Gyproc SoundBloc Infinaé 100
Innovation overview and development
Overview of the sustainable innovation
Gyproc SoundBloc Infinaé 100 is a landmark sustainable innovation in UK construction, representing the first plasterboard manufactured from 100% recycled gypsum. The product redefines how a core construction material can be produced without reliance on virgin raw materials, while maintaining the same performance, usability and compliance standards expected from conventional plasterboard.
By placing circularity at the heart of its design, Gyproc SoundBloc Infinaé 100 transforms gypsum waste, such as construction site off-cuts, into a high-performance building product. This innovation demonstrates how sustainability can be embedded directly into material production, enabling projects to reduce environmental impact without compromising quality, safety, or productivity.
How the innovation was developed, including effective collaboration, knowledge transfer and partnership along the project team
The development of Gyproc SoundBloc Infinaé 100 was driven by British Gypsum’s technical expertise, supported by close collaboration across its manufacturing, sustainability and technical teams. A key element of the project was knowledge transfer between production specialists and waste-recycling partners to ensure recycled gypsum could meet the stringent performance requirements of standard plasterboard.
British Gypsum also leveraged working with site teams and recycling partners to recover waste gypsum efficiently. Multiple trials and refinements of the production “recipe” ensured consistency, durability and acoustic performance, while embedding sustainability into an existing, scalable manufacturing process.
Use of new technologies, processes products or techniques or novel uses of existing
Rather than relying on new machinery, this innovation repurposes existing manufacturing infrastructure in a novel way. British Gypsum adapted its processes to allow 100% recycled gypsum to be used at scale, an unprecedented achievement in the UK plasterboard industry.
The innovation lies in the commercialisation of circular production, turning a waste stream into a fully compliant, high-performing construction product. This approach demonstrates how established technologies, when re-engineered creatively, can deliver commercially viable and industry-transforming sustainable solutions.
How the innovation provides a more environmentally friendly approach for the industry
Gyproc SoundBloc Infinaé 100 delivers a significantly more environmentally responsible approach by:
– Eliminating the need for virgin gypsum
– Reducing plasterboard waste sent to landfill
– Supporting circular economy within the supply chain
– indoor air quality: ‘Gold’ – eurofins certified
It supports project-level sustainability goals, contributing to assessment frameworks such as BREEAM, WELLS and LEED, and lowering the overall environmental footprint of construction projects.
How the innovation provides an improvement in social value
The innovation strengthens local and responsible supply chains by encouraging on-site waste segregation and participation in recycling schemes. It supports jobs and skills within recycling and manufacturing, while minimising the environmental and community impacts associated with waste disposal.
Because Gyproc SoundBloc Infinaé 100 installs in the same way as standard plasterboard, it avoids the need for retraining, helping maintain productivity, safety and accessibility across the workforce. This inclusive approach ensures sustainability improvements do not create barriers for contractors, installers or smaller projects.
How this innovation influences future specifications to improve sustainability
Gyproc SoundBloc Infinaé 100 sets a new benchmark for what is possible in mainstream construction materials. By proving that 100% recycled content can deliver identical performance to traditional products, it challenges long-held assumptions within specifications and procurement.
The innovation encourages specifiers, architects and contractors to prioritise recycled-content materials without risk, accelerating the shift towards circular construction. Over time, this approach has the potential to influence industry standards, normalising circular manufacturing and supporting the wider transition to a more sustainable built environment.