Wood Plastic Composites An Overview - LRPS Home Page€¦ · PPT file · Web view ·...
Transcript of Wood Plastic Composites An Overview - LRPS Home Page€¦ · PPT file · Web view ·...
![Page 1: Wood Plastic Composites An Overview - LRPS Home Page€¦ · PPT file · Web view · 2008-03-03Wood Plastic Composites An Overview ... filled WPC extruded profiles& shapes 1991](https://reader031.fdocuments.us/reader031/viewer/2022030702/5aee35ce7f8b9a585f9155c1/html5/thumbnails/1.jpg)
Wood Plastic Composites An Overview
![Page 2: Wood Plastic Composites An Overview - LRPS Home Page€¦ · PPT file · Web view · 2008-03-03Wood Plastic Composites An Overview ... filled WPC extruded profiles& shapes 1991](https://reader031.fdocuments.us/reader031/viewer/2022030702/5aee35ce7f8b9a585f9155c1/html5/thumbnails/2.jpg)
Presentation Outline
• Introduction to Wood Plastic Composites• Historical Development• Milestones in Commercialization• Technology Status• Benefits of wood plastic composites• Applications• Future markets & business opportunities
![Page 3: Wood Plastic Composites An Overview - LRPS Home Page€¦ · PPT file · Web view · 2008-03-03Wood Plastic Composites An Overview ... filled WPC extruded profiles& shapes 1991](https://reader031.fdocuments.us/reader031/viewer/2022030702/5aee35ce7f8b9a585f9155c1/html5/thumbnails/3.jpg)
Definition
Wood Plastic Composite ( WPC ) Any composite that contains wood & thermoset or thermoplastic
Thermoset : Epoxy , Phenolics Thermoplastics: PE, PP, PVC, PS
![Page 4: Wood Plastic Composites An Overview - LRPS Home Page€¦ · PPT file · Web view · 2008-03-03Wood Plastic Composites An Overview ... filled WPC extruded profiles& shapes 1991](https://reader031.fdocuments.us/reader031/viewer/2022030702/5aee35ce7f8b9a585f9155c1/html5/thumbnails/4.jpg)
Introduction
• 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
![Page 5: Wood Plastic Composites An Overview - LRPS Home Page€¦ · PPT file · Web view · 2008-03-03Wood Plastic Composites An Overview ... filled WPC extruded profiles& shapes 1991](https://reader031.fdocuments.us/reader031/viewer/2022030702/5aee35ce7f8b9a585f9155c1/html5/thumbnails/5.jpg)
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”
![Page 6: Wood Plastic Composites An Overview - LRPS Home Page€¦ · PPT file · Web view · 2008-03-03Wood Plastic Composites An Overview ... filled WPC extruded profiles& shapes 1991](https://reader031.fdocuments.us/reader031/viewer/2022030702/5aee35ce7f8b9a585f9155c1/html5/thumbnails/6.jpg)
Plastic Lumber
• Recycled Plastics• Extruded profiles• May / may not include wood flour• Application – Sleepers on rail roads
![Page 7: Wood Plastic Composites An Overview - LRPS Home Page€¦ · PPT file · Web view · 2008-03-03Wood Plastic Composites An Overview ... filled WPC extruded profiles& shapes 1991](https://reader031.fdocuments.us/reader031/viewer/2022030702/5aee35ce7f8b9a585f9155c1/html5/thumbnails/7.jpg)
Historical Perspectives
• 1900 : Bakelite ( Gear shift knobs for Rolls Royce)
• 1920: Birth of the WPC industry
Marriage of plastic processing &
forest products industry
![Page 8: Wood Plastic Composites An Overview - LRPS Home Page€¦ · PPT file · Web view · 2008-03-03Wood Plastic Composites An Overview ... filled WPC extruded profiles& shapes 1991](https://reader031.fdocuments.us/reader031/viewer/2022030702/5aee35ce7f8b9a585f9155c1/html5/thumbnails/8.jpg)
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
![Page 9: Wood Plastic Composites An Overview - LRPS Home Page€¦ · PPT file · Web view · 2008-03-03Wood Plastic Composites An Overview ... filled WPC extruded profiles& shapes 1991](https://reader031.fdocuments.us/reader031/viewer/2022030702/5aee35ce7f8b9a585f9155c1/html5/thumbnails/9.jpg)
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
