Gypsum industry news

US: CertainTeed Gypsum has received the 2023 Better Project Award from the Department of Energy for the company’s smart energy management system at its Buchanan wallboard plant in New York state. The system at the plant, which was designed in-house and consists of over 180 energy meters, allows the staff to track and contextualise energy data, forecast future energy use and tackle actual losses once identified. Within the first three months of installation, the system helped identify several opportunities to reduce energy usage and enabled the plant team to scope process changes and projects to address them. The subsidiary of Saint-Gobain now plans to deploy similar technology at sites throughout North America.

Jay Bachmann, Vice President and General Manager of CertainTeed’s Interior Product Group, said “In a dynamic, continuous production facility like our Buchanan plant, it is essential to have real-time, in-depth data that can help us reduce our energy consumption, and our smart energy management system does just that.” He thanked workers at the Buchanan plant for their efforts.

The Better Project awards recognise manufacturers who improve energy efficiency and competitiveness in the industrial sector. To be considered for an award, projects must deliver significant waste or energy savings and must be discreet, innovative, and replicable in similar industrial facilities.

Canada: CertainTeed Canada’s Delta wallboard plant in Vancouver has recycled over 1Mt of gypsum. The unit achieved this breakthrough in collaboration with New West Gypsum Recycling (NWGR). CertainTeed Canada chief executive officer Julie Bonamy Racine, Delta Plant Manager Richard Sebastianelli and NWGR Vice President Richard McCamley all attended a celebration event held at the plant.

Bonamy said, “Surpassing 1Mt of recycled gypsum returned to production is an important milestone, which demonstrates Saint-Gobain and CertainTeed Canada’s commitment to sustainability and minimising our environmental footprint.” She added “Thank you to the provincial government of British Columbia and NWGR for your important partnerships and congratulations to our entire Vancouver team for your hard work to make this accomplishment a reality.”

US: CertainTeed has updated its visual branding, including its logo. The new design was officially launched at the International Builders’ Show that took place in Las Vegas from late January 2023. The light building materials producer says that the exercise “represents a major paradigm shift for the manufacturer – reinforcing its customer-focused, comprehensive offering of light and sustainable building solutions and systems.”

CertainTeed’s chief executive officer Mark Rayfield said “As a leader at the forefront of the building sector, we recognised an opportunity to evolve how our customers specify our products." He added, "We're taking 'one-stop shop' to the next level by serving as a preferred source for cohesive systems and complementary products that not only help builders grow their reputation, but make it easier than ever to deliver on what matters most: performance, sustainability, and longevity."

The company says that the new visual identity is inspired by the creative ritual of reviewing and selecting materials in the early stages of construction or remodeling. Logo details, such as the cartouche, borrowed from the logo of parent company Saint-Gobain, serve as a nod to their connection, while the interlocking pattern acknowledges CertainTeed as an interdependent collective of connections - in its work, its communities, and the planet.

Canada: CertainTeed Canada has welcomed the Canadian International Trade Tribunal's ruling in favour of six provinces and territories' anti-dumping measures on imports of gypsum wallboard. The tribunal found that imports of gypsum wallboard from the US threatened material injury to the domestic industries of Alberta, British Columbia, Manitoba, Northwest Territories, Saskatchewan and Yukon.

CertainTeed Canada chief executive officer Julie Bonamy said "CertainTeed Canada is committed to free and fair trade; we have helped shape the Canadian building products industry for more than 80 years." Bonamy concluded "We are committed to supporting our customers and employees through our facilities in Vancouver, Calgary and Winnipeg."

US: Saint-Gobain subsidiary CertainTeed's Buchanan gypsum wallboard plant in New York has successfully participated in a gypsum wallboard recycling pilot. Together with contractors Structure Tone and Cooper Recycling, it processed 20t of gypsum from waste wallboard in its gypsum wallboard production.

CertainTeed interior products vice president and general manager Jay Bachmann said "For us to achieve our sustainability goals, we must change the way we think. By partnering with organisations in the community like Cooper Recycling and Structure Tone, we can get there faster." Bachmann continued, "As the only gypsum manufacturing plant in New York, our colleagues in Buchanan were able to create a true circular economy. From the creation of drywall products to construction, to processing scraps and back into drywall production, the material is continuously used and never leaves the state. This maximises our company's positive impact while working to minimise our environmental footprint. Our Buchanan plant has increased our capacity to reuse recycled material, and we look forward to growing this successful pilot into a long-term programme, while working with builders and recyclers across the state. Partnering with CertainTeed, New York builders have the opportunity to not only reduce waste at their job sites, but also gain Leadership in Energy and Environmental Design (LEED) points on their projects."

The Buchanan plant joins CertainTeed's units at Nashville in Arkansas and Palatka in Florida in supporting the company's circular economic efforts in the US. The Nashville plant commissioned a 65,000t/yr line in May 2022, while the Palatka plant increased the recycled content of its wallboard by 18,000t/yr in August 2022. The Palatka plant plans to install a new 100t/hr Rotochopper grinding unit to replace its existing trommel machine in its reclaim processing and screening operations.

Canada: Saint-Gobain has named Julie Bonamy Racine as the chief executive officer (CEO) of its subsidiary CertainTeed Canada. She succeeds Richard Juggery, who led the company for four years before being named CEO of Saint-Gobain Benelux in July 2022. She will also be CertainTeed Canada's first female CEO.

Bonamy previously worked as the CEO of Saint-Gobain Malaysia, Singapore and Indonesia. She joined the company in 2017 in Paris as Group Vice President, Strategy & Planning. Earlier in her career, Bonamy worked in the public sector, most recently as an adviser for the budget and digital sector for the Office of the French Minister for the Economy. She is a graduate of the Paris Institute of Political Studies (IEP de Paris) and the National School of Public Administration (Ecole Nationale d'Administration).

