(230) Start a Plastic Wood Composite Unit

Wood Plastic Composite (WPC) is a material manufactured by blending natural wood fibers with plastic.

It is a combination of highly refined wood fibers and virgin polymer resins (plastic) wherein the wood fibers are aligned and encapsulated in plastic. The plastic surrounds and bonds to the wood fibers, making them virtually moisture proof. The wood fibers reinforce the plastic, making it stiffer and greatly reducing its thermal movement.

Because of this composition, WPC enjoys the best qualities of wood & plastic and has a similar appearance as wood with a far higher durability.

Wood Plastic Composites (WPCs) are defined as composite materials that contain thermoplastics and wood in various forms. Mostly, either the polymer or the fiber, or both, can come from recycled materials. Because of the limited thermal stability of wood, only plastics that can be processed at temperatures below 392 degrees Fahrenheit are used in WPCs. The average product carries about 50% wood, generally in particulate form, such as wood flour or very short fibers. WPCs represent one of the rapidly growing markets within the plastics industry. Double-digit growth is expected through 2011 for WPCs used as replacement for treated wood in building products and related applications. These composites find usage in a wide range of applications in a number of market sectors including:

  •  Building and construction
  •  Interiors and internal finishes
  •  Automotive
  •  Garden and outdoor products
  •  Industrial and infrastructure
  •  Other low-volume, niche applications

As per a report by Freedonia, demand for wood-plastic composite and plastic lumber is projected to advance about 10% pa through 2011 to US$5.4 bln. These alternative lumber materials are expected to continue to penetrate the building materials market at a rapid pace, particularly in decking applications. Composite and plastic lumber will continue to benefit from their performance characteristics, such as durability, weatherability, low maintenance requirements and low life cycle cost. Demand for composite and plastic lumber will also be driven by increasing consumer and contractor familiarity, a widening distribution network and product improvements that enhance appearance. Furthermore, ongoing interest in “green” building products will bolster use of composite and plastic lumber made with recycled content. Plastic lumber has found significant use in agricultural fencing, molding and trim applications. Solid growth in decking, fencing and other end uses such as site and leisure furniture will continue to support demand going forward. However, WPC lumber will see much faster growth through 2011, posting gains of 14.3% pa to reach US$2.6 bln. Composite lumber demand will be fueled by strong demand in decking applications. In addition, rapid growth in windows and door applications, as well as smaller niche end uses (porches, site and leisure furniture) will support demand going forward. Among the major product categories window and door applications for WPCs are anticipated to post the most rapid gains through 2011 (albeit from a small base). As with other applications, WPC window and door components are making inroads because of their lower maintenance requirements, durability in exterior applications and similarities to wood. Decking applications are projected to see strong gains through 2011, continuing to increase its relative share of the composite and plastic lumber industry. By 2011, decking will be the largest end use for these alternative building materials, accounting for 44% of demand. Molding and trim will remain a key market for composite and plastic lumber, but will exhibit below-average growth through 2011. Increasing market maturity in the plastic lumber segment will limit growth, as will a weak new housing environment going forward. Fencing applications will see below-average gains through 2011, due to increasing market maturity in the plastic lumber segment. All other applications are projected to see rapid growth over the forecast period from small bases. Playground equipment and site and leisure furniture applications are expected to register strong gains through 2011, driven by the environmentally friendly profile of composite and plastic lumber, as well as their performance and maintenance characteristics. The US wood-plastic composite and plastic lumber industry is highly fragmented, consisting of hundreds of companies ranging from small, regional producers to large, national concerns. Manufacturers typically specialize in one type of material, although some companies offer both composite and plastic lumber. In 2006, the leading composite and plastic lumber firms were Louisiana- Pacific, Royal Group Technologies, Tapco International and Trex.

US Wood-Plastic Composite & Plastic Lumber Demand (US$3.4 bln, 2006)
Molding & Trim	39%
Windows & Doors	4%
Decking	38%
Fencing	13%
Other Applications	6%

Polyethylene (PE) is most commonly used in exterior applications and Polypropylene (PP) for automotive and consumer applications. The total market for WPC products in the two key market sectors in USA was estimated to exceed US$350 mln in 2001 with predictions to grow. WPC is already an established material in the USA particularly for garden decking and non-structural building applications, such as exterior window and door profiles. The combined value of the North American and Western European WPC markets was US$775 mln in 2002, with demand reaching 1.5 bln lbs. WPCs are projected to grow by 14% pa in North America and by 18% pa in Western Europe through 2010, according to a study by Principia Partners LLC. The North American market for WPCs accounted for over 85% of the combined North American and Western European demand in 2002. Building products represent the largest segment in the North America WPC market, accounting for more than 80% of consumption. In these applications, WPCs are used in decking and railing systems, window and door profiles and shingles. Infrastructure application was the second largest segment, at over 125 mln lbs. Primary applications in this segment are for boardwalks, docks and related structures.