![Page 10: Wood Plastic Composites An Overview - LRPS Home Page€¦ · PPT file · Web view · 2008-03-03Wood Plastic Composites An Overview ... filled WPC extruded profiles& shapes 1991](https://reader031.fdocuments.us/reader031/viewer/2022030702/5aee35ce7f8b9a585f9155c1/html5/thumbnails/10.jpg)
The Turn AroundThe 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
![Page 11: Wood Plastic Composites An Overview - LRPS Home Page€¦ · PPT file · Web view · 2008-03-03Wood Plastic Composites An Overview ... filled WPC extruded profiles& shapes 1991](https://reader031.fdocuments.us/reader031/viewer/2022030702/5aee35ce7f8b9a585f9155c1/html5/thumbnails/11.jpg)
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
![Page 12: Wood Plastic Composites An Overview - LRPS Home Page€¦ · PPT file · Web view · 2008-03-03Wood Plastic Composites An Overview ... filled WPC extruded profiles& shapes 1991](https://reader031.fdocuments.us/reader031/viewer/2022030702/5aee35ce7f8b9a585f9155c1/html5/thumbnails/12.jpg)
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
![Page 13: Wood Plastic Composites An Overview - LRPS Home Page€¦ · PPT file · Web view · 2008-03-03Wood Plastic Composites An Overview ... filled WPC extruded profiles& shapes 1991](https://reader031.fdocuments.us/reader031/viewer/2022030702/5aee35ce7f8b9a585f9155c1/html5/thumbnails/13.jpg)
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
![Page 14: Wood Plastic Composites An Overview - LRPS Home Page€¦ · PPT file · Web view · 2008-03-03Wood Plastic Composites An Overview ... filled WPC extruded profiles& shapes 1991](https://reader031.fdocuments.us/reader031/viewer/2022030702/5aee35ce7f8b9a585f9155c1/html5/thumbnails/14.jpg)
Technology Status Of WPCsMaterial Attributes
Thermoplastic Material End-Use
PE Virgin & recycled Exterior building components
PP Virgin AutomotiveProfiles
PVC Virgin Building profiles & decking & windows
![Page 15: Wood Plastic Composites An Overview - LRPS Home Page€¦ · PPT file · Web view · 2008-03-03Wood Plastic Composites An Overview ... filled WPC extruded profiles& shapes 1991](https://reader031.fdocuments.us/reader031/viewer/2022030702/5aee35ce7f8b9a585f9155c1/html5/thumbnails/15.jpg)
Technology Status Of WPCsPolymer Attributes
Selection of Thermoplastic matrix * Inherent properties of polymer * Product requirements * Availability * Cost
![Page 16: Wood Plastic Composites An Overview - LRPS Home Page€¦ · PPT file · Web view · 2008-03-03Wood Plastic Composites An Overview ... filled WPC extruded profiles& shapes 1991](https://reader031.fdocuments.us/reader031/viewer/2022030702/5aee35ce7f8b9a585f9155c1/html5/thumbnails/16.jpg)
Technology Status Of WPCsAttributes 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
![Page 17: Wood Plastic Composites An Overview - LRPS Home Page€¦ · PPT file · Web view · 2008-03-03Wood Plastic Composites An Overview ... filled WPC extruded profiles& shapes 1991](https://reader031.fdocuments.us/reader031/viewer/2022030702/5aee35ce7f8b9a585f9155c1/html5/thumbnails/17.jpg)
Technology Status Of WPCsManufacture & 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
![Page 18: Wood Plastic Composites An Overview - LRPS Home Page€¦ · PPT file · Web view · 2008-03-03Wood Plastic Composites An Overview ... filled WPC extruded profiles& shapes 1991](https://reader031.fdocuments.us/reader031/viewer/2022030702/5aee35ce7f8b9a585f9155c1/html5/thumbnails/18.jpg)
Salient Features of Extrusion of WPCs
• Two stage Process - compound & shaping
• Two Extruders in tandem Twin screw Compounding and shaping
![Page 19: Wood Plastic Composites An Overview - LRPS Home Page€¦ · PPT file · Web view · 2008-03-03Wood Plastic Composites An Overview ... filled WPC extruded profiles& shapes 1991](https://reader031.fdocuments.us/reader031/viewer/2022030702/5aee35ce7f8b9a585f9155c1/html5/thumbnails/19.jpg)
