Producing foamed gypsum board using a foaming agent blend

A process for producing foamed gypsum board which comprises the steps of: providing an aqueous gypsum slurry; providing a stream of a preformed first foaming agent which forms stable voids in a gypsum slurry; providing a stream of a preformed second foaming agent which forms unstable voids in a gypsum slurry; pumping and blending the streams of the first foaming agent and the second foaming agent together to form a blended stream of the foaming agents having a greater amount by weight of the second foaming agent and a lesser amount by weight of the first foaming agent; mixing the blended stream of foaming agents with the gypsum slurry to produce a foamed gypsum core wherein the mixing produces a multiplicity of large voids substantially uniformly distributed throughout the foamed gypsum core; and controlling the production of the large voids by adjusting pump settings to adjust the weight ratio of the first foaming agent to the second foaming agent […]