As per another report by Freedonia, although demand for wood decking in the US is projected to advance less than 1% pa through 2013, demand for alternative decking will grow nearly 10% pa. Demand for wood-plastic composite decking is forecast to rise 9.5% pa to 700 million lineal feet, while demand for plastic and other decking is projected to advance 9.7% pa to 135 million lineal feet in 2013. Overall, demand for decking will reach 3.6 billion lineal feet, valued at US$5.2 bln. Consumers will be attracted to alternative decking materials because of their long lifespans, minimal maintenance requirements, and imperviousness to degradation caused by general wear and tear and long-term exposure to moisture. In addition to its performance characteristics, gains in demand for composite decking will be encouraged by its close resemblance to natural wood, its ability to be cut like wood decking, and the perception that it is an environmentally friendly material, due to the use of reclaimed plastics in its production. Advances in demand for plastic decking will be driven by the high durability of this product, making it ideal for use in public parks, commercial spaces, and such facilities as dockyards and marinas. Wood decking will continue to account for the majority of decking demand in volume and value terms. Demand for wood decking is forecast to rise less than 1% pa to 2.8 bln lineal feet in 2013. Advances will be restrained by heavy competition from other materials, although increasing consumer interest in tropical hardwoods will offer some bright spots. The residential market, which accounted for 61% of total decking demand in 2008, will continue to account for the majority of decking demand through 2013, posting 2.6% annual growth rates. Advances will be boosted by consumers adding amenities to their existing decks, such as outdoor kitchens, spas and hot tubs, and areas for other activities. Not only do these larger decks require deck boards, but many homeowners will install additional railings and other accessories to separate areas of the deck, in order to enhance the safety of their decks by preventing falls by small children or older adults. Further gains will be derived from an expected recovery in new housing construction

History of Wood Plastic Composite (WPC)

Wood plastic composite (WPC) is a uniquely bonded material created from wood and plastic with many similar functions of timber, but with less maintenance requirements and with a lower weight to strength ratio. WPC nearly always incorporates at least some recycled raw materials into its composition.

The WPC industry is evolving rapidly. Internationally the WPC market steadily increases by the double digits each year, according to Wood Plastic Composites Technology Trends (Han, Gardner and Song, 2008). In less than thirty years, since WPC was introduced to the world, WPC has become a common material found in various forms from state of the art technology facilities, to individual homes. WPC is now used for large-scale cladding, roofing and structural construction support among many purposes. In these innovative uses lies opportunity to greatly expand the purpose and market of composite.

In North America more than 80 American WPC manufacturers contribute to an over one billion dollar industry. WPC is primarily used in the building sector as outdoor decking and railing. In fact three quarters of all North American WPC is used for building, ten percent for industrial purposes, eight percent for the automotive industry and the remaining seven percent for other uses, according to Wood-Plastic Composite Extrusion Overvew (Dr. Douglas J. Gardner, 2008).

In Europe WPC has found great popularity in the automotive industry as well as for home furnishings, such as furniture, pots and even tool handles. While the European decking industry is less than the Americans', the market for WPC decking rises at annual rates of around 14 percent. In just five years, from 2005 to 2010 the European WPC market grew by 280 percent (Han, Gardner and Song, 2008).

The Asian market was introduced to WPC nearly a decade after North America's and Europe's, but was 300 percent larger than the European market by 2005. To date more than 30 WPC manufactures operate mainly from China, Japan and South Korea. The Chinese WPC industry alone has grown by up to 30 percent annually since its formation (Han, Gardner and Song, 2008). Asian, particularly Chinese WPC holds export appeal for its competitive pricing but has a reputation for being lower-quality than its American and European competitors.

In Africa Eva-Last Distributors currently operates as the only WPC manufacturer.

Significant to the composite market are the international efforts made towards promoting green building products over traditional, more environmentally-harmful products, such as timber. The United States has created pro-WPC legislature and many other countries offer tax or other incentives that help attract more potential clients towards composite.

