The well known insulation curing oven producer Münstermann made its first moves into the gypsum wallboard dryer sector in 2012. Here, the company’s Christian Raestrup discusses the company’s history, its gypsum activities and future aims...
Global Gypsum (GG): Please could you introduce the company Münstermann?
Christian Raestrup (CR): Münstermann was founded in north west Germany in 1845. The company has remained in family hands since then and is now owned by the sixth-generation, run by Frank Münstermann. It is one of the many ‘typical’ medium-sized companies that provide a strong backbone to the national economy here in Germany.
For many years Münstermann was a local metal works but it 1989 it moved to a new facility, our current location in Telgte, where it was able to expand its capabilities. This was mainly down to the initiative of Bernd Münstermann, the father of Frank. This included making full machines for a number of sectors. In the 1990s Münstermann moved into the construction materials business. This was spearheaded by a successful launch into the insulation sector, where the company is now a large and well regarded producer of curing ovens and forming sections for mineral and glass wool production lines. Today the company has 290 personnel and a turnover in the order of Euro50 - 60m per year.
GG: What about the global gypsum sector?
CR: Münstermann took its first steps into the gypsum wallboard dryer sector in the early 2010s. It represents a natural progression from our work in insulation, as both industries function as continous line processes that have similar layouts and share the need for thermal treatment solutions. The dryer is one of the most critical steps in the wallboard production process and so it makes sense to use the company’s extensive expertise in this field.
In actual fact, Münstermann’s first move into the gypsum sector was the launch of a dryer for gypsum blocks, manufactured for a Rigips factory in Switzerland. This is our own design and we continue to supply such dryers to the market.
Shortly after the launch of the block dryer, Münstermann started to offer analysis services for wallboard dryers. These analyses are very thorough indeed. Our drying process experts, some of whom have >30 years of experience, will visit the wallboard plant and take very detailed measurements of all relevant process parameters. We can also carry out sophisticated tests in Telgte to complement the on-site studies. The drying experts will also discuss the dryer with the local plant staff to properly assess the pre-existing situation, their aims and how best we can improve the process. Münstermann then manufactures all relevant parts to improve the existing dryer based on the studies and discussions.
GG: What are the most common requests?
CR: The most common aim is to improve the efficiency of the dryer, often connected to leaks. We also handle inefficiencies on the mechanical side.
Typical solutions may include high-efficiency leak-proof doors and seals and devices to adjust the gas flow for better heat distribution. Solutions may also include heat exchangers, ducting and other pieces of equipment.
GG: Can you provide an example?
CR: After the Global Gypsum Conference in Bangkok in 2016, we were invited to undertake some studies at a wallboard plant in south east Asia owned by the local market leader USG Boral. Before the visit, we sent out our questionnaires, which indicated some issues with dryer efficiency. We carried out a detailed temperature and pressure study of the individual dryer zones, the humidity profile and leakage out of the dryer. Based on our on-site discussions some adaptations were made to the exhaust airflow, which was lowered considerably. This already saved the plant significant energy and the payback time was very quick. Later on in the same project, we implemented some further changes to the mechanical parts of the dryer, including leak avoidance. This also gave further and immediate improvement to dryer performance. To give another example, we have carried out several rewarding projects with Knauf, the well known German building materials producer.
The most important part in such a case-study, is not the dryer, nor the solution to the issues that the dryer has. It is the discussion between the plant operator and Münstermann that makes a project successful. All wallboard dryers can be improved, but not without clear communication between the parties involved.
GG: How long does it take between the decision to install a retrofit solution to installation?
CR: I would not like to commit a numerical answer to that question. There are so many variables that project timelines vary immensely. How big is the project, both in terms of cost and equipment size? Where in the world is the wallboard plant and how is access to the site? Is the plant new or old? Is the communication between Münstermann and the client clear and concise? There are many other similar questions.
Overall, the methodology with which the project is carried out is a strength of Münstermann, as it is with so many German engineering companies. We ask exacting questions to properly assess the client’s needs. This way, Münstermann can be as efficient carrying out the project as the dryer will be at the end of the project!
