Patent ID: 8262820

Claim:
A method of making gypsum board, comprising: (a) providing pregelatinized starch having a particle size distribution within the following ranges: d (0.1)=from about 20μ to about 35μ, d (0.5)=from about 60μ to about 110μ, d (0.9)=from about 100μ to about 220μ; (b) dispersing the pregelatinized starch in water to form a pregelatinized starch dispersion; (c) introducing stucco to a mixer having nozzles that deliver water into the mixer and injecting the pregelatinized starch dispersion into the mixer adjacent the nozzles to fully disperse the starch in the resulting slurry; (d) disposing the slurry containing the dispersed starch between a first cover sheet and a second cover sheet to form a panel; (e) cutting the panel into a board of predetermined dimensions; and (f) drying the board.