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Gypsum & Wallboard Handling Solutions

About the Gypsum & Wallboard Industry

What is Gypsum?

Gypsum, chemically known as calcium sulfate dihydrate (CaSO₄·2H₂O), is a naturally occurring mineral widely distributed across the globe. With its soft texture and ability to recrystallize when exposed to heat and moisture, gypsum is one of the most versatile materials in industrial applications. Major producers include Spain, Thailand, the United States, Turkey, and Russia, with deposits mined from sedimentary rock formations that span geological time periods.

 

Gypsum’s properties make it essential across multiple sectors:

  • Construction: Gypsum boards (drywall) dominate modern building practices due to their fire-resistant properties.
  • Agriculture: It is a soil amendment, improving aeration and aiding water penetration in clay-heavy soils.
  • Industrial Applications: Used in molds for ceramics, dental impressions, and as an additive in cement production to regulate setting time.


Economic Importance

The gypsum and wallboard industry is a cornerstone of global construction and infrastructure. The market for gypsum board alone was valued at approximately $55.91 billion USD in 2023 and is expected to grow at a compound annual growth rate (CAGR) of 12.7% from 2024 to 2030. This growth is driven by rapid urbanization, green building initiatives, and increased demand for lightweight, durable, and fire-resistant materials. In construction, the average new home contains more than 7 metric tons of gypsum. It is also indispensable for commercial projects, institutional buildings, and even temporary structures due to its affordability and ease of installation.

WTW Americas Industry Experience

WTW Americas has global expertise in conveying and storage technology for the gypsum and wallboard industry materials. The wide range of our products in use in this industry sector is quite extensive. WTW Americas products solutions are the equipment of choice when the task is to convey or store particularly challenging bulk materials.

Since its beginnings more than forty (40) years, WTW Americas has traditionally been supplying mobile solutions for bulk materials handling in the Gypsum & Wallboard industry. Our machines are specifically engineered to deliver reliable and dust-controlled reception and transfer of bulk materials between conveyors, trucks, rail wagons or ships that are tested for use in the industry environments.

Wallboard Manufacturing Process

Gypsum wallboard manufacturing is a complex and carefully monitored process that transforms raw gypsum into finished boards ready for construction.

  1. Mining and Preparation:
  • Mining: Gypsum is extracted from quarries or underground mines in crystalline form.
  • Crushing and Grinding: The raw gypsum is crushed into smaller particles and then milled to a fine powder for processing.

  1. Calcination:
  • The powdered gypsum is heated to approximately 150°C to remove water of crystallization, converting CaSO₄·2H₂O into calcium sulfate hemihydrate (CaSO₄·½H₂O). This is called calcination.

  1. Board Formation:
  • The calcined gypsum is mixed with water, starch, fibers, and other additives.
  • This slurry is spread onto a continuous sheet of paper backing. A second sheet of paper covers the slurry, creating a sandwich structure.

  1. Drying:
  • The wet boards pass through a multi-stage drying kiln where residual moisture is removed, ensuring structural integrity.

  1. Cutting and Finishing:
  • Boards are cut to desired lengths and quality-checked for consistency before being bundled and shipped.

Bulk Material Handling

Handling gypsum requires specialized equipment due to its tendency to clump and bridge under humidity:

  • Truck Discharge Machines (TDMs): Efficiently unload raw gypsum from transport vehicles.
  • Silo Discharge Machines (SDMs): Prevent ratholing and bridging in storage silos, maintaining consistent material flow.
  • Chain Conveyors: Used to transport gypsum between different stages of the process while minimizing dust.
  • Dust Control: Systems such as baghouses or dust-tight conveyors ensure minimal material loss and compliance with environmental standards.


Applications of Gypsum Beyond Wallboard

  1. Soil Conditioner:
  • Gypsum improves soil structure and provides essential nutrients, including calcium (Ca) and sulfur (S). These elements support plant growth and mitigate issues like soil salinity.

  1. Cement Additive:
  • Gypsum slows down the setting time of cement by interfering with the hydration of tricalcium aluminate (3CaO·Al₂O₃), enhancing workability.

  1. Industrial Uses:
  • Molds for ceramics and dental impressions rely on gypsum for precision.
  • Used in the production of sulfuric acid (H₂SO₄) and ammonium sulfate ((NH₄)₂SO₄) fertilizers.

  1. Energy Sector:
  • Flue Gas Desulfurization (FGD) gypsum, a byproduct of coal-fired power plants, is utilized as a synthetic alternative to mined gypsum.

Environmental and Sustainability Considerations

The gypsum industry is actively adopting sustainable practices:

  • Recycling: Waste gypsum from construction and demolition is processed and reused in manufacturing.
  • Energy Efficiency: Advanced kiln technologies reduce energy consumption during calcination.
  • Synthetic Gypsum: FGD gypsum not only minimizes waste from power plants but also reduces reliance on mining.


These efforts align with global green building standards and promote the circular economy within the construction sector.

Challenges and Innovations

Challenges

  • Environmental Impact: Dust emissions and energy-intensive processes.
  • Resource Depletion: Over-mining of natural gypsum deposits in some regions.


