1. Wood Plastic Composites An Overview

2. Presentation Outline Introduction to Wood Plastic Composites
Historical Development
Milestones in Commercialization
Technology Status
Benefits of wood plastic composites
Applications
Future markets & business opportunities

3. Wood Plastic Composite ( WPC )
Definition
Wood Plastic Composite ( WPC )
Any composite that contains wood & thermoset
or thermoplastic
Thermoset : Epoxy , Phenolics
Thermoplastics: PE, PP, PVC, PS

4. Introduction High Performance products First Generation WPCs
Recycled woodchips / flour & binder
Designed for undemanding applications
New Generation WPCs
High Performance products
Good mechanicals
High dimensional stability
Complex shapes
Extruded products with high dimensional tolerance

5. Introduction
“The new generation WPCs are produced by mixing wood flour or fiber & plastics to produce a material that can be processed like a conventional plastic & has the best features of wood & plastic”

6. Plastic Lumber
Recycled Plastics
Extruded profiles
May / may not include wood flour
Application – Sleepers on rail roads

7. Historical Perspectives
1900 : Bakelite ( Gear shift knobs for Rolls Royce)
1920: Birth of the WPC industry
Marriage of plastic processing
&
forest products industry

8. Initial Impediments to Growth
Forest Product Industry Viewpoints
Alien to Plastic materials
Few common material & equipment suppliers
Only exposure to vinyl sidings
Lack of Market Knowledge & application areas
Plastic Industry Viewpoints
Conversant with mineral fillers & reinforcements
Aversion to wood & natural fibers

9. Wood as a filler: Plastic Industry’s Viewpoints
Low bulk density of wood flour vis-a vis plastics
( 0.5)
Low specific gravity of wood
Low thermal stability of wood
Tendency to absorb moisture

10. The Turn Around The last decade saw
Greater awareness from both sides
Success of several WPC products
Greater understanding of wood filler
Developments in compounding equipments
Development in additives
Emerging opportunities in large volume building application sector

11. Forest Products Industry: Change in Perception
WPCs :Products with little maintenance
Low maintenance : USP Of WPCs
Forest Product companies : Suppliers of WPCs
Synergize knowledge of wood flour
&
core competence in building products

12. Milestones in The Commercialization Of WPCs
Year
Company
Product
1975
G.O.R., Italy
Woodstock patent
1983
American Woodstock
Lear Corporation
50% WF/PP sheets for thermoforming for auto interiors
1990
Strandex Corporation
Highly filled WPC extruded profiles& shapes
1991
AERT Later TREX
50 % WF/PE for deckboards, picnic tables etc
1993
Andersen Corporation
WF reinforced PVC sub sills for French doors & window lines

13. Technology Status of WPCs
Market Potential
Global market size : 320,000MT in 2000
Expected Volume : More than double in 2005
Wood Filled Composites
Natural Fiber Filled Composites

14. Technology Status Of WPCs Material Attributes
Thermoplastic
Material
End-Use PE
Virgin & recycled
Exterior building components PP
Virgin
Automotive
Profiles
PVC
Building profiles & decking & windows

15. Technology Status Of WPCs Polymer Attributes
Selection of Thermoplastic matrix
* Inherent properties of polymer
* Product requirements
* Availability
* Cost

16. Technology Status Of WPCs Attributes of wood
Wood flour : Particulate, l/d 2:1 to 4:1
Wood fiber : Reinforcing, l/d greater than 24:1
Commonly used species : Pine, Maple Oak
Typical particle size : 10 to 80 mesh
Price : Indian Rs. 15 to 20/- per Kg
Price : Imported Rs. 35 to 45/-per Kg

17. Technology Status Of WPCs Manufacture & Processing
Two stage Process: Compounded pellets & shaping
Commonly Used processing Techniques
Sheets & profile extrusion
Thermoforming
Compression Molding
Injection Molding
New Trend
In-Line Compounding & Processing

18. Salient Features of Extrusion of WPCs
Two stage Process - compound & shaping
Two Extruders in tandem Twin screw Compounding and shaping

19. Extrusion of WPCs

20. New Developments In Equipments
American Maplan Corp : Counter rotating TSE, conical & parallel for direct extrusion
Woodtruder American Davis Standard ( Crompton): First Stage drying extruder & side arm extruder for injection of polymer melt into the main extruder. Up to 80 % wood flour
Wilmington Machinery: 375 tons two stage injection molding for foamed WPCs

21. Manufacturing Wood / PP Composites

22. Machinery For Wood PP Composites

23. Additive Developments Aid Growth of WPCs
Tailor-made lubricants
Non stearate & compatibilizer package
Special HALS
Antimicrobials
Blowing agents

24. Wood Filled PP

25. Application Benefits
Improved dimensional stability - increased strength
Lower processing temperatures - less energy used
Increased heat deflection temperature - reduced thermal expansion
Up to 30% reduced cycle time for injection moulded products - increased productivity
Approximately % lower specific gravity lighter products
Reduced shrinkage - lower internal shear in pultrusion application
Low volumetric cost

26. Conventional Fillers Vs Wood Filler
AWF Wood Flour Weight Savings
Specific Gravity
40% Filled Resin - Polypropylene
Flexural MOE Versus %
Wood Flour

27. Wood Filled PP Products

28. Wood Filled PP Products

29. Wood Filled PP Products

30. Foaming Expands Possibilities For Wood Fibre / PP Composites

31. Foaming Expands Possibilities For Wood Fibre / PP Composites

32. Breakthrough Technology “Plastic Steel from Wood Filled PP”
Expanded Oriented Wood filled PP
Low temperature die drawing
Synthetic Hardwood Technologies USA
Automotive side beams
Wood look – alike
Product Flexural Modulus
( M Pa ) PP
EOW PP

33. ‘Plastics Steel’ Die Drawing Makes From Wood Filled PP
Ram extrusion of PP / wood filled creates light weight wood-like material, even stronger than wood

34. Wood Fibre Adds Stiffness & Value To Tight Tolerance Tubes

35. Polypropylene Developments
Wood Filled Repol PP
for Door Trims

36. PVC / Wood Composites

37. Outlook For The Future Innovation in processing & product performance
USA: 50 % growth rate of WPCs for building products
ASTM Standards for building products based on WPCs
Automotive : 15 % growth rate
Innovation in processing & product performance

38. Summary