GG: Where are the most gypsum dryer enquiries coming from at present?
CR: We receive enquiries concerning gypsum wallboard dryers from all over the world, usually via recommendation. However, there is also interest due to our expertise in the curing oven business. We see a tendency for some of our insulation clients to venture into gypsum materials. At the same time, some gypsum wallboard manufacturers are entering the insulation sector. For example, around a year ago, the Portuguese manufacturer of gypsum wallboard and other construction materials Gyptec Iberica installed a brand new glass wool line and launched Volcalis, a completely new brand of insulation material. We are really excited to accompany this partner with our technology and equipment, and we deeply appreciate the entrepreneurial commitment behind this move. Actually, we established initial contacts at the Global Gypsum Conference.
Of course, there is the technical overlap that I mentioned earlier, as the processes have things in common from a technical standpoint. This helps the manufacturer to learn the other process. The fortunes of the two materials are also linked in the construction market. When a project calls for gypsum wallboard, it is almost certain that insulation material will also be required in the same project. Lateral expansion between these two sectors provides a good way for producers to branch out while remaining in a market that they broadly understand. The world’s leading suppliers of construction materials have pursued this strategy for a long time.
GG: How will Münstermann develop its gypsum capabilities going forward?
CR: At present we have relatively few references in the gypsum sector but that is set to change in the future. We are developing our capabilities, with a view to producing our own Münstermann dryer in the near future. We are positioning the company on the market as turnkey supplier of the dryer. In this regard, we will take full responsibility for the material testing, design, engineering in Germany, construction at the customer site and commissioning of wallboard dryers.
On the retrofit side, we have some exciting opportunities in terms of automation in the coming years. Indeed, our automation department has been the fastest-growing department within the company for the past three years. It’s so dynamic that it’s becoming hard to hire enough automation experts to send out to all the automation jobs we’re undertaking! Münstermann is increasingly taking up more of the functions of a general contractor and so all projects are gaining size. On top of this, projects increasingly combine our transportation systems and air cleaning systems with our thermal treatment solutions.
As a result, needs relating to automation have risen sharply. The customers want to understand and monitor their processes ever more closely. The essential aims of our automation projects include: the automated description of production processes; monitoring of changes to the process and the quality of the product; Evaluation of process data; Recognition of mistakes and problems; Timely indication for necessary maintenance and correction measures; Making relevant data available for the process engineer. Such data is becoming a very important tool for our customers.
GG: Could a wallboard plant ever be run without humans?
CR: Technically yes. In the chemical industry there are already highly-automated plants with almost no workers present. However: What happens in case of unforeseen changes in the process, or a failure? Then process engineers will always be needed.
GG: What are the main opportunities for Münstermann over the next 5 - 10 years?
CR: One particularly strong opportunity is the increasing demand that many customers place on product quality. Münstermann aims to cooperate with customers that focus on high quality products, or want to diversify their product range from standard products into specialised products. In these processes, we can play out our competence as a designer and manufacturer of sophisticated drying technology. This plays into our strong capabilities in dryer efficiency and automation. Both contribute to ensuring consistent quality. Münstermann is chosen because its clients can make good products.
Another great opportunity is population growth in developing economies, which will maintain steady demand for building materials in general. At the same time, construction practices are gaining in complexity in these same markets, so demand for gypsum and insulation will remain stable or rise in the future.
GG: What are the largest threats?
CR: An essential risk is political instability and trade and tariff barriers, which could make activities difficult for our highly international company. There are also several low-level threats that are ongoing and that we have become used to and that characterise German industry in general. This includes competition from countries with lower cost manufacturing, the potential for intellectual property theft in some markets and competition in general. However, I think that Münstermann is not as threatened as some other companies in this field, as we know the areas we are involved in and liaise properly with the client.
As Frank Münstermann points out to us frequently in our sales team meetings and stated in an article a few years ago, any project is a two-sided story: it’s not just about Münstermann calculating and providing quotes. A successful project requires input from the client about its product, process and its aims for the project, and I think we’re doing quite well in this respect.
GG: Thank you for your time today.
CR: You are very welcome indeed!
