Raw Material Preparation and Dosing

The Heart of Gypsum Board Production: The Perfect Formula, High Precision

The secret to a high-quality, lightweight, and durable gypsum board lies in combining the right raw materials at the right time with the utmost precision. At IPS Makina, we design Raw Material Preparation and Dosing units—the most critical stage in gypsum board production—based on the zero-defect principle and advanced engineering standards.

We are not merely a supplier of machinery; we are a turnkey solution partner with complete mastery of the process’s chemistry, thermodynamics, and production dynamics. Thanks to the dosing systems we install, we ensure precise mixing ratios of calcined gypsum powder, water, foam, and special chemical additives, minimizing factory scrap rates while maximizing your production quality.

High-Precision Dosing Technology

In the production of gypsum board—a continuous process—even a momentary fluctuation in raw material feed can affect the quality of the entire sheet. To prevent this risk, IPS Makina dosing units utilize high-tech weighing belts and precise flowmeters that operate on the “Loss-in-Weight” principle.

Our systems, custom-engineered for your plant capacity (ranging from 5 million m² to 20 million m² annually), deliver every component in your recipe to the mixer simultaneously and with flawless stability.

Key Components of the Process

The system’s hardware and software infrastructure is configured to manage all dry and liquid additives in an integrated manner:

• Main Raw Material (Stucco) Feeding: Calcined gypsum powder is drawn homogeneously from specially designed silos and transferred to the main mixer without clogging or fluctuations.
• Dry Additive Dosing Stations: Dry components such as starch, accelerator (BMA), retarder, and fiberglass—which determine the strength and form of the gypsum board—are weighed using servo-motor-controlled augers and precise load-cell units.
• Liquid Additive and Water Automation: The incorporation of process water, silicone (for water-resistant green panels), and other liquid additives into the system via precision pumps and flow meters.
• Dynamic Foam Generator (Foam System): Production of foam—which is vital for lightening the gypsum board and creating the core’s porous structure—by mixing water and foam agent at optimal pressure, followed by direct injection into the mixer.

Smart Recipe Management with SCADA

When producing different types of panels (Standard, Water-Resistant, Fire-Resistant, etc.), your greatest need is the ability to switch between them quickly and without errors. IPS Makina’s advanced SCADA automation system stores multiple production recipes in its memory.

With a single click from the operator, the system automatically adjusts the stucco quantity, water-to-plaster ratio, and additive dosages according to the new panel standard. Real-time raw material consumption can be monitored on the screen, and precise historical data reports can be generated for cost-per-metric-ton analyses.

Why Choose IPS Makina Dosing Systems?

• Waste Minimization: Eliminates fluctuations found in traditional systems, preventing the waste of expensive chemical additives.
• Homogeneous Core Structure: Thanks to a consistent water-to-plaster ratio and stable foam injection, it creates a perfect plaster board core that does not explode in the drying oven or crumble during cutting.
• Uninterrupted Production (24/7): With vibration-equipped silo designs that prevent clogs and easily cleanable equipment geometry, it reduces your production line’s downtime to nearly zero.
• All of these precisely dosed raw materials are transferred to our high-speed, specially designed mixer (Pin Mixer) in the [Mixing and Forming] unit, which is the next and most dynamic stage of the process.