Extrusion of WPCs
![Page 20: Wood Plastic Composites An Overview - LRPS Home Page€¦ · PPT file · Web view · 2008-03-03Wood Plastic Composites An Overview ... filled WPC extruded profiles& shapes 1991](https://reader031.fdocuments.us/reader031/viewer/2022030702/5aee35ce7f8b9a585f9155c1/html5/thumbnails/20.jpg)
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
![Page 21: Wood Plastic Composites An Overview - LRPS Home Page€¦ · PPT file · Web view · 2008-03-03Wood Plastic Composites An Overview ... filled WPC extruded profiles& shapes 1991](https://reader031.fdocuments.us/reader031/viewer/2022030702/5aee35ce7f8b9a585f9155c1/html5/thumbnails/21.jpg)
Manufacturing Wood / PP Composites
![Page 22: Wood Plastic Composites An Overview - LRPS Home Page€¦ · PPT file · Web view · 2008-03-03Wood Plastic Composites An Overview ... filled WPC extruded profiles& shapes 1991](https://reader031.fdocuments.us/reader031/viewer/2022030702/5aee35ce7f8b9a585f9155c1/html5/thumbnails/22.jpg)
Machinery For Wood PP Composites
![Page 23: Wood Plastic Composites An Overview - LRPS Home Page€¦ · PPT file · Web view · 2008-03-03Wood Plastic Composites An Overview ... filled WPC extruded profiles& shapes 1991](https://reader031.fdocuments.us/reader031/viewer/2022030702/5aee35ce7f8b9a585f9155c1/html5/thumbnails/23.jpg)
Additive Developments Aid Growth of WPCs
• Tailor-made lubricants• Non stearate & compatibilizer package• Special HALS• Antimicrobials• Blowing agents
![Page 24: Wood Plastic Composites An Overview - LRPS Home Page€¦ · PPT file · Web view · 2008-03-03Wood Plastic Composites An Overview ... filled WPC extruded profiles& shapes 1991](https://reader031.fdocuments.us/reader031/viewer/2022030702/5aee35ce7f8b9a585f9155c1/html5/thumbnails/24.jpg)
Wood Filled PP
![Page 25: Wood Plastic Composites An Overview - LRPS Home Page€¦ · PPT file · Web view · 2008-03-03Wood Plastic Composites An Overview ... filled WPC extruded profiles& shapes 1991](https://reader031.fdocuments.us/reader031/viewer/2022030702/5aee35ce7f8b9a585f9155c1/html5/thumbnails/25.jpg)
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 10 - 20% lower specific gravity -
lighter products• Reduced shrinkage - lower internal shear in pultrusion
application• Low volumetric cost
![Page 26: Wood Plastic Composites An Overview - LRPS Home Page€¦ · PPT file · Web view · 2008-03-03Wood Plastic Composites An Overview ... filled WPC extruded profiles& shapes 1991](https://reader031.fdocuments.us/reader031/viewer/2022030702/5aee35ce7f8b9a585f9155c1/html5/thumbnails/26.jpg)
ConventionalFillers Vs Wood Filler
AWF Wood Flour Weight Savings
Specific Gravity40% Filled Resin -
Polypropylene
Flexural MOE Versus %
Wood Flour2.0 2.2
3.23.8
4.5
0.0
1.0
2.0
3.0
4.0
5.0
20 30 40 50 60
% Wood Filler
Flex
ural
MO
E (G
Pa)
1.1
1.251.27 1.27
1
1.05
1.1
1.15
1.2
1.25
1.3
Wood Flour(AWF - 4020)
Talc CalciumCarbonate
Fiberglass
Fillers
Wei
ght
![Page 27: Wood Plastic Composites An Overview - LRPS Home Page€¦ · PPT file · Web view · 2008-03-03Wood Plastic Composites An Overview ... filled WPC extruded profiles& shapes 1991](https://reader031.fdocuments.us/reader031/viewer/2022030702/5aee35ce7f8b9a585f9155c1/html5/thumbnails/27.jpg)
Wood Filled PP Products
![Page 28: Wood Plastic Composites An Overview - LRPS Home Page€¦ · PPT file · Web view · 2008-03-03Wood Plastic Composites An Overview ... filled WPC extruded profiles& shapes 1991](https://reader031.fdocuments.us/reader031/viewer/2022030702/5aee35ce7f8b9a585f9155c1/html5/thumbnails/28.jpg)
Wood Filled PP Products
