WPC Blog

Home  -   WPC Blog

WOOD PLASTIC COMPOSITES
Source: Plasteurope.com

Optimism at recent "Fourth German WPC" congress / Double-digit growth rates / US still world's largest WPC producer / China set to dominate the global market by 2015

Future growth driven by US, China
The industry’s optimism is anything but surprising if one turns the gaze beyond Europe, specifically to the US and China. With a production volume of 1.5m t/y, the US remains the world’s largest WPC producer. However, nova Institut points out, this growth has slowed in recent years amid numerous quality complaints that have seen a number of American WPC producers taken to court. Partly as a result of such legal action, the number of North American WPC producers has dropped from 27 to 16. Yet, in parallel to this contraction, output quality has also once again improved, with North American WPC output now on a par with European standards, fixed by the Association of the German Wood-based Panel Industries (www.vhi.de).

Another promising growth market is China, where some 700,000 t/y of WPC were produced in 2010. That output is expected to rise to an impressive 5m t/y by 2015, which – according to nova Institut – would make China the world's largest WPC producer. Domestic wood plastic composite producers number about 300, who mostly use wood flour or lignocellulose-rich crop residues, including rice straw and husks, as raw materials.

PLY REPORTER Magazine, January 2016, India.

Q. What would be the new products at your stall?
A: We shall demonstrate wood polymer composite technology and products (both) during this exhibition. We are going to launch ‘A purchase guide for WPC’ during this exhibition.

Q. How do you establish that WPC is an alternate of Plywood?
A: WPC has following specialties to replace plywood:
1. Good screw holding for furniture making (holes can be refilled easily with same material & solvent for life long sustainability)
2. Good Dimensional stability for structural applications
3. Good machinability for wood working and panel processing,
4. Water resistant and termite/borer resistant
5. Outstanding surface finish for direct applications in furniture and partitioning

Q. Besides Water resistance and Anti Termite properties, what are other advantage of WPC/PVC boards?
A:
1. Adhesive friendly and works well with self-adhesive tapes for HPL, Stainless Steel plates, Acrylic
2. Printability on surface for Direct Digital printing & roller printing possible,
3. Direct use of WPC panels for carcass/storage building without HPL or Paint or coating,
4. Light weight construction possible & best for green buildings
5. 100% recyclable nature and can be reused the material at any future date
6. Value for money and assures 20% money back (as scrap even) at any future date
7. Fastest material ever for furniture making with solvent joinery
8. Can be 90 degree bent with ‘V’ grooving technique for door making
9. WPC Thicker sheets can be directly used as Solid Door that replaces solid wooden door & ply doors
10. Best product for CNC routing and serving to a huge interior and exterior Grill board market, replaces MDF & Wood
11. No headache for putting filling and painting for end use, it’s plug and play material

Q. Strength of Board is directly related to Density, but WPC/PVC boards carry very low density, hence how do you compare these boards with Plywood?
A: Only Density doesn’t play a role in this new era. Property of a material also carries a lot of importance. Usually density remains in discussion with its relation to screw holding capacity of a materials. But WPC PVC boards holds screws nicely with having moderate density (not low density). You can get this boards with even 900 Kg/cum also. Most importantly, No screw furniture is an upcoming trend with this materials. WPVC boards are capturing furniture markets with its most effective joinery technique with solvent cements/cyanoacrylate adhesives. Furniture units are being made without screw with WPVC board & such adhesives. This mechanism works so precisely that a 15 ft long wardrobe build up with Cyanoacrylate & WPVC boards becomes one unit with several joints. It keeps standing with superb dimensional stability and no warpage. Small units like storage boxes, side trolleys, book shelves, office table units etc can be built in couple of minutes, just without screw.

Q. Who are your target visitors (Dealers/Architects/Furniture makers) at Indiawood?
A: As a Project & machinery player we look forward for investors from wood, plywood & plastic industry as visitors. As WPC CENTRE we look forward for Dealers, Architects, Interiors & Furniture makers as our target visitors.

Q. What is your expectation from visitors of Indiawood?
A: We forecast this exhibition to be benchmark for WPC industry in terms of number of visitors. Visitors will surely gain more information and knowledge for WPC products and industry as a whole during this Indiawood show. We look forward for more projects and more channel partners.

Q. How do you expect India’s WPC/PVC demand growth this year?
A: This year will be a benchmark year for WPC industry and targeted growth is 25-30%. Being added with more potential players from the industry, WPC PVC will fetch more awareness, demand and consumption too. This year we forecast for a TV advertisement from WPC players. Lot of happenings are expected with increasing demand.

Q. Brief about your company?
A: We work for wood plastic composites only.

Technology division: We take up turnkey projects under HARDY SMITH firm, where we help entrepreneurs establish WPC manufacturing facilities from concept to commissioning. Our scope of business includes Machines, formulations, and production and application know-how.

Product division: As WPC CENTRE we manufacture and supply WPC boards, WPC Doors, WPC Door frames, WPC Decking & WPC wall cladding under HARDYPLAST brand. We take up turnkey projects with architects for supplying modular furniture for farm houses and village sites of Gujarat.

