Gypsum industry news

Belgium: Etex’s revenue rose by 16% year-on-year to Euro1.79bn in the first half of 2022 from Euro1.46bn in the same period in 2021 on a like-for-like basis. Its earnings before interest, taxation, depreciation and amortisation (EBITDA) grew by 20% to Euro319m from Euro266m.

Bernard Delvaux, the chief executive officer of Etex said, “In the first half of 2022, like many other industrial players, Etex had to cope with significant raw material and energy price inflation in the context of post-Covid-19 disruptions, volatility and the war between Russia and Ukraine. To face this situation, we had to implement a number of price increases. Our volumes and margins have been impacted, but these measures allowed us to achieve a positive evolution of both top line and bottom line.”

The company’s Building Performance division reported slightly lower gypsum wallboard sales volumes despite delivering a 16% increase in revenue to Euro1.23bn. The group also created an Insulation division in May 2022 following the completion of its acquisition of URSA.

US: Gypsum wallboard producers sold 1.32Bnm² of gypsum wallboard in the first half of 2022, a similar amount to that in the first half of 2021. Total supply of gypsum fell by 2% to 20.3Mt from 20.8Mt. This was due to decline in mined gypsum supplies, although imports rose and synthetic gypsum supply remained the same.

Exports of gypsum wallboard fell slightly year-on-year to 18.6Mm² throughout the second quarter of 2022, up by 10% year-on-year from 16.9Mm². Canada received 95% of US gypsum wallboard exports. The US imported 22.9Mm² of gypsum wallboard from eight countries. The figure corresponds to an increase of 10% year-on-year and 3% quarter-on-quarter. Mexico supplied 91% of US gypsum wallboard imports, followed by Canada with 8%.

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.

China: BNBM’s operating revenue grew by 2.4% year-on-year to US$1.50bn in the first half of 2022 from US$1.46bn in the same period in 2021. Its net profit fell by 11% to US$237m from US$266m. Parent company CNBM reported that its sales volumes of gypsum wallboard fell by 5.8% to 1.09Bnm² from 1.16Bnm2. It said that continued coronavirus lockdowns and problems in the real estate market had affected market demand. It added that the price of raw materials and energy had also risen, leading to increased production costs and mounting product prices.

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.