Next-Generation Gypsum Plasterboard Plants Powered by IPS Technology
With over 20 years of industrial engineering expertise, we design and deliver turnkey gypsum plasterboard production plants with advanced automation for customers worldwide. Meeting the growing demand for lightweight, versatile, and high-performance building materials, we provide innovative production systems that maximize productivity while minimizing waste, downtime, and energy consumption.
From one of the most technologically advanced gypsum plants in Oman to large-scale projects exceeding 20,000,000 m² of annual plasterboard production on a single line, our references demonstrate our ability to deliver world-class manufacturing solutions. Stay ahead of the competition with IPS Makina Technology, designed to secure every stage of your investment.
- 3D Detailed Plant Design (Digital Twin): Our engineering team creates a complete 3D digital model of your production line—often exceeding 100 meters in length—allowing you to review the entire mechanical layout and structural integration before installation begins.
- Energy Recovery Drying Technology: Drying is the most energy-intensive stage of plasterboard production. Our multi-deck dryers, equipped with advanced heat recovery systems, significantly reduce energy consumption per board while maximizing thermal efficiency.
- Precision Dosing & Continuous Pin Mixer Technology: Our high-speed pin mixers accurately blend calcined gypsum, water, foam, and specialty additives, ensuring precise control of board core density, consistency, and product quality.
- Intelligent SCADA & Line Automation: Every stage of production—from raw material feeding to end-of-line packaging—is monitored and controlled from a centralized SCADA system. Automatic rotary shearing, dryer transfer, and board matching are performed with maximum precision and minimal operator intervention.
- Modular Capacity Expansion: Our production lines are designed with a modular layout, allowing future capacity increases and product diversification with minimal modifications.
Plaster Board Factory Capacity Table
Feature | Annual Production | Line Speed |
Standard Capacity | 4.000.000 m2 - 5.000.000 m2 | 4-7 mt/min |
Standard Capacity | 7.000.000 m2 | 14 mt/min |
| High Capacity | 8.000.000 m2 | 16 mt/min |
| High Capacity | 10.000.000 m2 | 20 mt/min |
| High Capacity | 12.000.000 m2 | 24 mt/min |
| Industrial Capacity | 15.000.000 m2 | 30 mt/min |
| Industrial Capacity | 20.000.000 m2 | 40 mt/min |
Process Flow (Production Stages)
- Raw Material Preparation & Dosing: Calcined gypsum powder, starch, accelerator, glass fibers, water, and foam are accurately weighed and automatically fed into the mixer according to the production recipe.
- Mixing & Board Forming: The homogeneous slurry prepared in the specially designed mixer is deposited between the top and bottom liner papers and formed to the required board thickness using the forming table and calibration systems.
- Forming Conveyor (Setting Belt): As the continuous board travels along the forming conveyor, the hydration process (setting and hardening) is completed.
- Cutting & Transfer Automation: The continuous hardened board is precision-cut into standard lengths using a synchronized rotary shear and automatically transferred to the dryer by board turning units.
- Drying Technology: Excess moisture is removed under controlled conditions in multi-deck dryers equipped with advanced hot-air circulation systems.
- End-of-Line Finishing & Packaging: After drying, the boards undergo book booking (pairing), edge trimming, stacking, and automatic palletizing before shipment.
Plant Configurations & Product Range
Our flexible production lines enable the manufacture of the complete range of gypsum plasterboard products required by today's construction industry within a single facility:
- Standard Gypsum Plasterboard (White Board)
- Moisture-Resistant Gypsum Plasterboard (Green Board – WR)
- Fire-Resistant Gypsum Plasterboard (Pink Board – FR)
- Moisture & Fire-Resistant Gypsum Plasterboard (Burgundy Board – WR & FR)
- Acoustic & Specialty Performance Gypsum Boards
After-Sales Support & Warranty
Project completion is not the end of our commitment—it is the beginning of our partnership. Following installation, cold and hot commissioning, we provide operator training, preventive maintenance services, and critical spare parts support to minimize production downtime. With rapid-response technical service teams available worldwide, IPS Makina remains by your side throughout the entire lifecycle of your investment.