Q. Please also mention your stall number and Managing Director pics
A: Stall number “H2 UL E510”. Please find attached image fyi.

Researchers at VTT Technical Research Centre of Finland have developed a kitchen furniture framework material from plastic polymers reinforced with natural fibre.
It is claimed that the new material, a possible alternative to chipboard, reduces raw material consumption by 25–30 per cent and the carbon footprint of production by 35–45 per cent.

In a statement, VTT's research professor, Ali Harlin, said: 'The frames are lighter by nearly a third because they contain more air. Wastage during production is also reduced. This is a generational shift that revolutionises both manufacturing techniques and design.' According to Harlin, the framework for the kitchen of the future will be compression moulded or extruded. The result is a component of exact dimensions, which does not need to be cut or drilled after production.

The natural fibre reinforcement in biocomposites can be sawdust, pulp, flax, hemp or peat. The new material is also claimed to be significantly stronger than chipboard and has excellent moisture resistance.

Future furniture
VTT has developed this new material in co-operation with Finnish kitchen fitments maker Puustelli.

Harlin believes that furniture companies will be attracted to the new production technique because it will enable them to save on production and transport costs. Furthermore, Harlin said that investments in new machinery will pay for themselves in a few years.

Industrial designer Juhani Salovaara, designer of the Puustelli composite kitchen, said that the starting point for the design was to achieve the smallest environmental impact and the largest degree of domestic origin possible.

The composites used in Puustelli kitchens are manufactured by Finnish forest industry enterprise UPM. According to Salovaara, the degree of domestic origin of biocomposite furniture frames is in the region of 90 per cent. The material’s breaking strength and moisture resistance are claimed to be excellent. It is also significant for the end user that the furniture’s formaldehyde discharge is diminished.

Harlin thinks it is likely that the innovation will also be of interest outside Finland as some European furniture makers have tried composites, but their production techniques are based on traditional cutting.

According to Harlin, VTT will continue developing biocomposites and charting new applications for them. 'One point of interest lies in whether biocomposites could be used in cars and other vehicles. In that field, weight is money even more than in furniture.'

RESINS FOR WPC
Popular polymer resins for WPC are PVC (Polyvinyl chloride), PE (Polyethylene) and PP (Polypropylene). Globally PE and PP based wood polymer composites are widely used. Indian has started with PVC based WPC board manufacturing in last years. With main resins there are several additives and fillers get mixed to create a proper formulation according to the property requirement of the product. PVC is widely used for making WPC boards, WPC Indoor profiles as well outdoor profiles too.

PVC’s properties like lead the material for use into interior products like modular furniture, door frames, window frames, doors and other profiles. Products made with PVC can be printed and painted directly. It has a tendency to work with cyanoacrylate adhesive for faster joineries.

PE/PP are widely used for exterior grade products such as outdoor WPC Deck floors, Wall claddings, Pergolas, Gazebos, Benches, Deck tiles, Fencing and facades. It is heavy material by density as a final products and used for rough and tough outdoor applications. Globally PE/PP are known for their use with natural fibre polymer composites.

NATURAL FIBERS
WPC is known as NFPC (natural fiber polymer composite), globally. WPC is made with the use of natural fibers like wood and other agriculture residues/waste fibers. Saw mill dust is widely used after converting into fine mesh wood powder. This can be of different species of wood e.g. Pine, Teak etc.

Countries like India - where Agriculture is a major activity – has variety of agricultural waste fibers. Rice husk is one of them and can be collected easily compare to other fibers. Apart, jute fibers, wheat straws and bamboo are also termed as fiber resources.

WPC sheets can be used for architectural sculptures and murals. Previously we understood about the application of sheets for heritage design preservations. Moving further towards sculptures and murals architects can create unique formations from WPC boards because of its precision for CNC cutting. WPC boards carry outstanding properties for use if outdoor weather applications as shown in the picture.

Here it is a ‘Whale sculpture’ created by CEPT students of Ahmedabad from Co-extruded white sheets. There is no paint or surface protections used and this structure is placed at the shown premise since almost 4 years now. It has suffered 4 monsoons and 4 winters now. Importantly it has faced 4 scorching summers of Ahmedabad also that goes upto 50 Degree Celsius.

At times you can paint this also for adding more life, not immediately like wood but may be after several years. I would say this as a very important material for architectural creations those need to be made faster, economic, smarter and for long life also. Similar sculptures if designed for interiors, then what to say about its life….may be endless!

Published: 15 August, 2011

Panel producer Sonae is diversifying into the wood-plastic composites industry after signing a licensing deal to commercialise new technology in Europe.

Sonae has signed a licensing deal with New Zealand-based Crown Research Institute Scion to manufacture and sell the latter's technology, which enables production of wood-plastic composites with long wood fibre reinforcement.

"Our company has been interested in this technology for a few years, and our successful trials with plastic processing operations have given us the confidence to introduce this new material to Europe," said Christophe Chambonnet, Sonae’s chief marketing and sales officer.

