Production line and factory setup overview
A large integrated gypsum-board factory converting calcined Afghan gypsum, water, additives and facing papers into tested drywall boards through rock receiving, crushing, calcination, stucco storage, slurry mixing, continuous board forming, setting, multi-zone drying, trimming, stacking, laboratory release and dispatch.
Recommended lowest-entry line configuration Treat this as a strategic project with a confirmed gypsum reserve and an off-take route. Confirm gypsum purity and moisture, paper supply, board thickness/width portfolio, drying energy, power, water, plant footprint, fire/moisture standards, logistics, maintenance capacity and experienced line supplier before investment.
Production process and implementation sequence
- Buyer requirement and site-data review
- Engineering/design and material selection
- Equipment manufacture or tool preparation
- Installation, alignment and utility connection
- Representative operating trial
- Output, quality and safety inspection
- Documentation, training and release
Products, capacity and market fit
- Confirm the precise customer product, target machine or plant flow before procurement.
- Approve representative trials, measured outputs and critical safety/quality requirements before release.
- Document specifications, operating settings, inspections and maintenance responsibilities.
- Gypsum board and drywall panels - Approved board types, thickness and width, gypsum purity, facing paper, density, edge profile, moisture/fire performance, length tolerance and packing - Housing, offices, retail, schools, contractors, drywall installers and building-material distributors
Core production machinery and line specifications
| Machine / stage | Function / value | Production note |
|---|---|---|
| Gypsum receiving/crushing/calcination | Produces controlled stucco | Purity and calcination |
| Paper and slurry preparation | Controls board formulation | Paper alignment/density |
| Continuous board forming line | Forms sheet and edge profile | Width/thickness |
| Setting dryer and finishing | Dries, cuts and stacks boards | Moisture and speed |
| Board laboratory/packing | Releases saleable panels | Strength and dimensions |
Raw materials, utilities and factory requirements
- Proven Afghan gypsum, facing paper, starch/foam/retarder and approved additives, water, packaging, dryer fuel, cutting consumables, laboratory materials and critical spares
- Stable three-phase electricity, protected material/finished-product storage, calibrated quality-control instruments and appropriate process ventilation
- Documented maintenance, critical spares, site safety procedures and product-specific environmental controls
Indicative low-entry investment and implementation plan
These planning ranges prioritize economical machinery, local labor and local civil works. Final pricing follows confirmed capacity, product specification, delivery terms and site conditions.
| Scope | Indicative range | Entry-plan note |
|---|---|---|
| Gypsum preparation, calcination and stucco handling | US$8m-28m | Reserve and capacity dependent |
| Continuous board line, dryer and finishing | US$18m-65m | Width/speed/product mix |
| Laboratory, packing, utilities and installation | US$6m-22m | Quality and energy scope |
| Indicative strategic project total | US$32m-115m | Mine, land, financing and working capital excluded |
Detailed proposal and next step
The proposal contains the complete line flow, machinery scope, raw-material and utility requirements, implementation stages and indicative entry planning. Final configuration follows confirmed products, capacity, site and budget.