets

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

Before attaching the cardboard to the gypsum core, it must be coated with a special adhesive. This can be done on 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 front layer of the edge of the cardboard.

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

Characteristics of drywall: high production standards

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

In accordance with the characteristics of the material produced, drywall can be divided into several main categories. Ordinary drywall, which can be used if the humidity does not exceed 70%. Moisture resistant - which includes silicone granules. Thanks to this, it can withstand humidity of 82-85%. The next type is fire-resistant, not collapsing 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.

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

Will there be a demand for drywall in its production

This sheet material V 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 the production of drywall

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.

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

• 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.

Drywall production 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.

Stages of drywall production

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 of drywall production

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 the necessary equipment in it, which will allow you to effectively use the production line.

It is difficult today to find an apartment where, as a draft 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, false ceiling and many other functional or decorative coatings. The high popularity of this material is associated with its universal 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

GKL production, 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. Among Russian manufacturers, the largest is the Volgograd gypsum plant, which produces gypsum boards under the Volma trademark. Another popular brand is Magma. IN different regions expand the drywall business and their own, local manufacturers, so in Kazan LLC "Arakchinsky gypsum" produces several types of drywall under the brand name Abdullingips.

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 slab, glue and additives are needed to improve the characteristics of dry plaster.

The main ingredients of GKL:

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

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

Drywall production technology

The gypsum mass is kneaded by adding the fillers necessary for a particular type of GCR. Continuous sheet webs are formed on a conveyor by a special shaper technique. Gypsum dough is automatically poured between sheets of cardboard supplied by the machine, the layers are glued, and the edges are rolled.

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

Drywall production equipment

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

The list is supplemented by machines that form sheets, dryers and conveyors, plants that cut the edge and shape the edges, 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 GKL, supplying a mixture, etc ...

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

Guide rail manufacturing as a business

Drywall profile - steel fasteners that form a frame for plasterboard. Strong bases allow you to securely fasten partitions, sheathe walls, etc. Metallic profile easy to cut and easy to attach. It is more durable than wood.

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

For convenient installation, a wide range of profiles for various applications is produced:

• rack- for racks of a framework of partitions and facings.
• Ceiling- for the frame of ceilings and wall cladding, suspensions are attached to the supporting base. The edges are folded inward to stop when installing crabs.
• guide– for rack and ceiling profiles, as well as for installing jumpers.
• guide ceiling - for PP-profile guides when installing the ceiling frame and cladding.

Equipment for the production of a profile for drywall

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

Machines for the manufacture of profiles are:

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

The optional touch operator panel simplifies the input and control of parameters, allows memorizing 10 modes. When working from a roll, one operator is needed to fill the strip and set the ACS operating mode.

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

Drywall production (video)

Drywall business plan

The construction fever in Russia has created 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 for launching their own production is the most favorable. Russia produces only 4% of the world's drywall, while in America - 42%.

The budget plan for the mini-project is 5-6 million rubles, necessary for renting premises, purchasing raw materials and equipment, for the production of gypsum boards for the production of 200,000 m² / year (200 gypsum boards / day).

Drywall is a versatile, 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-flammable, 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 compare with it.

Drywall as a commodity

Consider the commodity characteristics of the product in question.

Drywall sheets are used for:

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

Main consumers

The consumers of the products are individuals, acquiring material for personal needs, and enterprises construction industry, making repairs and decoration of 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 it per day for no more than 10 hours);
• fire-resistant - its structure contains fiberglass that protects the layers of gypsum from destruction 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, GKL 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.

Necessary raw materials and equipment for the production of drywall

The main raw materials for the production of drywall are: natural or artificial gypsum, facing cardboard, modified starch and synthetic foaming agent. Chemical industry wastes - borogypsum and phosphogypsum - are sometimes used as raw materials. However, their use requires additional costs aimed at purification from a large amount of impurities. The composition of the molding sand can also contain table salt, cellulose, casein, caustic soda and some other components that affect the weight of the finished sheet, its flexibility and other indicators.

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

• A machine for the production of a gypsum mixture, in which the formation of a gypsum mass is carried out.
• A machine that continuously feeds cardboard to the shaper.
• The shaper, on which the process of forming a gypsum sheet and then gluing cardboard leaves together takes place.
• Belt conveyor, equipped with additional shapers for the profile and thickness of the web. Provides a product that exactly matches the required dimensions.
• A roller conveyor, on which a gypsum sheet is cut into sheets using a guillotine.
• A sheet conveyor that moves sheets from a roller conveyor to a cantilever conveyor.
• Cantilever conveyor, which lays out the plasterboard on the dryer conveyor.
• A dryer conveyor that advances the sheet slowly to ensure that it dries completely.
• An additional roller conveyor that ensures 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 drywall per year (which corresponds to the production of 200 sheets per day) will cost approximately $160,000 - $170,000.

room

To accommodate a small factory, a room of 600 square meters is required. m, which must correspond the following requirements:

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

Estimating the costs required for production

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

• The cost of the production mini-line is 5 million rubles.
• Line delivery - 500 thousand rubles.
• Repair and preparation of the 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 drywall sheet is 160 rubles. Thus, the monthly revenue of the GKL-0.2 mini-production will be about 1 million rubles, and the profitability will be about 60-70%. Under these conditions, investments in production will pay off in approximately 18 months.