Sonae has named the technology's product 'WoodForce' because of the strength the material combination gives to traditional polymers.

"As one of the world leaders in wood technology, with over 10 million tons of wood processed annually, Sonae Indústria needs to have an important role in the future of the wood sector," added Mr Chambonnet.

"I have no doubt that we are creating a new future by mixing wood fibres with thermoplastic polymers and a new perspective on the use of the wood fibre."

Wood plastic 'pellet' composites produced by the technology can be fed easily into conventional extruders and injection moulders and processed as bio-based fibre reinforced plastics."

Technology Partner

The research has great relevance given that disposal of plastic waste by way of landfills induces environmental and space problems while incineration leads to air pollution and aggravation of global warming

By Bonnie James/Deputy News Editor/Gulf Times

In a development that could substantially improve the quality of recycled plastics, Qatar University’s Centre for Advanced Materials (CAM) has made progress in research to produce recycled polymer composites which are cheaper than pure synthetic fibre composites and have superior properties.

"Date palm wood flour and date palm leaf fibre, abundantly available as agro-waste material in Qatar, were added to produce recycled polymer composites which could be utilised for a wide range of applications in different fields," post doctoral researcher Dr Noorunnisa Khanam Patan told Gulf Times.

Glass fibre and mica were also used as reinforcements with recycled polymers in the research programme being conducted under the supervision of associate professor and CAM director Dr Mariam al-Ali al-Ma'adeed.

"The objective is to use recycled polymers as a matrix to reduce environmental pollution, considering that Qatar produces a large quantity of polyethylene plastics and substantial amounts of plastic wastes are available as municipal solid wastes," Dr Patan explained.

The research has great relevance given that disposal of plastic waste by way of landfills induces environmental and space problems while incineration leads to air pollution and aggravation of global warming.

"Over the past few decades, polymers, due to the ease of processing, better productivity and cost reduction have replaced many of the conventional materials such as metals, wood and ceramics in various applications," she pointed out.

Polymer is a macromolecule, made up of many small molecules which have combined to form a single long or large molecule. The individual small molecules from which a polymer is formed are known as monomers and the process by which they are linked to form a big polymer molecule is called polymerisation.

There are natural and synthetic polymers. Natural polymers are those isolated from materials such as cotton, wool, leather, silk, and cellulose rayon. Synthetic polymers are synthesised from low molecular weight compounds and examples include polyethylene, polyvinyl chloride, and nylon.

Depending upon its ultimate form and use, a polymer can be classified as thermoplastic, thermosetting, plastic, elastomer, fibre and liquid resin. "The combination of conventional polymers with fibre or fillers is an important alternative to obtain new polymeric materials with designed properties to suit the high strength/high modulus requirements, and these are called polymer composites," Dr Patan said.

A composite is a mechanically separable combination of two or more component materials, different at molecular level, but mixed purposefully to obtain a new material with optimal properties.

Polymer composites are widely used in varied fields, including automotive, sports goods, construction, aerospace, marine, electrical, biomedical applications, and chemical equipment.

There are two types of constituent material: matrix and reinforcement. Thermoplastic, thermosetting matrices are used as the matrix in polymer composites with natural and synthetic fibres as reinforcing materials.

The most common include polyester, vinyl ester, epoxy, phenolic, polyimide, polyamide, polypropylene, and polyether ether ketone.
The most common natural fibres are sisal, jute, coir, and date palm fibre and synthetic fibres are glass, Kevlar and carbon.

"The objective of the current research at CAM is to produce recycled polymer composites that incorporate naturally available, environment-friendly plant-based fibre as an alternative reinforcement material, imparting high specific strength and stiffness," Dr Patan said.

Though recycling helps conserve materials, it is known to change the mechanical, physical and chemical properties of the recycled plastics to some extent, thereby lowering their economic value. This could be overcome by adding suitable plant-based fibres.

"Deforestation and growing environmental concerns were the main driving forces for the launch of wood-plastic composites as a natural wood substitute over two decades ago," the researcher recalled.

The research at CAM comprised four parts. In the first stage, glass fibre was added to date palm wood flour to improve its mechanical properties. In the second stage, recycled polymer composites were prepared by using date palm leaf fibre and in the third stage recycled polymer and mica were used. The fourth stage involved a study of the mechanical, thermal, and morphological properties of the composites.

Source – Plastemart.com

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:

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 from the low level in 2008.

David Vink, European Plastics News

Germany-based Bayerische Maßindustrie (BMI) is using profiles made by NaturinForm, a wood-plastic composite (WPC) profile producer also based in Germany, for its Polywood spirit level – the first housed in WPC.

BMI said it looked for a material that provide the consistent and smooth surface necessary for the strict measurements for spirit levels - 0.5mm/m for flat positions and 0.75mm/m for rotated positions.

According to NaturinForm design and development manager Bernd Motschenbacher, the company achieved the smooth surface by using a finer wood fibre and a symmetrical profile contour, as well as an enhanced extrusion calibration process. And the cooling of the extruded WPC profile ensures that it does not warp in storage, says Motschenbacher.