Composite has the fastest growing materials market in the world. Composite materials are any engineered materials created from two or more constituent materials whose unique physical and/or chemical properties remain intact and separate from each other on a microscopic level. They are an incredible useful and popular type of material thanks to their high performance in an array of applications and lighter weight to strength ratio. Composites are used in industries such as aerospace, automotive and primarily building.

Composition of wood plastic composite (WPC) will vary from manufacturer to manufacturer. However as the very name suggests, WPC is a combination of wood and plastic that are uniquely bonded to create long-lasting material. WPC is lighter weight than most other materials suitable for the same application. It has a long lifespan and can operate effectively in even extreme climates. WPC can be used for a variety of outdoor applications traditionally created from timber. Most often WPC is used in automotive, window and door profile and decking industries. Wood plastic composites account for over one third (approximately 40%) of all materials used in light-frame residential construction in the United States.

In many instances, from office accessories to hot tub siding, WPC can take the place of timber or other materials traditionally used. However unlike timber, WPC does not require extensive maintenance. While specific care will vary slightly from composite to composite, most will not require the frequent staining and sealing of wood. This works to save time and money for the end user, as well as prevent the overuse of environmentally harmful chemicals for the purpose of maintenance. Quality composite reduces the need to use natural resources and, in fact creates a durable product from otherwise wasted materials that is in many ways superior to timber.

Eva-Last is currently the only WPC manufacturer in all of Afric

Advantages of our WPC products:
Low maintenance
No moisture absorption
Won’t warp or crack
Resists fungus & mold
Resists termites & insects
Thermally stable than plastics
Dimensional stable than wood

In short, WPC is durable, maintenance-free, eco-friendly and therefore an excellent alternative to tropical hardwood.

To convert low-value wood resources into high-value
products, researchers at the Forest Products Laboratory
(FPL) are combining wood fiber with thermoplastic resin,
resulting in woodñplastic composites (WPCs). To optimize
composite performance, researchers are exploring material
options, investigating processing effects, and improving
engineering performance and durability.
Thermoplastic resins, such as polypropylene, polyethylene,
polystyrene, and polyvinyl chloride, soften when heated
and harden when cooled. This property allows other materials, such as wood, to be mixed with the plastic to form a
composite product. The resulting WPCs can be easily
processed into various shapes and can be recycled.
WPCs are typically made using 30% to 60% wood filler or
reinforcements. Most composites research at FPL has used
wood flour as a filler in plastics. Wood flour is made commercially by grinding postindustrial material, such as
planer shavings, chips, and sawdust, into a fine, flour-like
consistency. Wood fiber, although more difficult to process
than wood flour, can lead to superior composite properties
and act more as a reinforcement than as a filler. Wood fiber
is available from both virgin and recycled sources.
Recycled sources include pallets, demolition lumber, and
old newsprint. Wood from small-diameter trees and underutilized species can also be used.

Wood-plastic Single-screw Extrusion Lines

Wood-plastic Single-screw Extrusion Lines

Additives are also often used in WPCs. Additives are
materials that are added in small amounts to enhance
properties. For example, lubricants improve surface
appearance and processing; coupling agents improve
adhesion between the wood and plastic components. Other
possible additives include colorants, light stabilizers,
foaming agents, and thermosetting resins.
The first step in producing a WPC is to determine what raw
materials, and in what amounts, will produce a WPC that
meets the processing and performance requirements.
Manufacturing melt-blended composites is usually a twostep process consisting of compounding and forming. In
the compounding step, wood flour or wood fiber and additives are combined with molten thermoplastic to produce a
homogeneous composite material. Three common forming
methods for WPCs are extrusion (forcing molten composite
through a die), injection molding (forcing molten composite into a cold mold), and compression molding (pressing
molten composite between mold halvesSeveral factors influence processing WPCs. Moisture can

disrupt many thermoplastic processes, resulting in poor

surface quality and voids. The wood material must be predried or vented equipment used. Also, melt temperatures

should be kept below 200°C (392°F) because prolonged

exposure to high temperatures can result in release of

volatiles, discoloration, odor, and degradation of the wood

component.

Mechanical and physical properties, such as strength, stiffness, impact resistance, density, and color, are important

considerations in many WPC applications. Different

applications take advantage of properties that WPCs offer.

For example, automotive applications take advantage of a

lower specific gravity, compared with inorganic filled

thermoplastics. Household products, such as paintbrush