A composition and process suitable for making acoustic tiles are
disclosed. Certain embodiments of the composition comprise: perlite;
inorganic material selected from the group consisting of calcium sulfate,
calcium carbonate, clay and mixtures thereof; a binder selected from the
group consisting of starch, a combination of starch and cellulosic
fibers, latex, kraft paper gel and mixtures thereof; optionally mineral
wool; optionally gypsum; and cellulosic fiber, wherein at least a portion
of the cellulosic fiber and at least a portion of the inorganic material
are pulp and paper processing waste comprising cellulosic fiber, clay and
calcium carbonate. Certain embodiments of the process comprise: forming
an aqueous slurry; continuously flowing slurry onto a moving foraminous
wire to form a cake; dewatering the cake to form a base mat; and drying
the base mat.