Gypsum Plaster Board

Detailed Project Report, Profile, Business Plan, Industry Trends, Market Research, Survey, Manufacturing Process, Machinery, Raw Materials, Feasibility Study, Investment Opportunities, Cost and Revenue, Plant Economics, Production Schedule, Working Capital Requirement, Plant Layout, Process Flow Sheet, Cost of Project, Projected Balance Sheets, Profitability Ratios, Break Even Analysis

Gypsum board (also known as plasterboard, wallboard, gypsum panel, sheet rock, or Drywall) is a panel made of calcium sulfate dihydrate (gypsum) with or without additives and normally pressed between a facer and a backer (typically thick sheets of paper). It is used to make interior walls and ceilings. The plaster is mixed with fibre (typically paper and/or fibreglass), plasticizer, foaming agent, and various additives that can decrease mildew, increase fire resistance, and lower water absorption.

Gypsum building materials are used in all construction types (residential, non-residential, new or refurbished), ranging from complex high-tech systems to easy to install products adapted for use by the general public.

Gypsum board is widely used for internal walls and ceilings by the construction industry, and is a material of growing importance in the do it yourself sector. Gypsum board is also a common fire barrier used in house and general building construction. Commonly gypsum boards used in walls and ceilings, in moist areas, in exterior applications, for fire resistance and area separation and special systems. Gypsum plaster board (GPB) popularly known as gypboard, is a low cost, light weight construction material made from aerated gypsum plaster and produced in varying thicknesses suitable for different applications. Gypsum is an important raw material used in the manufacture of cement. Consumption of gypsum varies from 2 to 6% in different plants depending upon the quality of clinker. India has good reserves of natural gypsum, mainly concentrated in Rajasthan, Gujarat and Tamil Nadu. Besides, a number of chemical industries obtain gypsum as a byproduct in the form of phospho gypsum. The chemical gypsum can be utilised as a whole or as part substitute to natural gypsum. Many cement plants, which are located near the source of phosphogypsum are using this substitute product.

Types of Gypsum Plaster Board

Gypsum plaster boards are classified according to their use. Gypsum wall board has a face to which decoration may be applied. There are five types of gypsum board product that are considered standard. Innovation has created several new products now available.

• Standard Gypsum Board: Regular core, Flexible board, Type “X”- fire resistant, Moisture resistant and Plaster baseboard.

• Specialty Gypsum Board: Interior ceiling board, Mold & Moisture resistant, Shaft liner, Abuse resistant and Impact resistant.

The global gypsum market is valued at $1.49 billion in 2016, equivalent to 252 million tonnes, with 33.3% and 60.9% being consumed in the plasterboard and cement industries, respectively.

The gypsum market is forecast to grow at a CAGR of 9.9% to reach nearly $2.4 billion by 2018 and $3.8 billion by 2026.

The plasterboard market size is estimated to grow from USD 18.07 Billion in 2016 to USD 23.85 Billion by 2021, at a CAGR of 5.7% from 2016 to 2021. The base year considered for the study is 2015 and the market size is projected from 2016 to 2021.

The global gypsum board market was valued at $22.6 bn in 2016 and is forecast to grow at a steady CAGR of 8.2% between 2017 and 2024, culminating in 2024 global sales of $42.6 bn.

Global gypsum market demand 10,700.0 million square meters in 2014 and is expected to reach 15,804.7 million square meters by 2022, growing at a CAGR of 5.1% from 2015 to 2022.

The global demand for drywall will approach 10.7 billion square meters by 2016, growing by some 8.5% annually.

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Assumptions for Profitability workings	Plant Economics
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Other Fixed Assets Furniture & Fixtures Pre-operative and Preliminary Expenses Technical Knowhow Provision of Contingencies
Working Capital Requirement Per Month Raw Material Packing Material Lab & ETP Chemical Cost Consumable Store
Overheads Required Per Month And Per Annum Utilities & Overheads (Power, Water and Fuel Expenses etc.) Royalty and Other Charges Selling and Distribution Expenses
Salary and Wages	Turnover Per Annum
Share Capital Equity Capital Preference Share Capital
Annexure 1:: Cost of Project and Means of Finance
Annexure 2:: Profitability and Net Cash Accruals Revenue/Income/Realisation Expenses/Cost of Products/Services/Items Gross Profit Financial Charges Total Cost of Sales Net Profit After Taxes Net Cash Accruals
Annexure 3 :: Assessment of Working Capital requirements Current Assets Gross Working. Capital Current Liabilities Net Working Capital Working Note for Calculation of Work-in-process
Annexure 4 :: Sources and Disposition of Funds
Annexure 5 :: Projected Balance Sheets ROI (Average of Fixed Assets) RONW (Average of Share Capital) ROI (Average of Total Assets)
Annexure 6 :: Profitability ratios D.S.C.R Earnings Per Share (EPS) Debt Equity Ratio
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Annexure 8 to 11:: Sensitivity Analysis-Price/Volume Resultant N.P.B.T Resultant D.S.C.R Resultant PV Ratio Resultant DER Resultant ROI Resultant BEP
Annexure 12 :: Shareholding Pattern and Stake Status Equity Capital Preference Share Capital
Annexure 13 :: Quantitative Details-Output/Sales/Stocks Determined Capacity P.A of Products/Services Achievable Efficiency/Yield % of Products/Services/Items Net Usable Load/Capacity of Products/Services/Items Expected Sales/ Revenue/ Income of Products/ Services/ Items
Annexure 14 :: Product wise domestic Sales Realisation	Annexure 15 :: Total Raw Material Cost
Annexure 16 :: Raw Material Cost per unit	Annexure 17 :: Total Lab & ETP Chemical Cost
Annexure 18 :: Consumables, Store etc.,	Annexure 19 :: Packing Material Cost
Annexure 20 :: Packing Material Cost Per Unit	Annexure 21 :: Employees Expenses
Annexure 22 :: Fuel Expenses	Annexure 23 :: Power/Electricity Expenses
Annexure 24 :: Royalty & Other Charges	Annexure 25 :: Repairs & Maintenance Exp.
Annexure 26 :: Other Mfg. Expenses	Annexure 27 :: Administration Expenses
Annexure 28 :: Selling Expenses	Annexure 29 :: Depreciation Charges – as per Books (Total)
Annexure 30 :: Depreciation Charges – as per Books (P & M)	Annexure 31 :: Depreciation Charges - As per IT Act WDV (Total)
Annexure 32 :: Depreciation Charges - As per IT Act WDV (P & M)	Annexure 33 :: Interest and Repayment - Term Loans
Annexure 34 :: Tax on Profits	Annexure 35 ::Projected Pay-Back Period And IRR