Drywall - building material for wall decoration. Sheets of this material are used for the repair of residential and working premises. Recently, the volume of consumption of GKL has fallen 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 plasterboards, and give approximate calculations of the payback of the business.

GKL market overview

Due to the stagnation in Russian economy The drywall market is shrinking. According to recent studies, there has been a decline over the past 3 years. Consumption of drywall (gypsum boards) rolled back to the level of 10 years ago.

In 2016, consumption decreased by 6% compared to the previous year, amounting to 220 million square meters. 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 the volume of construction in the country. It is construction companies that are the main consumer of the material.

However, there is unsatisfied demand - especially in regions where there is no open production drywall sheets. This is where it makes sense to start a business.

Applications of building material

Drywall is most often used in finishing work. GKL is a building material that allows you to perform 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 pre-treatment, pipes, cables and wiring can be hidden under it. Laminated and non-laminated (painted) drywall is used in interior design.

Other areas of application of the material:

• creation of multi-tiered ceiling structures (suspended ceilings);
• production of partitions, columns and arches that do not carry loads;
• creating niches and recesses.

Types of drywall

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

Table 1. Types of drywall.

	Main characteristic	Marking
Ordinary (GKL)	Retains properties at air 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)	It has an increased resistance to open flame, which is achieved through fiberglass reinforcement	Gray color with red markings
Moisture-resistant (GKLVO)	Combines the properties of GKLV and GKLO	Green color with red markings

Start-up costs

The main expense item in 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. A drywall manufacturing plant must store enough raw materials.

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

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

Documentation

An entrepreneur may conduct business in the form of a physical or legal entity. However, an individual entrepreneur will not be able to build a large distribution network, cooperate with wholesalers, 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 plaster 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 a similar document that guarantees the proper quality of the goods. The certificate will help you quickly negotiate with intermediaries for supplies 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 shaper, where the sheets are glued and the web is formed.
3. The "semi-finished product" is fed to the conveyor belt, where the sheet is formed according to the programmed program and profile dimensions.
4. On the roller table container, the web is cut using guillotines.
5. The resulting sheets are transported through the device to the cantilever conveyor, which lays them out for drying.
6. GKL are processed in the dryer for at least 1 hour until completely dry.
7. The sheets are fed to an additional roller conveyor, where they are cut off.
8. The finished product is stacked and packaged.

The production technology can be seen in the following video:

room

To organize a plant for the production of drywall sheets, a fairly large area will be required - at least 500 square meters. m. Most of the territory will be occupied by a working workshop and warehouses. It is necessary to equip a room for workers, a bathroom, an administrative office.

It is necessary to carry out an industrial electrical network, water supply and sewerage, as well as heating. The air temperature in the workshop should not fall below 15ºС.

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 standards and close enough to the sales market.

Raw material

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

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

The materials of the next group are needed to create sludge, 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 composition of the mixture to improve the characteristics of the product - fiberglass, silicone granules, lignosulfonates.

Drywall production equipment

With the use of GKL-0.2 production lines, the production of gypsum boards will be fully automated. Personnel are needed only for maintenance of production equipment.

The line consists of:

• devices for forming a mixture of gypsum;
• a conveyor that ensures the movement of the product through all stages of the production of drywall;
• a shaper necessary for forming a web and gluing sheets;
• a belt conveyor that ensures that the sheet exactly matches the desired dimensions;
• roller and additional roller conveyor for cutting and trimming the product;
• console and drying conveyor - for drying plasterboard.

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 cost of delivery and installation - about 9 million rubles.

Sales of finished products, target audience

Drywall consumers are construction and repair organizations, specialized stores and individuals who need drywall for domestic needs.

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

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

The drywall market is filled with products from several large companies (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. Economic rationale 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 manufacture of gypsum boards are the Moscow and Samara regions, the 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 competition will not be above 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 factory. The amount of initial costs for this business is quite large, so it is extremely risky to approach the manufacture of GKL without a clear plan.

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 certain components are added to it 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. 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 - drywall sheet(gcl).

Drywall is indispensable in the production of construction and finishing works: construction interior partitions, wall cladding and 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.