The Polywood spirit level is made from an insulating, non-conductive WPC material so can withstand exposure to voltages of up to 1,000 volts. It is suitable for use in Zone 1/21 and Zone 2/22 explosion-protection environments, such as in coal mines.

BMI says its Polywood spirit level is warm to touch and resistant to soiling. The company produces the cutouts for the spirit bubbles and says there is unrestricted visibility of the horizontal spirit bubble, as there is no separate edge around the recess, as there is in conventional spirit levels.

The Polywood spirit levels are available in lengths of 40cm, 60cm and 80cm. They join a range of spirit levels made by BMI that also include models housed in ABS for smaller mini and pocket models and glass fibre reinforced ABS for a torpedo-shaped spirit level, as well as standard aluminium versions up to 100cm.

NaturinForm was founded by its managing partner Horst Walther, who invested €1m in the former Poly-Pro-Tec (PPT) company’s WPC production facilities and product diversification in 2009, bringing PPT out of insolvency.

Aside from spirit levels, BMI products also include ABS, glass fibre reinforced ABS or PA, PVC, metal and wooden extending rulers, as well as retracting tape measures enclosed in ABS and two-component ABS/elastomer soft-touch housings.

India's WPC Capacity today

WPC market has actually evolved with really a good pace. In these four years, India has witnessed establishment of more than 50 odd manufacturing facilities for making different WPC products including WPC Sheets and WPC Decking. More players are in pipe line and we are projecting a volume of more than 300 manufacturers in coming 5 years. This subject will go nuclear way. Today, Gujarat is leading the subject with more than 22 players. Ahmedabad is the leader city with more than 7 Lines. We are ahead of Japan as a country manufacturing WPC.

Weather & Cultural issues
We are genuinely facing problems of moisture and termite. Our furniture – be kitchen or bedroom – can be affected anytime due to these two issues. We are carrying culture of cleaning floors with wet clothes or free water. Any culture cannot be changed over the night. This has created a problem of reduced life of furniture – be it with wood or modular with particle board or MDF board.

WPC sheets play a strong and positive role here and it is becoming more and more popular amongst Indian users. Carpenters and Architects have got good understanding about the product and they are using WPC now more effectively in their creations.

Customers' anxiety
We have always got curious, interesting and positive responses, while we promote or talk about WPC. At initial stage some threw it off just without understanding it. But such cases are very low. More we have got positive and solid interest only. Once one understands the product he/she will say "This is a future product!"

Basic question was coming with two techno commercial challenges - price and screw holding and those answers are also well understood by the market.

Price comparison
Reiterating the same here "Any plywood/MDF/Particle board cannot be used without surface protection. This surface protection is must and required expense for HPL on both the side, glue for that and labour. With WPC you can directly apply the sheets while making furniture. For elevation/shutters only you have to use HPL or Paint or any other substrate which is normally being used with wood panels also. An average cost of WPC sheet match the cost of a wood panel that is ready for application. Importantly, it is 100% recyclable and its user can get at least 15% cost back at any point of time in future.

Screw Holding
Screw holding is moderately perfect and better than MDF and Particle boards. Apart, you can refill the screw gap with PVC grips available in the regular market with use of PVC Solvent Cement.

Mass level awareness
Amongst Other challenges one is the mass level awareness of this product. Still product is not reached to each and every corner of the country. Larger players like Century Ply has started marketing this product and we are waiting for more such players’ entry those can brand this product on TV Media.

Global interest in India
India is becoming popular destination for WPC products. With more than 50 odd manufacturing lines our country is fetching attraction from all over the world. We are targeting equal percentage (50%) turnover from foreign markets. This will include WPC sheets and WPC decking, respectively.

WPC actually is well accepted in Global markets. I would say, we are late for understanding and taking interest in this product. Those countries are well developed and they are using WPC as a part of their consciousness about greenness. For us WPC is becoming necessity. We don’t have effective plantation practices, rules and initiatives. We are importing lot of timber and today only Gandhidham has become the largest timber import zone of Asia.

Logically, WPC has started being accepted as WPC Sheet first and now we are accepting WPC decking too. This is reverse in case of global markets. Today India has overtaken Japan in WPC production with total installed capacity more than 60,000 Tones/year. It has happened in last 4 year only and it goes more aggressively now. This is happening because of a comfort for accepting a product that is already running in Europe, USA, Japan & Australia like countries.

WPC PANELS for furniture
India is using WPC panels most effectively than the entire world. You may get amazed but this is the fact that we are using WPC sheets in variety of applications taking from Doors, Frames, Carcass, and Shutters and so on. You make Grill boards, wave boards, digital panels, molding panels etc.

Mandatory material for Carcass
It's a forecasting that for carcass making PVC WPC panels will become 'mandatory material'. You can directly use WPC panels for kitchen, wardrobes, shoe racks, book cases or any other box making. You don't need to apply any HPL while using in this application. Further, Carcass occupies more material than shutters so in terms of volume also it covers a larger market. Direct use of WPC Sheets can give advantage of ‘buy back' to the manufacturer and this system is already into implementation. This way same material can be used and flow of material & revenue will be maintained. This cycle will encourage bringing the overall price level of the material down in the future.

