How to start Plaster of Paris (POP) Production

About one billion tons of gypsum deposits are spread over many sites in Nigeria. Plaster of Paris which is calcium sulphate with half molecule of water of crystallization (CaSo4. ½ H2 o) and hygroscopic characteristics obtained by duly calcined the raw material i.e. Gypsum (CaSo42H2o). It possesses outstanding property of setting and subsequent hardening when mixed with water.

Nigeria Company envisages the establishment of a plant for the production of plaster of Paris with a capacity of 600 tons per annum in Gombe State. Plastic of Paris is widely used in the manufacture of models in pottery industry, for making ornamental castings, plaster boards, for building decoration as wall plaster and floor cement and as dentist & orthopedic plaster. We basically concentrate on plaster of Paris for sceeding, decoration, molding and pottering.

The raw materials for manufacturing plastic of Paris otherwise known as POP cement is primarily Gypsum which occurs in commercial quantity in Kaduna, Adamawa, Taraba, Yobe, Borno, Gombe, Bauchi, Benue, Ogun, Sokoto, Edo, Kogi and Abia states. Gypsum deposits in Nigeria are in sixteen states (16 states) of the federation has a total estimated reserve of over 156.5 million metric tons. It was revealed that there could be much more reserve within these prospects to the depth of 100 meters if more surface area was considered, adding that the gypsum purity range between 67-95%. Our findings and research shows that large scale mining of these deposits would not be economically feasible due to the mode of occurrences and thickness of the gypsum, went further that the Nafada-Fika in Gombe State areas offer the best prospects in terms of extractable tonnages and over burden thickness to the limit of the work carried out with purity between 80-95%.

To install the boards after hardening, for a ceiling of concrete decking, the yarn is also mixed with a concentration of pop cement to form a strong adhesive (gum) between the concrete ceiling and the boards, just make sure you have a good paste of the pop and enough yarn to sustain the weight, the plaster-boards are usually light after drying anyway.

And for wooden ceiling same process can be used as above also binding wire can also be applied to tie the boards to the woods above ceiling.

When you want to place the boards, establish the edges where the pop will be placed, make sure any point you mark use range and plumb to transfer round the room to achieve very straight line round the room. Get some iron range(straight iron of about 3.6m) use them to support the boards from one side to the other, you do this by tying the range to the wood on the roof by binding wire, then in-between the range you place the boards and start joining them together on the roof with the mixture of yarn and cement and you also join the boards at the edges together by thick mix of same pop cement. Try to achieve a smooth and even surface by patching with pop paste and gradually untie the range by removing the binding wire under the boards. Fill holes left with pop pastes using putty knife to blend the surface.

For the cornice at the edges follow same process of forming the molds. However the molds container are already forms in plastics which can be bought from the market,depends on the type of design you want out of the ones available in market, get the same cement, water mixture with yarn for strength and pour into mould. When is dry you will still need the range and plumb to establish the line of the cornice, and also place just like the boards, but this time it will be along the walls.

Medallions are pop designs usually in flowery patterns that are mostly placed at the center of the room, they are also of the pop mix and you can also buy them in the market. Adding ornamental ceiling plaster around your pendant light fixtures can bring beauty and value to your home.

POP can be painted with any kind of color surprisingly 90% prefers white paint or they thought POP must come in white since that's what they’ve been seeing around.

Before you give a final paint leave the finished pop for two weeks minimum to properly dry.

POP is also used on walls to smoothen the walls and give a perfect interior when painted or when wallpapers are applied . Just use the putty knife to smoothen it.

To apply light fittings, check the size of the bulb cover and you can easily cut the POP boards to fit the lights into it.

The growth and demand for Plaster of Paris in this sector has been further strengthened by the boom in the Nigerian real estate sector, which is growing faster than the average GDP at a rate of 8.7 percent (GDP growth at 7.4 percent).

The growth in the hospitality industry and the advent of new malls, commercial complexes and multiplexes also lend support to the growth prospects of this industry.

Rising disposable incomes of the growing middle class and sixteen million (16,000,000) units of housing shortage, however, hold out a reassuring potential for the industry.

Location Strategy: Choose a site close to gypsum deposits with good transportation links, minimizing costs and ensuring a steady supply of raw materials.

Market Focus: Decide whether to cater to the high-volume construction market with basic crushed gypsum or target the higher-value POP segment. This will influence your processing technology choices.

Environmental Responsibility: Implement sustainable practices throughout the mining and processing stages to minimize environmental impact and gain community support.

Gypsum processing presents a compelling investment opportunity within Nigeria’s booming mining industry. With its abundant gypsum resources, growing domestic market, and government support, the industry is poised for significant growth. By carefully considering location, processing methods, and sustainability, investors can contribute to building a strong foundation for Nigeria’s economic future and reap the benefits of a thriving market.

Get our Training Guide on Plaster of Paris Production in Nigeria. This report seeks to confirm the financial viability or otherwise of establishing a gypsum powder (plaster of paris) production plant in Nigeria. The production capacity of the proposed business is seven (7) tons per hour of plaster of paris working double (2) shifts of eight (8) hours each working at seventy-five percent (75%) of the installed capacity in the first, second, third, fourth and fifth year of operations respectively.

The project is financially viable with an internal rate of return (IRR) of 560.23% and a net present value (NPV) of 87million Naira, discounted at 10% for three years.

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 Analyses based on sales of six (6) trailer loads daily. 

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