Abstract: This disclosure provides systems and methods for continuous wallboard manufacturing, and in particular methods that include measuring a wallboard width and edge profiles in a post-kiln stack of at least two wallboards or more with a laser scanner, preferably a two-dimensional (2D) laser scanner positioned at a distance from a post-kiln conveyor and performing a laser scan of the stack passing by on the post-kiln conveyor.

Abstract: A gypsum slurry mixer output canister is provided, including a canister housing having an upper end, an opposite lower end and defining a canister interior, a cover secured to the upper end, a slurry inlet in operational relationship to the upper end, a spiral block associated with the upper end, and having a helical flow surface depending into the interior. A flow distributor is secured to the lower end and is in fluid communication with the interior, and a slurry outlet is defined by the lower canister housing end.

Abstract: A gypsum slurry mixer output canister is provided, including a canister housing having an upper end, an opposite lower end and defining a canister interior, a cover secured to the upper end, a slurry inlet in operational relationship to the upper end, a spiral block associated with the upper end, and having a helical flow surface depending into the interior. A flow distributor is secured to the lower end and is in fluid communication with the interior, and a slurry outlet is defined by the lower canister housing end.

Abstract: Embodiments of a system and a method for detecting voids in a cementitious board can be used in connection with the manufacture of products, including cementitious board products such as gypsum wallboard, for example. Such systems and methods can be used to generate numerical void measurements based upon a series of thermal images obtained during the continuous manufacture of the cementitious board.

Abstract: Embodiments of a system and a method for determining an edge hardness value for a cementitious board can be used to effectively determine the hardness of the board after it has been made and dried at a predetermined location, such as, at a stacking station, for example. An actuator assembly can manipulate a punch such that the punch is inserted into one of the edges of one of the cementitious boards in the stacker in a controlled manner. A force gauge can be associated with the punch to measure the resistance force exerted by the cementitious board in response to the punch being inserted into its edge. The measured resistance force can be used to determine the edge hardness value.

Abstract: Embodiments of a system and a method for determining an edge hardness value for a cementitious board can be used to effectively determine the hardness of the board after it has been made and dried at a predetermined location, such as, at a stacking station, for example. An actuator assembly can manipulate a punch such that the punch is inserted into one of the edges of one of the cementitious boards in the stacker in a controlled manner. A force gauge can be associated with the punch to measure the resistance force exerted by the cementitious board in response to the punch being inserted into its edge. The measured resistance force can be used to determine the edge hardness value.

Abstract: An apparatus for production of a gypsum product is provided which comprises a conveyer comprising a conveyer belt and means for rotating the conveyer belt; means for forming a gypsum product; and at least one laser scanner positioned over the conveyer belt at the location where the scanner scans at least one edge of the gypsum product which is at least partially set; and the laser scanner is in communication with a processor. Methods for forming a gypsum product with the apparatus are provided as well.

Abstract: Embodiments of a system and a method for detecting voids in a cementitious board can be used in connection with the manufacture of products, including cementitious board products such as gypsum wallboard, for example. Such systems and methods can be used to generate numerical void measurements based upon a series of thermal images obtained during the continuous manufacture of the cementitious board.

Abstract: An apparatus for production of a gypsum product is provided which comprises a conveyer comprising a conveyer belt and means for rotating the conveyer belt; means for forming a gypsum product; and at least one laser scanner positioned over the conveyer belt at the location where the scanner scans at least one edge of the gypsum product which is at least partially set; and the laser scanner is in communication with a processor. Methods for forming a gypsum product with the apparatus are provided as well.