Knauf and BSR receive permit for gypsum recycling plant

Knauf and BSR receive permit for Bavaria's most modern gypsum recycling plant

With the emission control permit for the most modern gypsum recycling plant of its kind in Bavaria, the Knauf Group (Iphofen), the world's leading manufacturer of building materials and construction systems, and its partner BSR Bodensanierung Recycling GmbH (Ingolstadt) have reached the next important milestone in the development of a regional raw materials network. In addition to the continuing need to mine natural gypsum, the joint venture's plant in the heart of Bavaria represents an important building block for securing regional raw materials for the building materials industry.

With the approval by the district of Neustadt an der Aisch-Bad Windsheim, the further timetable for the implementation of the project is now in place. The permit covers the recycling hall, storage and handling areas, traffic and access areas as well as plant operation on a total area of around 10,000 square meters. The next steps will be the earthworks in the summer and then the construction of the hall.

According to the current state of planning, the installation of the recycling machinery will begin in late autumn. By 2027, gypsum-based materials from dismantling and remediation measures as well as suitable production residues are to be processed in the plant to a high quality and then returned to the industrial cycle as a valuable raw material.

The plant is designed for a processing capacity of up to 90,000 tons per year. In the future, the processed recycled gypsum will be delivered to the Knauf Group's production sites around 50 kilometres away and used in plasterboard production. The short transport routes are an essential prerequisite for resource-saving value creation and at the same time contribute to the reduction of CO2 emissions.

The combination of regional natural gypsum extraction and high-quality gypsum recycling creates a regional raw material network with short transport routes and a sustainable circular economy. Knauf is already investing in the development of further comparable networks in Europe. The Knauf Group is also considering other locations in Germany.

Martin Brown, Managing Director of Knauf Recycling Holding and Head of Supply Chain Management EMEA, emphasises the strategic importance of securing raw materials: "Raw material security is a key issue – not only for the building materials industry, but for Germany as an industrial hub as a whole. Knauf is investing in its own capacities for recycled gypsum to become more independent. The gypsum gap is developing faster than originally expected. As Knauf Group, we have therefore made a conscious decision to combine domestic natural gypsum sources and high-quality recycling in order to ensure a stable and sustainable supply of raw materials in the long term."

Maximilian Hammer, Managing Director of BSR Bodensanierung Recycling GmbH, sees the permit as an important signal for the region and for Bavaria as an industrial hub: "With this project, we are jointly creating a regional raw materials network that combines supply, value creation and sustainable recycling in the long term. We are particularly pleased that we were able to successfully implement the approval procedure very efficiently and in close coordination thanks to the constructive and solution-oriented cooperation with the municipality, the district and all the specialist agencies involved. This record-time progress creates planning security for companies and shows that innovative industrial and recycling projects in the region can be implemented in partnership."

The gypsum gap is caused by the loss of FGD gypsum from coal-fired power generation. Current data shows that the available quantities are already declining faster than originally forecast. At the same time, the demand for gypsum as a raw material for residential construction, energy-efficient renovations and infrastructure projects remains at a high level.

The annual raw material demand of the gypsum processing industry in Germany is currently around 9 to 10 million tons. In contrast, less than 600,000 tons of gypsum waste per year from dismantling and remediation measures, only part of which is technically suitable for high-quality recycling.

Knauf Group
The Knauf Group is an international building materials manufacturer based in Iphofen, Germany. Founded in 1932, the family-owned company today is the world's leading producer of gypsum-based construction materials and systems, energy-efficient insulation, and system solutions for ceilings. It operates more than 300 production sites and sales organizations in over 90 countries on all continents. In 2024, its approximately 43,500 employees generated sales of €15.6 billion.

About BSR Bodensanierung Recycling GmbH
BSR Bodensanierung Recycling GmbH is an established company in the field of recycling, material flow management and circular economy with many years of experience in the processing and recycling of a wide variety of mineral and industrial materials. The company operates several recycling sites and develops innovative solutions for the resource-saving recycling of recyclable materials and building materials. Through its cooperation with Knauf, BSR is making an important contribution to the sustainable securing of raw materials, the strengthening of regional material cycles and the reduction of CO₂ emissions in the construction sector.

Further information: www.bsr-recycling.de