About HARDY SMITH
We have been serving wood panel industry more than a decade now. Derived from the alma maters like Rushil Décor & Hallmark, wood panel technology has been a domain of interest always for us. We have entered into 5th year now as a company dedicated to WPC sector. We are working as a pioneer for WPC subject in India and our march is still on will remain continue, as it is a passion for us now. We take up turnkey advisory projects for WPC product. We have got business cooperation with battenfeld-cincinnati, Austria for larger projects. At the same time we are cooperating with Jelu, Germany for WPC compounds for different mouldings.

We have established WPC CENTRE at Ahmedabad to develop, promote, educate and supply of WPC products and vivid applications. This is the state of the art centre supplying WPC sheets, WPC Doors, WPC Door frames, WPC modular furniture, WPC Wall claddings, WPC Flooring and WPC planks. This is all under one roof.

WPC - Wood Plastic Composite – a promising and sustainable green material

Hardik Panchal for Wood News, India.

WPC - Wood Plastic Composite – a promising and sustainable green material is being evolved as a fundamental product for India, after being well adopted by the world.

India, a country is having vivid climate conditions, vivid culture, vivid growth patterns and booming infrastructure industry today. Increasing industrial growth is empowering entire India by covering four of its extreme corners, geographically. Increasing human potential is being supported by fascinating employment and business opportunities pan India.

Demand is rapidly increasing for interior and exterior grade materials in building material industry. Modular kitchen are in high demand today, parallel to modular office and home furniture. Timber import is increasing day by day and lot of waste is also being generated in volumes. This waste is coming out of saw mills, plywood mills, veneer units, Particleboard units, MDF units as well as from good quality agriculture residues like Cotton stalks, Sugarcane bagasse, Coir fibers and even Rice husk.

Wood panels are tested and tried to be made out of agriculture residues other than bagasse. At certain level success is achieved but not really promising, thus, question for ‘effective utilization pattern’ of good quality agro residues is still remain. At the same time demand for environmentally appropriate technology is increasing which can really reduce consumption of natural wood. Wood panel technology demands for efficient fiber conversion techniques that can drastically reduce fiber wastage.

WPC, Wood plastic composite, a product with a class, can help meeting global demand of wood products and wood panels. It is a new kind of synthetic material made from waste plastic & wood discharged from mills & factories as well as agriculture residues. It is a natural fit with primary and secondary forest product industries. By construction this product is formulated from - plant fibers as fillers and reinforcements - for polymers. This is one of the fastest growing types of polymer additive.

WPC can replace many direct materials like Solid/Natural wood, Plywood, MDF boards, Particle boards, Steel in various applications. Finished Products can be made out with Wood plastic Composite is classified as follows:

Lakda Udyog Darshan, July 2013, India.

Q1: Why wood polymer composite (WPC) is becoming more and more important for India, even though import of wood is increasing day by day?
A1: Wood plastic composite manufacturing doesn’t need logs or timbers, but this subject is a boon for wood wastes including sawmill dust, plywood sanding dust, bagasse dust, Rice husk, Jute husk and other forms of wood wastes. WPC product formation can use such natural fibre wastes ranging from 10% to 70% of formulation. Thus directly it has no relation with forests and bigger formats of wood and timbers. This way we are saving forests at the first sight and utilizing waste materials at a great instance.

India is being developed as a prominent manufacturing destination for WPC products, globally. Started reversely from international WPC trends India has picked up WPVC panels, rapidly due to all time favourite and upcoming infrastructure developments within the country. India has 'yet to see' situation for furniture industry.

Q2: How WPC can be compared with Wood panels and Softwood in terms of quality aspects?
A2: Please find the following properties of WPC boards made with PVC as the core polymer.

WPC boards are ideal for panel applications in modular furniture. They can withhold screw well. It has dimensional stability. Moisture and termite resistance gives long lasting durability. Surface is printable. You can apply HPL, Veneer and PVC foils. You can perform carpentry jobs just as like as the natural wood and wood panel. It has good machinability on any panel processing machine. Its polymeric structure with PVC makes WPC 100% recyclable and green material. WPC for India-in indoor applications-is the best material than any other wood panel.

Properties of comparison	WPC - Smart wood	Plantation timbers like eucalyptus/ poplar
Sturdier core
Recyclable material
Stronger impact resistance
Low water absorption
Mould resistance
Stain resistance
Rot and splinter free
Easy to cut, router and fasten
Easier installation
High insulation properties
Aesthetic value
Ready to use
Termite and borer resistance
Easier to clean
Easier lamination
Good printing

WPC – Becoming popular amongst Re-sellers and End users

Wood polymer composite and India both are becoming popular for each other nowadays. India, as a country is becoming popular destination for PVC based WPC board’s supply. Country is set with more than 35 odd manufacturing lines for WPVC sheet lines and more than 10 lines for profile production.

