Extrusion Materials: Wood Plastic Composite (WPC)

WPC (Wood Plastic Composite) extrusion transforms blends of thermoplastic polymers and natural fibers into high-performance materials for numerous applications. The process can be geared either toward producing granules (compound) for use in later stages, or directly toward finished profiles for construction, urban furniture or technical components. Bausano extrusion lines are designed to offer process stability, consistent melt quality and operational versatility, even with formulations containing a high percentage of organic fillers. The mechanical configuration, screw geometry and thermal profile are optimized to ensure uniform, repeatable processing over time.
Bausano solutions ensure:

• uniform melting even with high percentages of natural fibers
• precise thermal control across all process zones
• plant modularity for producing either compound or profiles

Depending on the intended use, the entire line can be adapted with specific modules for cooling, cutting and calibration, ensuring compatibility with different geometries and density grades of the extruded material.

High line performance, sustainability and productivity

Bausano extrusion lines represent one of the most advanced plant solutions for processing WPC, combining operational efficiency, high productivity and reduced environmental impact — the three main advantages that set these lines apart from generic solutions. In the context of wood-plastic composite production, a well-designed plant must ensure uniform dispersion of natural fibers within the polymer matrix, promote homogeneous mixing and accurately control melt temperature to prevent defects and quality variations in the extruded profile. Bausano lines address these needs through a dedicated screw geometry, mixing zones distributed along the barrel and optimized mechanical components, which ensure constant contact between the polymer matrix and the fibers, together with an advanced thermal profile capable of maintaining a stable process even with formulations containing high organic filler content. The result is high hourly output while maintaining consistent product quality.
From an environmental sustainability standpoint, WPC is considered a material with strong potential, as it can incorporate recycled polymers and natural fibers, reducing the use of virgin resources and supporting a circular economy approach. Thanks to the ability to process post-consumer materials and combine two components of different chemical nature in an integrated process, Bausano lines support production strategies that make use of production waste and secondary materials without compromising performance or stability.
In addition, the adoption of technologies such as high-efficiency induction heating helps reduce specific energy consumption, improving the economic sustainability of the entire plant. To request a customized WPC extrusion solution, Bausano provides complete technical support starting from formulation development, continuing with process testing in its in-house laboratory, and extending to custom plant configuration based on production capacity and required geometries; leasing and financing options are also available to support the investment. These characteristics make Bausano extrusion lines not only highly reliable operational tools, but also ideal solutions for those seeking high performance, sustainability and production continuity in processing composite materials such as WPC.