Gypsum industry news

France: Knauf France aims to use 35% recycled gypsum at its Fos-sur-Mer gypsum wallboard plant in Bouches-du-Rhône, with an interim target of 10% by 2025. The company inaugurated the 30Mm²/yr plant in March 2024. It is currently using its own offcuts in production, but has a dedicated silo in which to also store gypsum from other sources in future. The plant’s wallboard requires 15 – 20% less energy than is used at a ‘traditional’ Knauf plant through the use of a vertical mill and high-efficiency driers. Its water use is optimised by drawing it in batches.

Les Cahiers Techniques News has reported that general manager Christine Muscat said "The ramp-up is gradual and we are at a third of production capacity, which we plan to reach fully in the second half of 2025."

Ukraine: Saint-Gobain Building Products Ukraine, an importer and distributor of gypsum products in Ukraine, has inaugurated its new 60,000t/yr Ivano-Frankivsk plaster plant. LIGA Business News has reported that the plant cost €11m, will employ 50 people and produce plaster mixes for sale under the Rigips brand.

Saint-Gobain Poland and Ukraine president Joanna Czynsz-Piechowiak said "The opening of the first Saint-Gobain plant in Ukraine is an important step for our company. Even in difficult times, we continue to move forward and invest in the future.”

Canada: CGC is holding a series of meetings between 5 November and 3 December 2024 in which to discuss the possible impacts of its upcoming Wheatland wallboard manufacturing plant in Alberta with the local community. The Canadian Press News has reported that 100 jobs will be created at the plant. Hiring will commence in early 2025, prior to the plant’s commissioning later in 2024.

Plant manager Duane Van Douren said "We are focused on making sure that the communities around us are well aware of who CGC is, and providing information about our plant and the build that is happening on our site right now, which started back in early spring 2024 and is progressing very quickly.”

CGC reportedly told the Toronto Sun newspaper that current anti-dumping measures have reduced the availability of gypsum wallboard in Canada by 65Mm² cumulatively since 2016. As a result, extant gypsum wallboard stocks are sufficient only to build 220,000 homes.

France: Knauf France’s Fos-sur-Mer gypsum wallboard plant, which it inaugurated earlier in 2024, will receive 300,000t/yr of Spanish gypsum for use as raw materials, the Le Marin newspaper has reported. The plant is situated behind Sea-Invest Group’s mineral terminal at the port of Fos-sur-Mer. It has begun receiving its gypsum in regular shipments of 14,000t from the port of Garrucha, Spain.

Egypt: Knauf Egypt is planning to invest US$86m in the construction of its upcoming third gypsum plant. Al Mal News has reported that the unit will double Knauf Egypt’s total production capacity of products including gypsum wallboard. It will raise the company’s installed gypsum wallboard capacity to 60Mm²/yr. The upcoming plant will serve both domestic and export markets. Knauf Egypt currently sells its wallboard in 13 countries, including Greece, Morocco and South Africa.

Brazil: Trevo Drywall plans to invest US$25m in an expansion to its Juazeiro do Norte gypsum wallboard plant, scheduled for commissioning in 2025. This will initially raise the plant's capacity to 20Mm²/yr, and subsequently to 30Mm² by 2026. The expanded plant will be equipped with a new enterprise resource planning system to assist with the increased automation of its operations. Trevo Drywall also plans to build a second plant, the location of which is subject to on-going evaluations.

Chief financial officer Gabriel Rodrigues Granja de Alencar said "We will also strengthen compliance tools and soon announce the creation of a people development programme."

China: Grenzebach BSH, a leading global supplier of process and production technologies, has received a ‘significant’ order from XINFA Group for the supply of two gypsum wallboard lines to XINFA’s existing production plant at its headquarters in Chiping-Liaocheng, Shandong Province. XINFA, one of the world’s leading aluminium manufacturers, will expand its gypsum wallboard production capacity to approximately 830,000m²/day (273Mm²/yr). This will make its plant the world’s largest, and is the second time that XINFA has relied on Grenzebach’s expertise.

XINFA Group runs its own coal-fired power plants to cover the high electricity requirements of its aluminium plants. Flue gas desulphurisation (FGD) gypsum is produced during the purification of the exhaust gases. Using Grenzebach equipment, XINFA has been able to recycle this gypsum to produce gypsum wallboard since 2021.

Robert Brier, CEO of Grenzebach BSH, said “The project demonstrates how close we are to our customers and our competitiveness, as well as our innovative strength in supplying manufacturing plants with a focus on sustainability aspects. By recycling the FGD gypsum, we are supporting our customer’s circular economy, while at the same time using the electricity generated and the waste heat from the power plants to operate the gypsum dryers and systems.”

China: BNBM says that despite issues with the domestic real estate sector demand for wallboard had ‘remained relatively stable’ in the first half of 2024. It attributed this to retrofit activity, government changes to the housing market and infrastructure projects. Its operating income grew by 19% year-on-year from US$1.60bn in the first half of 2023 to US$1.91bn in the first half of 2024. Sales volumes of gypsum wallboard rose by 7% from 1092Mm² to 1168Mm². The company added that overseas sales had grown in the reporting period and its Thailand Gypsum Board project had started construction.

CNBM’s New Materials business division, comprising BNBM and other subsidiaries, saw its sales grow slightly but profit fell. However, CNBM’s group revenue and gross profit fell significantly due to the poor performance of its heavy building materials division.

Peru: France-based Saint-Gobain has submitted a technical report for a proposed upgrade to its Huachipa facility. The project aims to optimise production and secure compliance with environmental regulations. Noticias Financieras News has reported that the work will cost US$259,000 and take up to eight weeks complete.

Australia: Saint-Gobain subsidiary CSR plans to expand its Welshpool gypsum wallboard plant in Western Australia. The producer plans to upgrade the plant’s production line and expand warehouses that serve it and the neighbouring Bradford building materials plant. CSR said that the upgrade to the Welshpool wallboard plant will reduce its consumption of natural gas and electricity and facilitate its transition to alternative fuels or electricity.

CEO Paul Dalton said "This significant investment will make Welshpool safer and more sustainable, increase capacity and improve productivity and cost efficiency, all while removing risk from our supply chain.”