Earlier this month the German Gypsum Association (GIPS) gave its approval for an inventory of natural gypsum deposits in Germany that was presented at the Conference of Economics Ministers that took place in early July 2022. The Federal Commission on Geosciences (BLA-GEO) had previously been given the job of taking an inventory of deposits and this was then put in front of the policy makers. The association’s stance was all about securing future supplies. In its view there will be no large-scale alternatives to natural gypsum supplies in the foreseeable future due to low recycling rates and falling production of flue gas desulfurisation (FGD) gypsum as coal power plants are shut down. So a list of where natural gypsum might be found is the start of conversations about which ones might be mined. Readers who are interested can download the inventory of German gypsum deposits here.

Security of supply of raw materials has been in the air since the end of the coronavirus lockdowns started to cause supply chain disruption around the world and the Russian invasion of Ukraine further exacerbated this and rocked energy markets. Part of the reaction to this new reality could be seen in a conference that the Federal Institute for Geosciences and Natural Resources (BGR) and the German Resource Research Institute (GERRI) ran, also in early July 2022. The state of German gypsum supplies was presented at this event too. The BGR-GERRI conference came up with a ten-point plan to strengthen the supply of raw material. Some of these recommendations were to grow domestic raw material extraction, expand recycling and the circular economy and keep supply chains closer internationally, ideally within Germany and Europe.

A focus on gypsum supplies isn’t restricted to Germany though. The issue arose in late July 2022 during an earnings call for US-based Eagle Materials’ first quarter results. These kinds of questions from analysts about supply of raw materials are common for a public company but it reinforces the general declining trend around the world of synthetic gypsum supplies. Craig Kessler, the chief financial officer of Eagle Materials, mentioned that a scarcity of synthetic gypsum might be creating cost pressures for other gypsum wallboard producers. Although he was quick to describe his company as a “natural gas or natural gypsum oriented business.” The wider picture in the US is that the ratio of natural to synthetic gypsum production has grown over the last decade. United States Geological Survey (USGS) data shows that it was 37% / 49% in 2011 compared to 53% / 32% in 2021, with the remainder imported in each year.

One more point to make here is that many of the new gypsum wallboard plant projects announced in the over the last few months have involved recycling in one form or another. For example, Siniat’s forthcoming wallboard plant in Bristol in the UK aims to achieve 30% post-consumer gypsum recycling. CertainTeed’s current upgrade plans for its Palatka plant in Florida are also recycling-based. Similarly, the subsidiary of Saint-Gobain also completed an upgrade in June 2022 to allow more recycling at its Nashville plant in Arkansas.

Finally, some of the thinking in Germany and elsewhere has been influenced by the current geopolitical situation in Ukraine. However, one potential consequence of prolonged disruption to European energy markets could be a delay to the decline of coal power plants as plant lifespans are elongated or even new ones built. This in turn could mean more synthetic gypsum supplies in Europe in the short to medium term. How all of this plays out in the placement of new gypsum wallboard plants in Europe over the next few years will be interesting to observe.

US: CertainTeed plans to spend US$1.1m towards installing recycling equipment at its Palatka gypsum wallboard plant in Florida. The upgrade will increasing the recycled content of its wallboard products manufactured at the unit by 18,000t/yr while also reducing the site’s CO₂ emissions by 2260t/yr.

The new recycling equipment at the Palatka plant will work by grinding the waste gypsum and waste paper down into fine particles, allowing the plant to capture and internally recycle the materials, which are sorted and then reintroduced to the production process at the plant. The kit will be powered by electricity and will replace older machines currently powered by diesel, lowering the plant’s Scope 1 Emissions from its operations. Additionally, by consuming more recycled gypsum, the plant will become less reliant on feedstock that is shipped to the site from external sources, allowing the unit to also reduce Scope 3 Emissions associated with transporting the feedstock.

Jay Bachmann, the Vice President and General Manager of CertainTeed Interior Products Group, said, “The new technology in Palatka will allow us to increase the recycled content in our products, reduce our carbon CO₂ at the plant, and strengthen our operations at a time of unprecedented consumer demand for gypsum wallboard in the south-eastern US.”

The investment at the Palatka plant follows similar investments that will increase the recycled content of wallboard made at CertainTeed’s wallboard plants in Silver Grove in Kentucky and Nashville in Arkansas. Parent company Saint-Gobain continues to roll out its global ‘Grow and Impact’ strategy, which includes reducing waste and increasing recycling efforts at its manufacturing sites.

US: CertainTeed has completed an upgrade to the grinding control technology at its gypsum wallboard plant at Buchanan in New York state. The new variable frequency drive at the site can vary the speed at which raw gypsum is ground and save energy accordingly. It is expected to reduce the plant’s energy consumption by nearly 700,000kWh/yr. Other recent sustainable upgrades at the plant include the installation of 2.4MW solar array on its roof in 2018.

Parent company Saint-Gobain North America has announced a number of sustainability-focused upgrade projects at its wallboard plants so far in 2022. These include switching to renewable energy at its Montreal plant in Quebec, using recycled materials at its Nashville plant in Arkansas and installing a waste heat recovery system at its Vancouver plant in British Colombia.

US: CertainTeed has completed a US$1.3m upgrade to its Nashville wallboard plant in Arkansas to use recycled waste gypsum and paper. The plant will reuse 65,000t/yr of waste materials generated from the production process. The company plans to increase the amount of recycled materials in its gypsum wallboard in the future.

“In Nashville and at our manufacturing sites around the world, we remain laser-focused on reducing waste, reducing our consumption of natural resources, and increasing recycling and circularity throughout our value chain,” said Jay Bachmann, Vice President and General Manager of CertainTeed Gypsum.