How are PVC Decorative Gypsum Ceiling Boards Produced?
PVC decorative gypsum ceiling board (PVC laminated gypsum board) is a composite panel made by first producing a paper-faced gypsum board base, then laminating a PVC decorative film onto its surface via hot or cold pressing. The whole process is completed on an automatic production line, divided into two main stages: gypsum board base production and PVC film lamination.
1. First Stage: Gypsum Board Base Production
1.1 Raw Material Mixing and Slurry Preparation
Main materials: building gypsum powder (plaster of Paris, CaSO₄·½H₂O), upper and lower protective paper
Additives: retarder, accelerator, water reducer, foaming agent, starch, glass fiber (for toughness, weight reduction and crack resistance)
Process: gypsum powder + water + additives → stirred into uniform gypsum slurry
1.2 Continuous Forming
The lower protective paper is conveyed continuously, and the slurry is evenly spread on it
The upper protective paper covers the slurry, then pressed to a set thickness (normally 8.5/9.5/12 mm) by a roller forming machine
The board enters the solidification zone, where gypsum hydrates and crystallizes to gain initial strength
1.3 Cutting and Drying
Cut to standard size (usually 1220×2440 mm)
Sent into a drying kiln to reduce moisture content to ≤1% for better strength and stability
1.4 Edge Trimming and Quality Inspection
Trim and chamfer four edges for easy installation
Inspect flatness, thickness and strength; qualified boards are stored for lamination
2. Second Stage: PVC Film Lamination
2.1 Base Board Pretreatment
Dust removal, degreasing and sanding to ensure a clean and flat surface
Apply special environmental adhesive (water-based polyurethane or acrylic adhesive) evenly
2.2 PVC Film Preparation
Use PVC decorative film (0.08–0.15 mm thick) with wood grain, stone pattern, solid color or embossed texture
Unroll, correct deviation and preheat the film (40–60°C) to improve adhesion
2.3 Hot or Cold Press Lamination
Hot pressing (mainstream): Gypsum board and PVC film go into a hot press at 100–130°C under 0.3–0.5 MPa for 10–30 seconds to cure the glue
Cold pressing: Laminated at room temperature under high pressure, suitable for heat-sensitive films
2.4 Cooling and Setting
Cool quickly by air or cooling rollers to avoid wrinkling or delamination
The board cools naturally to room temperature for full curing
2.5 Cutting and Finished Products
Cut to common ceiling sizes: 600×600 mm, 595×595 mm, etc.
Edge trimming, deburring and surface protection
Final inspection (no bubbles, delamination or pattern defects) → packaging and warehousing
3. Key Production Requirements
Gypsum base: controlled density, glass fiber reinforcement, sufficient drying
Lamination: uniform glue coating, stable temperature and pressure, accurate film alignment
Environmental protection: adhesive and PVC film meet low-formaldehyde or E0 emission standards
How are PVC Decorative Gypsum Ceiling Boards Produced?
PVC decorative gypsum ceiling board (PVC laminated gypsum board) is a composite panel made by first producing a paper-faced gypsum board base, then laminating a PVC decorative film onto its surface via hot or cold pressing. The whole process is completed on an automatic production line, divided into two main stages: gypsum board base production and PVC film lamination.
1. First Stage: Gypsum Board Base Production
1.1 Raw Material Mixing and Slurry Preparation
Main materials: building gypsum powder (plaster of Paris, CaSO₄·½H₂O), upper and lower protective paper
Additives: retarder, accelerator, water reducer, foaming agent, starch, glass fiber (for toughness, weight reduction and crack resistance)
Process: gypsum powder + water + additives → stirred into uniform gypsum slurry
1.2 Continuous Forming
The lower protective paper is conveyed continuously, and the slurry is evenly spread on it
The upper protective paper covers the slurry, then pressed to a set thickness (normally 8.5/9.5/12 mm) by a roller forming machine
The board enters the solidification zone, where gypsum hydrates and crystallizes to gain initial strength
1.3 Cutting and Drying
Cut to standard size (usually 1220×2440 mm)
Sent into a drying kiln to reduce moisture content to ≤1% for better strength and stability
1.4 Edge Trimming and Quality Inspection
Trim and chamfer four edges for easy installation
Inspect flatness, thickness and strength; qualified boards are stored for lamination
2. Second Stage: PVC Film Lamination
2.1 Base Board Pretreatment
Dust removal, degreasing and sanding to ensure a clean and flat surface
Apply special environmental adhesive (water-based polyurethane or acrylic adhesive) evenly
2.2 PVC Film Preparation
Use PVC decorative film (0.08–0.15 mm thick) with wood grain, stone pattern, solid color or embossed texture
Unroll, correct deviation and preheat the film (40–60°C) to improve adhesion
2.3 Hot or Cold Press Lamination
Hot pressing (mainstream): Gypsum board and PVC film go into a hot press at 100–130°C under 0.3–0.5 MPa for 10–30 seconds to cure the glue
Cold pressing: Laminated at room temperature under high pressure, suitable for heat-sensitive films
2.4 Cooling and Setting
Cool quickly by air or cooling rollers to avoid wrinkling or delamination
The board cools naturally to room temperature for full curing
2.5 Cutting and Finished Products
Cut to common ceiling sizes: 600×600 mm, 595×595 mm, etc.
Edge trimming, deburring and surface protection
Final inspection (no bubbles, delamination or pattern defects) → packaging and warehousing
3. Key Production Requirements
Gypsum base: controlled density, glass fiber reinforcement, sufficient drying
Lamination: uniform glue coating, stable temperature and pressure, accurate film alignment
Environmental protection: adhesive and PVC film meet low-formaldehyde or E0 emission standards
