greenprofile wpc Wood plastic composite (WPC) profile extrusion
Setting benchmarks battenfeld-cincinnati stands not only for state-of-the-art machine manufacturing and innovative technologies, but also for more than five decades of experience in the production of extruders and extrusion equipment. We plan, design and install wood plastic composite extrusion lines with perfectly coordinated components that feature high output combined with excellent end product quality all along the line and have made us a market leader in the extrusion of natural fiber composites. battenfeld-cincinnati ranks among the pioneers of WPC extrusion and has installed more than 200 lines to date. In all of this, functionality, machine availability and cost-efficiency are absolute priorities. With our quality standards, we are real partners for our customers, offering them top-class service. Here, we make a special point of comprehensive counseling in process technology, which is one of our particular strengths.. battenfeld-cincinnati leading solutions
WPC profiles sustainable and eco-friendly Wood plastic composites (WPC) can be formed by a thermoplastic process and consist of renewable materials (natural fibers), mostly synthetic plastics and additives. Typical WPC products are, for example, extruded profiles for decking consisting of 65% wood flour, 30% polyethylene or polypropylene and 5% additives, such as bonding agents, UV protection additives and colorants. Although thermoplastic WPC products have only been in existence for a few years, they have already conquered a sizeable market, thanks to their superior attributes. In contrast to wood materials, WPCs can be freely formed and are more resistant to moisture, and consequently possess excellent resistance to weathering. Compared to synthetic plastics, WPC compounds score with their lower prices, touch, natural look, higher stiffness and significantly lower thermal expansion. WPC profile extrusion perfectly chiseled Customized turnkey solutions for WPC extrusion have long been one of our core competencies. With intelligent machine and automation concepts, we successfully meet our customers requirements. Every line is designed by us from start to finish, with all individual components matching perfectly. With more than a century of combined extrusion experience, battenfeld-cincinnati offers the optimal solution for every application, powerful and resource-efficient. Current market research has revealed that more than 1.5 million tons of WPC are being produced today. With a share of about 1 million tons, North America is by far the largest market, followed by Europe, Japan and China.
WPC profiles in action The natural fiber content in WPC formulations varies from one application to the next. It normally ranges from 30 to 85 per cent. Polyethylene, polypropylene or PVC are used as the plastic matrix. In North America, preference is given to PE, while PP is predominant in Europe. Due to the thermal sensitiveness of wood, processing temperatures below 200 C are required, as higher temperatures cause degradation of certain wood components. Additives improve the process ability of WPC and optimize the desired product attributes. Extruded WPC profiles are found mainly in outdoor applications, but to a lesser extent also in furniture for interiors. About 75% of all WPC products worldwide are used as floor coverings, terrace and verandah floorboards, known as decking profiles. Depending on the region, either hollow or fully walled profiles are preferred. Other fields of application for WPC products in building construction and garden landscaping are hand rails, railings and fences, and most recently to an increasing extent shingles and garden furniture. In some cases, WPC products are used instead of fiber and particle boards. WPC profiles are 100% recyclable. Since processing of reclaim material with a share of up to 20% presents no problem, WPC products feature an excellent eco balance and are making a substantial contribution to responsible, sustainable resource management.
WPC processing In WPC processing, a distinction is made between one-step and two-step processes. Which process is ultimately used depends on the quality of the raw material, the compound, the dispersion capability and the desired end product functions. In one-step, direct extrusion, the natural fibers and plastic granulate are fed into the extruders multaneously. The plastic melt is homogenized and the plastic-fiber compound dispersed in the extruder. A critical factor here is the moisture content of the natural fibers. During the extrusion process, the moisture is mostly sucked off. For one-step processes, mainly conical, counter-rotating twin-screw extruders are used. In the two-step extrusion process, the WPC compound is produced in a compounder or heating-cooling mixer. The actual extrusion process takes place in a separate extruder. The WPC extrusion process actually consists of five different steps: raw material preparation, extrusion, calibration through the die and downstream, and finally treatment of the end product.
During material preparation, the various material components are metered in, homogenized and dispersed. At this stage, most of the moisture is extracted from the fiber material. The resulting semi-finished product in the form of a granulate or dryblend or agglomarate is then fed continuously into a counter-rotating twin-screw extruder by gravimetric feeding and homogenized. The final profile shape is created in the die and subsequent calibration system. The end product is then cooled, cut to length and finished. battenfeld-cincinnati fiberex extruders have proved their worth in practice many times in direct extrusion as well as in the two-step process. With outputs ranging from 10 kg/h to 1,000 kg/h, they rank among the most powerful WPC extruders on the market. They are specially designed to meet the requirements for fiber-composite extrusion, to ensure an optimal melt quality of materials that are sensitive to shearing and high temperatures over the entire process. Degassing of the melt as well as the necessary pressure build-up, without overheating and degrading the material, are of paramount importance. This is ensured by a range of screws individually adapted and equipped with a special coating for a great variety of compounds. Through co-extrusion it is possible to restrict the application of additives, such as UV stabilizers or colorant master batches, to the visible surface of WPC profiles, which significantly reduces the costs of the product. Co-extrusion lines are available in various different configurations.
Downstream equipment and control technology Downstream equipment battenfeld-cincinnati profile extrusion lines are rounded off by downstream equipment precisely matching the performance class of the extruder and die. From a modular range of different calibration tables, single- and double-belt or caterpillar haul-offs and various cutting devices, processors can select the optimal downstream equipment for their particular application. In downstream equipment, battenfeld-cincinnati also pays special attention to energy-efficiency and end product quality. Automation Powerful control systems that are easy to understand and to operate, in combination with a step-by-step automation concept, ensure efficient operation in all areas of profile extrusion. All profile extrusion lines are equipped with an intuitively operating control system. Ultimate user-friendliness enables easy handling of even the most complex machine systems. Thanks to individual configuration options, every operator can adapt the control unit to his own special requirements. To facilitate monitoring of all parameters of the extrusion line, a modular monitoring concept is available, consisting of energy monitoring, production monitoring and maintenance monitoring. An automatic calculation function for specific key figures supports processors in optimizing and increasing the efficiency of their extrusion lines. The integration of system extensions such as dosing units, co-extruders and intelligent sensors in the central control system presents no problems whatsoever. The network functionality integrated in the control system provides access to remote maintenance and a convenient facility for integrating the line in corporate production planning systems.
battenfeld-cincinnati Austria GmbH battenfeld-cincinnati Germany GmbH battenfeld-cincinnati (Foshan) Extrusion Systems Ltd. American Maplan Corporation Laxenburger Str. 246 1230 Wien Königstraße 53 32547 Bad Oeynhausen 2 Jinxiang Road, Daliang, Shunde Foshan, Guangdong 823 S. By-Pass, P.O. Box 832 McPherson, KS 67460, USA P +43 (1) 61006-0 F +43 (1) 61006-8 P +49 (5731) 242-0 F +49 (5731) 27124 P +86 (757) 2238 0110 F +86 (757) 2221 1801 / 2238 0195 P +1 620 241-6843 F +1 620 241-0207 austria@battenfeld-cincinnati.com germany@battenfeld-cincinnati.com china@battenfeld-cincinnati.com usa@battenfeld-cincinnati.com www.battenfeld-cincinnati.com