PVC (Poly vinyl chloride) is a major raw material for making WPVC products and Reliance has been Instrumental as a major supplier from within the country. Apart from Reliance local manufacturers are importing PVC from abroad. Companies have well understood the subject and gained enough knowledge about raw materials. PVC additives also are being imported directly by the existing players and major supplier is China, again. Recently, Reliance prices are reduced and companies are offering price discount benefit to the Indian market, positively.

At the other end, Gurjan scarcity and increased resin prices are making plywood more and more costly, day by day. WPVC is being controlled by PVC prices and effectively capturing the market, replacing plywood. WPVC decking, exterior cladding, lumbers and fencing are really becoming popular within end users including architects, interiors, builders and retailers. Good demand is being generated and manufacturers are really less!! WPVC is becoming stronger with new experiments in the quality by Indian players. PVC processing needs lot of patience, as it is the subject of formulations. You can make customized WPVC boards, as per your technical need. WPVC sheet can be made 100% Fire retardant by adding Fire retardant additives. E.g. Finolex PVC cables. Mosquito repellents also are being added, based on the application requirement. Most importantly, WPVC boards can be custom made in any colors and you can directly apply it for the end use, without HPL or paint.

There are exclusive WPC displays are coming into action across the country. Recently, WPC CENTRE is launched by HARDY SMITH and there are numerous WPVC applications showcased including Boards, Doors, Door frames, Kitchen carcass, Wardrobes, Shutters, Wall cladding, Flooring, Modular kitchens, Bathroom vanities, Shoe racks, office partitions, Ceiling panels etc.

There is specific demand being generated directly from the end users for PVC WPC solid sheets. WPVC is enjoying replacements for both the ends, where at one end it replaces Marine grade plywood and at second end it replaces hollow PVC profile market. Hollow PVC profile based doors and furniture market is evolved very fast within a few years. It has also captured a considerable market share of wood panel furniture. That market is nowadays started being replaced with solid WPVC boards, as it looks and works similar like a wood panel. Awareness is still a problem and we forecast presence of big ticket players in WPC market very soon.

WPC PVC foam sheets –Replacing Plywood, MDF & Natural wood in furniture applications

Interestingly, WPVC foam sheets are started being used in several new applications in the market. Since its inception in the Indian market PVC foam sheets have been the product of curiosity and questions. It has happened because of the manufacturing technology which was unfamiliar to the wood industry in India. All wood panels – from particle board, MDF, Plywood, Block boards or Door skin- are manufactured with pressing technology. WPC is being produced majorly from the Extrusion technology where polymer processing, formulations, chemical know how and technology understanding are the major areas to be learned and accepted.

WPC as a Polymer with thermoplastic nature gives advantage of ‘Re-cycling’. Thus, we can save lot of natural resources. It gives other natural advantages of Moisture resistance and Termite resistance. Thus, it is being accepted as the ‘Life time Investment product’ by the Indian lower middle class.

Surface of WPVC is quite polished, even, grain less, non porous, clean, calibration free which can be printed, painted and coated directly. It is a ‘ready to use product’ for total carcase applications. WPVC is the best product for ‘Joinery systems’ and it can be joined or sandwiched very fast and solid with ‘PVC Solvent Cements’. This is the fastest technique –played with WPVC boards for making of various product compositions. Whether it’s a 35 to 100 mm thick solid structure or curvilinear chair/tripod or a master piece in children furniture, you can make it quickly possible with WPVC sheet and solvent cement.

With all above advantages WPVC boards are replacing plywood in Kitchen carcases, wardrobes, office cubicles, overhead units as well in bathroom furniture. Density from 550 kg/cum to 650 kg/cum is the perfect fit for screwing and screw holding applications. The regular method of carpentry with PVC foam sheet works well with ‘screw and solvent’ mechanism. Actually it is similar to the plywood and water based adhesive system only but making time will be minutes instead of long hours. And final structure will be moisture proof, termite proof and may be with even ‘Buy back warrantee’ too!

WPVC sheets are being used for Door frame and Children furniture making also because of its easy to cut, easy to mould nature. The structure doesn’t carry in long fibres, thus it is safe for little kids during use. Applications shown in the images can give enough idea about the end use of the material with solvent joinery, curvature shapes and painted surfaces……but with NO WOOD.

Hardik Panchal,
CEO (MBA, BEng Polymer Technology)
HARDY SMITH WPC CENTRE

Best practices witnessed in last years for modular kitchen manufacturing is with MDF or Plywood panels because of its engineered structure and dimensions. These panels are in practice to be used with mandatory laminations of HPL/Paint on front and back surfaces. This is not only for decoration but also to protect the wooden material from moisture and termite. For high end applications PU laminations are in practice. But the basic structure of the panel is still wood and cannot be considered 100% water proof or termite proof. WPC BOARDS a new generation panels derived technically from Polyvinyl chloride polymer and natural fibre (saw mill dust or agriculture fibre e.g. rice husk) composite. Globally it is termed as natural fibre polymer composite or wood polymer composite.