![Page 29: Wood Plastic Composites An Overview - LRPS Home Page€¦ · PPT file · Web view · 2008-03-03Wood Plastic Composites An Overview ... filled WPC extruded profiles& shapes 1991](https://reader031.fdocuments.us/reader031/viewer/2022030702/5aee35ce7f8b9a585f9155c1/html5/thumbnails/29.jpg)
Wood Filled PP Products
![Page 30: Wood Plastic Composites An Overview - LRPS Home Page€¦ · PPT file · Web view · 2008-03-03Wood Plastic Composites An Overview ... filled WPC extruded profiles& shapes 1991](https://reader031.fdocuments.us/reader031/viewer/2022030702/5aee35ce7f8b9a585f9155c1/html5/thumbnails/30.jpg)
Foaming Expands Possibilities For Wood Fibre / PP Composites
![Page 31: Wood Plastic Composites An Overview - LRPS Home Page€¦ · PPT file · Web view · 2008-03-03Wood Plastic Composites An Overview ... filled WPC extruded profiles& shapes 1991](https://reader031.fdocuments.us/reader031/viewer/2022030702/5aee35ce7f8b9a585f9155c1/html5/thumbnails/31.jpg)
Foaming Expands Possibilities For Wood Fibre / PP Composites
![Page 32: Wood Plastic Composites An Overview - LRPS Home Page€¦ · PPT file · Web view · 2008-03-03Wood Plastic Composites An Overview ... filled WPC extruded profiles& shapes 1991](https://reader031.fdocuments.us/reader031/viewer/2022030702/5aee35ce7f8b9a585f9155c1/html5/thumbnails/32.jpg)
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 1800 EOW PP 7585
![Page 33: Wood Plastic Composites An Overview - LRPS Home Page€¦ · PPT file · Web view · 2008-03-03Wood Plastic Composites An Overview ... filled WPC extruded profiles& shapes 1991](https://reader031.fdocuments.us/reader031/viewer/2022030702/5aee35ce7f8b9a585f9155c1/html5/thumbnails/33.jpg)
‘Plastics Steel’ Die Drawing Makes From Wood Filled PP
Material Flexural Strength Flexural Modulus(MPa)
PP 48 1860
Wood 96 8946O-PP 276 7585
EOW-PP 138 7585
Ram extrusion of PP / wood filled creates light weight wood-like material, even
stronger than wood
![Page 34: Wood Plastic Composites An Overview - LRPS Home Page€¦ · PPT file · Web view · 2008-03-03Wood Plastic Composites An Overview ... filled WPC extruded profiles& shapes 1991](https://reader031.fdocuments.us/reader031/viewer/2022030702/5aee35ce7f8b9a585f9155c1/html5/thumbnails/34.jpg)
Wood Fibre Adds Stiffness & Value To Tight Tolerance Tubes
![Page 35: Wood Plastic Composites An Overview - LRPS Home Page€¦ · PPT file · Web view · 2008-03-03Wood Plastic Composites An Overview ... filled WPC extruded profiles& shapes 1991](https://reader031.fdocuments.us/reader031/viewer/2022030702/5aee35ce7f8b9a585f9155c1/html5/thumbnails/35.jpg)
Polypropylene Developments
Wood Filled Repol PPfor Door Trims
![Page 36: Wood Plastic Composites An Overview - LRPS Home Page€¦ · PPT file · Web view · 2008-03-03Wood Plastic Composites An Overview ... filled WPC extruded profiles& shapes 1991](https://reader031.fdocuments.us/reader031/viewer/2022030702/5aee35ce7f8b9a585f9155c1/html5/thumbnails/36.jpg)
PVC / Wood Composites
![Page 37: Wood Plastic Composites An Overview - LRPS Home Page€¦ · PPT file · Web view · 2008-03-03Wood Plastic Composites An Overview ... filled WPC extruded profiles& shapes 1991](https://reader031.fdocuments.us/reader031/viewer/2022030702/5aee35ce7f8b9a585f9155c1/html5/thumbnails/37.jpg)
Outlook For The Future
• 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
![Page 38: Wood Plastic Composites An Overview - LRPS Home Page€¦ · PPT file · Web view · 2008-03-03Wood Plastic Composites An Overview ... filled WPC extruded profiles& shapes 1991](https://reader031.fdocuments.us/reader031/viewer/2022030702/5aee35ce7f8b9a585f9155c1/html5/thumbnails/38.jpg)
Summary
The future of wood plastic composites will ultimately
depend on many factors; including new product
identification, product quality, consumer perception
& performance of these materials !