WPC extrusion

WPC (Wood Plastic Composite) is a composite material that contain a wood component in the form of particles and a polymer matrix. A product class that has developed over the last fifty years, resulting in an increase in applications, thanks to the extrusion and compounding process.

It can be described in a few words as: Attractive, durable, versatile, and as elegant as wood but without its flaws.

The matrix can be a thermoplastic polymer such as PVC, PE or PP that can be processed at relatively low temperatures, avoiding thermal degradation of the wood.

The primary manufacturing processes for wood plastic composites are extrusion, injection molding, and compression molding or thermoforming (pressing). The primary purpose of the extruder, like any compounding process, is to melt the plastic polymer and mix the polymer, wood, and additives in the compounding process (linkare pagina nuova sul compound).

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WPC Advantages

Wood as a filler has many advantages over other traditional filler materials:

Lower cost,
High strength-to-weight ratio
Low density and, last but not least,
Renewable resource.

In fact, the wood material used in WPC can be of virgin source, but often comes from post-industrial co-products.

Composite materials are often optimized by selecting components for their strength, stiffness, flexibility and durability. Compared to individual materials, composites can offer more consistent performance, lower production costs and environmental friendliness. WPCs are no different, as mechanical and durability properties are the most important, as decking, fencing, and railing applications of WPCs account for the largest share of the WPC market.

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Properties

Because of its common uses, described above, we, in Bausano, have to consider at least two properties: the ultimate tensile strength (UTS) and the modulus of elasticity (MOE).

The former represents the maximum stress a material can be subjected to before breaking, while the latter refers to its ability to resist deformation. These two characteristics can vary depending on the loading ratio of the filler in the composite. A higher loading ratio - up to 60% - increases the strength of the final object. Generally, this is the best possible ratio, as more filler would not be encapsulated by the polymer, increasing the likelihood of problems. Another crucial aspect to consider is the size of the wood particles, which influences the mechanical properties mentioned above. The proportion between the length and width of the particles influences the properties of the final product; larger aspect ratios - such as wood fibre - lead to better mechanical properties, but difficulties can occur when feeding the extruder.

Compared to wood, WPC is less susceptible to moisture absorption and has better resistance to fungal attack. In addition, it is not subject to dimensional changes due to the encapsulation of wood particles by the polymer, which provides a good level of protection against biological decay. Thanks to its intrinsic properties, it does not age under UV light and requires no special maintenance.

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Environmental impact

Nowadays, with an increasing focus on the environmental impact of products, WPCs are one of the smartest choices in terms of sustainability. Bausano has at heart also the environmental impact, for this reason we also offer extrusion lines for WPC.

The particularities of Wood-plastic composites are that they have the advantage of a lower melting temperature, which translates into lower energy costs for manufacturers and further reduces the environmental impact of the product. And, since wood does not need to be treated to be used as a filler, wood waste could be used immediately after being recovered, without the need to add potentially harmful chemicals. In addition, recycled plastic can also be used, further reducing its environmental impact. Finally, WPCs are fully recyclable and once used can be converted into new granules and products.

In fact, Bausano builds extrusion lines suitable to produce WPC granules and profiles with high quality mechanical characteristics and from renewable and 100% recyclable raw materials. Bausano produces lines with the POLYWOOD technology.

For these reasons, WPCs fit well into a cradle-to-cradle scenario and represent a sustainable solution.

WPCs are the ecological answer to the needs of construction and architecture. They combine the aesthetics of natural wood with the strength of plastic resins. They can adapt to any style, from classic to modern. By experimenting with the type and proportion of plastic mixed with wood, different visual and tactile effects can be achieved. Different formulations can produce a variety of colours, more fibrous or smoother textures, more flexibility or more rigidity, as desired.

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