Innovations

  • Smart Factories: Automation can optimize production efficiency and minimize waste.
  • Enhanced Fire Resistance: New formulations incorporate vermiculite (Mg,Fe)₃(Al,Si)₄O₁₀(OH)₂·4H₂O and other materials to enhance performance.
  • Bio-based Additives: These reduce the environmental footprint of wallboard production.

WTW Americas: Leading Expertise in Gypsum and Wallboard Solutions

With over 40 years of experience, WTW Americas has established itself as a trusted global leader in conveying and storage solutions for the gypsum and wallboard industry. Our equipment is meticulously designed to handle the unique challenges posed by sticky, wet, and abrasive materials such as flue gas desulfurization (FGD) gypsum and natural gypsum. With installations worldwide, we are proud to work with many of the industry’s leading names, including repeat customers like National Gypsum, Georgia-Pacific, CertainTeed, US Gypsum, and many others.

Our tailored solutions support every step of the gypsum and wallboard manufacturing process, from mining operations to plant production and finished product handling. Whether your needs involve receiving raw material directly from barges, railcars, trucks, or front-end loaders, or optimizing processes at your gypsum mine, WTW Americas has the expertise to ensure seamless integration and maximum efficiency.

Material Receiving: Flexible and Efficient Solutions

At the start of the gypsum processing chain, the WTW Truck Discharge Machine (TDM) provides an ideal solution for receiving bulk gypsum. Designed for efficiency and minimal civil work, the TDM can handle gypsum, limestone, FGD by-products, recycled gypsum board, and other raw materials, delivering them at a controlled rate of up to 1,200 tons per hour (t/h). Whether sourced from mines or transported by truck, barge, or railcar, this equipment ensures a smooth flow into your plant processes.

Bulk Material Handling: Dust-Tight and Efficient Systems

WTW Americas excels in handling gypsum and gypsum-derived materials with a focus on dust-tight, efficient systems that mitigate environmental and operational risks. Two of our flagship discharge machines—the Silo Discharge Machine (SDM) and Bunker Discharge Machine (BDM)—are engineered for reliability in handling abrasive and cohesive materials like FGD gypsum.

Silo Discharge Machine (SDM)

The SDM features a rotating discharge arm that extracts gypsum uniformly from storage silos, maintaining consistent flow and preventing common challenges like bridging and ratholing. Its flexibility, with diameters ranging from 1.5 to 6 meters and discharge rates up to 500 t/h, makes it a top choice for gypsum producers.

Bunker Discharge Machine (BDM)

The BDM is ideal for long stockpiles, hoppers, and large-scale storage solutions. It can reclaim gypsum or FGD by-products and transfers them efficiently to the next stage of processing. With rates ranging from 10 to 2,500 t/h, it offers unparalleled reliability for demanding applications. The BDM can even be used to blend materials.

Conveying Systems: Reliable Transport for Challenging Materials

Gypsum and FGD gypsum, often sticky and abrasive, require specialized conveying systems to maintain flow and reduce downtime. WTW’s TKF Chain Conveyors are engineered to handle these materials with ease, transporting up to 1,000 t/h. Chain conveyor have been used to unload rail cars, hoppers, silos, and truck dumps.

  • Dust-tight and explosion-proof: Minimizes exposure to hazardous dust and reduce fire risks.
  • Versatile operation: Can run horizontally, vertically, or on incline, adapting to your existing layout (retrofit).
  • Durable materials: High-quality alloy steel chains are treated for maximum wear resistance and longevity.


Our conveyors ensure gypsum is moved safely and efficiently between processing stages, from the mine to the production plant and beyond.

Comprehensive Solutions for Mining and Processing

WTW Americas supports gypsum production at every stage, starting at the mine. Our robust equipment is designed for direct installation at mining sites, handling gypsum ore as it’s extracted. From there, our machines can receive and transfer material to the plant with precision, reducing waste and optimizing throughput.

For wet, hot, or cohesive gypsum by-products, our solutions, such as the SDM and BDM, ensure reliable discharge and transfer even under extreme conditions. Sticky FGD gypsum, a critical by-product in the modern wallboard industry, is no challenge for our engineered systems.

Why Choose WTW Americas for Gypsum and Wallboard?

  1. End-to-End Expertise: From the mine to the final product, our systems cover every stage of gypsum handling
  2. Tailored Solutions: All equipment can be customized to meet the unique demands of your facility, or retrofit to fit into existing operations.
  3. Global Reach: With installations worldwide, our proven solutions are trusted by top gypsum producers.
  4. Repeat Customers: Most of our clients return for additional installations, highlighting our commitment to quality and performance.
  5. Specialized Materials Handling: We excel in handling sticky, wet, and abrasive materials like FGD gypsum.


By integrating WTW Americas’ advanced equipment into your gypsum and wallboard processes, you can achieve unparalleled efficiency, reduce operational risks, and ensure consistent product quality.

Contact us today to learn how we can help optimize your operations from the mine to the market.

Learn More

To learn more about WTW Americas equipment and experience in the Gypsum & Wallboard Industry email info@wtwamericas.com or call +1705-749-3544.

Contact Us

Email
info@wtwamericas.com

Phone
705-749-3544

Address
159 King St. Suite 208
Peterborough, ON, Canada
K9J 7H7

WTW Americas specializes in handling sticky, wet, hot (up to 750°C), abrasive and non-free-flowing bulk materials.

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