These panels are made with a vast thickness range from 5 mm to 40 mm. Furniture makers can ask for any odd or even thickness to us for the same. WPC BOARDS are available in different density range e.g. 500 kg/cum, 600 kg/cum, 700 kg/cum and 800 kg/cum. 700 kg/cum and 800 kg/cum is the best product from HARDYPLAST known as HYPER WPC boards. It carries higher wood contents for best screw holding and dimensional stability.

Apart WPC BOARDS are available in 3 layer variant for ready to fix applications in furniture like ‘WPC Prelam boards’. Made with co-extrusion technology 3 layer WPC Boards are having surface density of 1400 kg/cum and shore D hardness more than 85. Plain colour furniture requirements e.g. Hospital furniture can be completely made with 3 layer WPC boards in any colour. These panels are available in any colours based on MOQ.

Most upcoming application and markets for WPC boards are into Digital printing Panels for designer kitchen segment. Same format will become popular for office & home furniture, cabins, toilet cubicles, partitioning systems etc. for designer furniture. Complete interior can be conceptualised with WPC boards with digital printing technology. WPC boards can be directly printed with flat-bed printing technology with high resolution and long lasting UV ink based.

Thus a versatile water proof and termite proof WPC BOARD is ready to fit to your kitchen furniture requirement.

WPC CARCASS – An application becoming ‘mandatory’…

CARCASS becomes a very critical application, while it is placed adjacent to a wall. Depending on the atmosphere and weather pattern of surroundings, seepage/moisture gets accumulated in the walls.

This also happens due to Transpiration. The major mechanism for long-distance water transport is described by the cohesion-tension theory, whereby the driving force of transport is transpiration. The evaporation of water from the exposed surfaces of a furniture in room side. Water molecules cohere (stick together), and are pulled up the wood body by the tension, or pulling force, exerted by evaporation at the exposed surface of a furniture. This is unavoidable and uncontrollable phenomenon.

Apart, Indian system for floor cleaning uses ‘mopping with water’ and it leaves water particles on the furniture panels. This also incurs into well-known problems of decay, fungus, delamination of HPL, bubbling, bending, de-layering etc.

It becomes dangerous when termite comes into picture. Termite in major cases attacks from within the furniture body and we have heard many cases where wardrobes, cupboards falls down leaving the back walls. Wardrobe carcasses, kitchen carcasses, overhead units, storage units, shoe racks etc… are sensitive to termite attacks when placed adjacent to walls.

In coming days, majority of Indian homes will start using WPC PVC boards for this application, as mandatory.

WPC CNC GRILLS - A modern material for preserving heritage…

WPC can be routed with CNC and hand routing machines, just like conventional MDF and wood. Importantly it can be used without surface protection, paints or coatings. WPVC can be available in custom colors and it can help in making versatile creations for designers.

WPC can be grilled for the best artistic creations like following image. Here in image is a world famous heritage site of 'Sidi Saiyad's Mosque and popularly known as 'Sidi Saiyad’s Jali' from Ahmedabad. It is carved on WPC sheet without paint and applied with LED backlighting. Such many architectural and heritage derivations can be developed for interiors. Surely this will long last than wood or MDF as its moisture and termite proof.

You can work with 5 mm WPC single layer sheet for minor and major carvings, without any stability issue. 3 layer WPC sheets can be a better option for such a work. As WPC sheets can be made with lower and higher density architects can choose the right substrate based on the requirement on Grill work. 3D routing also can be efficiently done on higher thickness – higher density sheets. This can be done well on 28/30/35/40 mm sheets. There are unique applications of WPC Grill works in luxurious look outs of home, hotels, hospitals, temples, apartments, villas and farm houses.

WPC DOORS | WPC SOLID DOOR FRAMES

Wood polymer composites is evolving as a great material for India. Popularly known as 'WPC' – fetches attention and becoming material of attraction for architects, interiors, project engineers and contractors. Because of its core technical properties of 100% water proof, 100% termite proof, 100% borer proof and 100% recyclable. HARDY SMITH with its known product brand of ‘HARDYPLAST’ is the single largest supplier of WPC products in the country.

WPC Doors and WPC Door frames are becoming essential part of new projects and government departments are also including WPC products into tenders. HARDYPLAST Doors are supplied in different thicknesses from 24 mm to 35 mm. WPC Doors are available in Plain solid door format, 3 layer Flush door format and Profile Door format also. WPC Solid door frames are made in different dimensions to fit to the main door, internal doors and bathroom doors. WPC Door frame is a unique product that is becoming favourable amongst carpenters and installer because of its 'ready to fix' design.

One can paint, polish or coat to the WPC Door and Door frame surfaces. WPC products are maintenance free, while being used in its natural form itself. Hotels, hospitals, hostels, temples, farm houses, village sites, clubs, restaurants, villas are the best suitable places for all WPC materials. HARDY SMITH has rendered the WPC arena in India and as a techno-commercial advisor serve to foreign territories also. 'WPC CENTRE' - a retail chain is coming soon across India for a complete WPC product solution. For more details kindly check www.wpc-centre.com.

