Gypsum Wallboard is made:
is manufactured from gypsum mined from the ground. Once the gypsum
is shipped to the plant it is then crushed and mixed with water
and other ingredients to make a "slurry," or paste. This
slurry is spread between two sheets of paper to be formed into wallboard.
This sheet travels 600-800 feet on conveyors to harden before it
is cut. Once the wallboard is cut into panels it is placed in the
kiln to dry. After it leaves the dryer, the wallboard is bundled,
stacked and shipped out to retail stores.
When the Gypsum is being crushed, it creates a powdery dust and
settles on machinery. A Plant Supervisor stated that they produce
1.2 million sq ft of product build-up/day.
is mixed with liquid and formed into wallboard, some of the compound
will leak out and onto the conveyor rollers, bearings and motors.
The compound will then dry and form cement like characteristics
causing extreme wear and contamination on these parts and sometimes
jams, which cause back-ups quickly.
Hand chipping and sometimes using a pressure washer. The pressure
washer does nothing to eliminate the problem because one is
just adding water back into the equation and the problem starts
all over again.
Ice blast cleaning versus current cleaning method:
Dry ice blasting drastically reduces clean-up time.
Dry ice does not soften the mixture once it has hardened and
adhered to the rollers, bearings, and motors.
Anticipate using their dry ice blast machine on a daily basis
to control dust and product contamination.
The customer eagerly awaited the arrival of their AeRO
75 with a variety of nozzles. The plant supervisor told us that
he tracked the shipment online up until the day of its arrival!