Ceiling basemat water reduction through strategic use of pressing and vacuuming

A method for continuous manufacturing of a ceiling tile by a water-felting process, the method comprising:

• a) felting an aqueous slurry comprising fibers, perlite, and a binder into a green ceiling basemat on a foraminous wire conveyor;
• b) drawing water out the green ceiling basemat by free drainage;
• c) after step b), drawing water out the green ceiling basemat by applying suction generated with one or more vacuum boxes operably connected to a vacuum fan;
• d) after step c), compressing the green ceiling basemat with a first press to a first caliper;
• e) after step d), compressing the green ceiling basemat with a second press to a second caliper, the second caliper being the final caliper for the green ceiling basemat;
• f) after step e), drawing water out the green ceiling basemat by applying suction generated with one or more vacuum boxes operably connected to a set of vacuum pumps;
• and
• g) drying the green ceiling basemat in a dryer.