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Mixing and Forming

The Critical Stage Where Plaster Becomes a Panel: Perfect Homogeneity and Form

The mixing and forming stage, where raw materials from precision dosing units are transformed into a physical building material, is the most dynamic process in gypsum board production. At IPS Makina, we are not merely a supplier offering standard machines during this critical phase; we act as a turnkey solution partner with comprehensive expertise in the entire process—from the microstructure of the cardboard to the thermodynamics of gypsum hydration.

Our fully automated mixing and forming lines ensure a homogeneous core structure for the panels while enabling you to achieve perfect edge profiles and millimeter-precise thicknesses that fully comply with standards.

Advanced Pin Mixer Design

At the heart of the continuous production process is our specially engineered high-speed pin mixer. Calcined plaster (stucco), water, special chemicals, and dynamic foam come together inside the mixer, creating perfect turbulence in a matter of seconds.

At the heart of the continuous production process is our specially engineered high-speed pin mixer. Calcined gypsum (stucco), water, special chemicals, and dynamic foam come together inside the mixer, creating perfect turbulence that lasts only seconds.

  • Homogeneous Slurry: Thanks to the specially arranged pins on the rotor and stator, lump formation is completely prevented, and the ideal core structure is created.
  • Foam Injection Optimization: To reduce energy costs in the drying kiln and ensure lightweight panels, foam is integrated into the system at the mixer’s most efficient points.
  • Self-Cleaning: Our design prevents plaster from hardening inside the mixer, minimizing production downtime and maintenance costs while ensuring operational continuity.

Precision Shaping and Calibration Table

The mixture, which exits the mixer as a fluid slurry, is spread onto a specially tensioned bottom cardboard sheet (surface paper). It is then covered with a top cardboard sheet (back paper) and enters the IPS Makina shaping station.

  • Cardboard (Paper) Tension and Centering Control: The integration of the upper and lower cardboard rolls into the system is controlled by precision braking and web guiding systems. Cardboard wrinkles and tears are reduced to zero.
  • Scoring and Edge Forming: The plate’s tapered or square edge profiles are flawlessly formed using high-precision grinding/scoring discs and folding guides.
  • Millimeter-Precision Thickness Adjustment: Our advanced forming plate/rolls system maintains the sheet’s width and thickness tolerances in accordance with international standards. It offers fast, motorized calibration via SCADA during recipe changes or when transitioning between thicknesses such as 9.5 mm, 12.5 mm, and 15 mm.

Setting and Hydration Belt (Setting Belt)

The shaped gypsum board begins to move along a long, continuous, and vibration-free conveyor belt (board line). This line is designed based on your production capacity and speed (ranging from 15 m/min to 100+ m/min). As the board moves along this conveyor, it undergoes its chemical reaction (hydration), sets, and reaches the appropriate hardness for cutting.

The smooth drive drums and automatic belt centering mechanisms used in our belt systems ensure that your production line operates quietly, smoothly, and with a long service life.

The gypsum board, having hardened and taken its perfect shape, is directed at the end of the belt to the [Cutting and Transfer Group]—a marvel of automation that determines the speed of the production line.

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