Bausano POLYWOOD Technology

The extrusion technique designed for WPC and composite woods

Direct and indirect extrusion for wood-plastic composites

WPC (Wood Plastic Composite) is a composite material made of natural fibers – such as wood flour or plant waste – blended with thermoplastic polymers. It combines the look of wood with the strength of plastic, offering a sustainable and durable solution for producing profiles for construction, urban furniture and decking.
Drawing on its experience, Bausano has developed the POLYWOOD extrusion technique, designed to process up to 100 phr of wood or natural fiber, ensuring quality and production continuity even with complex blends.

POLYWOOD technology stands out for two operating modes:

Direct extrusion: makes it possible to obtain the finished profile directly from the blended raw material (fiber + polymer), reducing process steps.
Indirect extrusion: involves processing the material in the form of WPC pellets, previously obtained through compounding.

Both solutions ensure maximum flexibility and production cost optimization, adapting to the specific needs of each line.

PLANT
COMPONENT

Bausano's twin-screw extruders are designed to work with various plastic materials – such as PVC, PE, PP and PLA – offering wide flexibility in WPC formulation. The synthetic component improves compound processability, facilitates extrusion and ensures better resistance to weathering. This makes it possible to obtain durable structural profiles, even under high loads or prolonged exposure to moisture.

SYNTHETIC COMPONENT

100% RECYCLABLE

WPC is fully recyclable: at the end of its life, it can be recovered, re-pelletized and extruded again to create new products. Bausano lines also make it possible to process reconditioned material, ensuring consistent quality and savings on raw material costs. A concrete advantage for those aiming for an efficient production process in line with circular economy principles.

Solutions for extruding durable, reliable WPC profiles

WPC profiles (Wood Plastic Composite), produced with the Polywood extrusion technique, represent an advanced solution for those seeking durable, versatile and sustainable materials.
Thanks to the combination of natural fibers and recycled polymers, it is possible to obtain high-performance elements, suitable for numerous technical and construction applications, such as decking, cladding and fencing.
Bausano's extrusion lines, based on parallel co-rotating twin-screw technology, ensure homogeneous mixing, precise thermal control and uniform fiber distribution within the compound.
Bausano's Polywood technique enables stable processing even with complex formulations, ensuring consistent quality and production flexibility for every industrial need.

TWIN-SCREW EXTRUDERS

WPC pellet extrusion: stability for every application

WPC is a composite material obtained from plant fibers – such as wood flour, rice husks or other organic waste – and recycled polymers, including PVC, PE, PP or PLA. Bausano's lines for WPC compounds use parallel co-rotating twin-screw extruders, designed to ensure homogeneous mixing, precise thermal control and consistent pellet quality.
Thanks to an integrated system of dosing, degassing, filtration and cutting, pellets with uniform shape and density are obtained, ready for extrusion or molding. An efficient and versatile solution, WPC pellets enable optimal raw material management, improve production stability and reduce waste, supporting a sustainable, high-performance approach.

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WPC and sustainable extrusion: the Bausano response

The use of Bausano twin-screw extruders in WPC production offers concrete advantages in terms of reliability, flexibility and compound quality. Thanks to the ability to handle complex blends of natural fibers and thermoplastic polymers, it is possible to obtain high-performance pellets and profiles, with particular attention to process sustainability. The plants are designed for the use of recycled raw materials and plant fibers, promoting a more efficient production model with lower environmental impact.

To ensure high productivity and stability in the extrusion process, Bausano's WPC lines are equipped with parallel co-rotating twin-screw extruders, precise dosing systems, effective degassing and constant thermal control. The pellet cutting system is configured based on the blend's composition. For PVC-based formulations, air cutting is generally recommended, ensuring rapid cooling compatible with the material's properties. Conversely, when the plant component is combined with polyolefins, the more fluid nature of the melt makes water cutting preferable, as it stabilizes the pellet and ensures its shape. This flexibility allows the line to be optimized based on the raw material and production goals.

The long-term goals of clients operating in the WPC sector concern production continuity, waste reduction and the adoption of technologies that enable more responsible use of resources. Since WPC is fully recyclable, it can be regenerated and extruded again, contributing concretely to a circular economy and more sustainable industrial processes.