Monitoring & metering
SAINT-GOBAIN LOWERS CARBON FOOTPRINT OF PLASTERBOARD
The manufacture of dry wall, also known as plasterboard, relies heavily on precise moisture control, so accurate temperature and humidity measurements during the drying process are essential. However, process conditions change significantly within a short period of time and this can be challenging for many sensors on the market. Looking for ways to enhance the efficiency and sustainability of this process, engineers at Saint-Gobain in France have worked closely with Vaisala to develop monitoring solutions that help optimise plasterboard quality, improve efficiency, save energy and improve sustainability.
M
any different industrial processes involve drying operations, and this is frequently the most energy-intensive stage of the process, so accurate
monitoring and control of drying can represent significant potential for improvement.
Dry wall has had an enormous effect on the global construction industry since it was first developed in the early 1900s. Lightweight, simple to fit, moisture, fire and mould resistant, and with good insulation properties, plasterboard has become the world’s most commonly used construction material for internal walls and ceilings, after concrete. Saint-Gobain is the worldwide leader in light and sustainable construction, with around 161,000 employees and over 1100 manufacturing facilities. As a signatory to numerous global sustainability initiatives, Saint-Gobain has committed to reach net-zero emissions by no later than 2050, and the company’s core purpose is to ‘Make the World a Better Home’ The development of Saint-Gobain’s gypsum brands began with the acquisition of the British Plaster Board company in 2005. Today, the company is keenly focused on the improvement of plasterboard manufacturing – improving product quality and lowering carbon footprint. Saint-Gobain has three controls during the drying process – temperature, air flow and air humidity. However, the accurate management of these controls depends on accurate measurements on the air inside the dryers.
THE MEASUREMENT CHALLENGE Plasterboard is manufactured by pouring gypsum slurry onto carton paper, drying the slurry and adding a second paper layer to form a ‘sandwich’ structure. The gypsum is cured and cut into panels
38 April 2026 Instrumentation Monthly
before being passed through drying ovens to obtain the correct moisture content. The whole process can take less than one hour, during which the product can be exposed to temperatures as high as 300°C, depending on the process, and the moisture content of the air varies considerably during the process. “These conditions present a significant challenge for sensors,” explains Jérôme Cantonnet, drying process team leader at Saint-Gobain. “We tried a number of different humidity and temperature sensor suppliers in the early days and found their products to be insufficiently accurate.
Saint-Gobain was one of the pioneers of dew point measurement in plasterboard drying. They chose dew point sensors because they provide an absolute measure of moisture in the air, unlike humidity which changes with temperature. Crucially, there are no similar dew point sensors on the market surviving high temperatures up to +350 °C. Saint- Gobain therefore established a relationship with Vaisala around 2010, working in partnership to adapt Vaisala’s dew point sensors for the specific requirements of their plasterboard application. For Saint Gobain, it is critically important to be
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