Patent ID: 8882943

Claim:
A method of producing lightweight gypsum board, the method utilizing a board production line including a mixer, a forming table, and dryers, the method comprising: providing a plurality of foamed starch pellets, the pellets being formed via an extrusion process and having an approximate particle size of between 1/32″ to 1/64″, the pellets being only slightly soluble at temperatures below 140° F.; adding the pellets to a gypsum slurry in a ratio of between approximately 5% to 50% volume; blending the gypsum slurry and pellets within the mixer whereby the pellets become fully encapsulated within the slurry; supplying a first facing sheet to the forming table prior to the mixer; discharging the blended gypsum and pellets from the mixer and onto the first facing sheet; supplying a top facing sheet over the blended gypsum and pellets to form a composite panel; drying the composite panel within the dryers to a temperature in excess of 140° F., the drying causing the pellets to dissolve and the residual moisture to be removed from the board, whereby the dissolved pellets provide starch to the gypsum slurry and create voids within the set gypsum.