Poly vinyl chloride – is an instrumental material behind the making and formulating of wood polymer composites, in case of India. India is becoming popular destination for PVC based WPC. Country is witnessing a continuous growth with addition of new players regularly since last 4 years now. Indian exhibitions are adding stalls for WPC products now for new brands. A lot of activities are going on for this product and its promotion, carpenter meets, and architect meets etc at different levels are on. Product showcasing also is in action and you can find exclusive ‘WPC CENTRE’s in action.

WPVC board as a popular product is set for quality, supply and varieties. At inception wood PVC board was woody brown. Now it is available as WHITE PVC foam sheet. Recently it is being available in all the colors with beautiful surface luster. WPVC sheets can be available in different colors and can be applied to the end use without HPL or Paint. A few standard colors are Brown, Grey and Ivory. These boards are replacing MDF and Corian type materials in CNC designer panel applications. Apart from this Ivory and grey colored sheets are becoming fit for kitchen carcass and wardrobe carcass. For office furniture and partitions such colored sheets are replacing compact HPL. Toilet cubicles are also being made with this.

PVC is resistant to ignition. The temperature required to ignite rigid PVC is more than 150oC higher than that required to ignite wood. The high chlorine content of PVC polymer reduces its ignitability and also the heat it contributes to a fire. High concentrations of organic materials will increase flammability; high concentrations of inorganic materials will reduce it.

Ignition Temperatures for Various Materials (ASTM 1929)

WPC MODULAR KITCHEN – A waterproof, termite proof, clean & hygienic set up for homes

Modular Kitchen – a necessity in today's world for each and every homes. Well designed, engineered, customized and user friendly kitchens are made in modular format with conventional wood panels like MDF and Plywood. Most favoured panel for kitchen was water proof ply before WPC panels. Now WPC PVC panels are becoming the most favourable panel material, replacing wood, plywood and MDF.

Be it a carcass or shutter, WPC panels are used for both the applications vigorously. Indian system for 'mopping with water' leaves moisture in the atmosphere as well as on the furniture panels. This incurs into well-known problems of decay, fungus, delamination of HPL, bubbling, bending, de-layering etc in case of plywood.

WPC panels have a homogeneous structure throughout made with PVC polymer. Being a polymerised product, it doesn't have tendency for moisture absorption, de-layering, termite attraction, fungus attraction, borer growth platform. These all are the prominent and promising characteristics for modular kitchen application.

VERTICAL GARDEN ON WPC SHEETS

HARDY SMITH recently supplied 'GREEN WPC SHEETS' for 'VERTICAL GARDEN' at a known project brand 'SAHITI' in Hyderabad. This is a fresh application introduced with WPC Sheets in outdoor application for creating artificial garden on vertical façade of a building.

Vertical gardens are becoming very much popular in the country and as a part of 'Green Buildings' it is becoming almost mandatory for professional builders. Many companies are introducing Vertical Gardening in their 'Indoor' office walls also. Antilia is a private home in South Mumbai, India. It is owned by Mukesh Ambani, Chairman of Reliance Industries and that is also cladded with vertical gardens on outer walls. Because of space issue and increasing cost of land, people those are sincere/fond about environment keeping vertical gardens in/out side of their buildings.

Recently applied vertical garden at Sahiti, Hyderabad was a unique creation, where metal fabrication structure was mounted on the facade areas of the building first. WPC sheets with Green pigments were fixed randomly over the façade. WPC Sheets were mounted as a base for fixing the garden templates over it. Artificial Grass is used here to create the 'Vertical Garden' and fixed on the pre-mounted WPC Green sheets. The final look created as vertical garden that is completely maintenance free with 100% water proof and 100% termite proof properties. Becoming rapidly popular WPC (wood polymer composites) are finding many new application spaces and replacing conventional wood and plywood. WPC acts efficiently where plywood and wood gets restriction because of its 'limitations with water, moisture, weather and termite'.

Overall ambience of the building became eye-soothing and cool as 'Garden and Greenery' is the most attracting layout for the human being. At this application we eye for more and more Eco-friendly/Enviro-friendly Green applications with WPC.

Wood Polymer Composite

A best alternative to natural resource 'Wood'
A smart material for the next generation

It has been 7 years recently to the inception of WPC sector in the country. Started with WPC sheets manufacturing, the sector today is making WPC Doors, WPC Door frames, PVC Laminates and Marbles, WPC flooring, WPC Decking, WPC Pergolas and so on. India has witnessed a new industry parallel to the conventional wood sector. A new whole Industry with more than 150 odd manufacturing lines making different kind of WPC products today. An Industry producing and promoting new generation material those save lot of trees in its daily operation.

Every 25 Door frames save one fully grown virgin tree and if considered the recycling of the same, it can save 3 fully grown virgin trees. Same is there with WPC Sheets and other products. This is a benchmark phenomenon for the country like India, where still no huge plantation drives are in action. Country is loosing it's green cover and water levels are depleting day by day. Summers are becoming more and more scorching and weathers are changing their patterns.

USE of WPC is a responsible approach towards the mother earth, towards the next generation and towards the nation. It is a material which is simply replacing the use of Virgin trees/wood for furniture and allied products making. This material with several other technical properties can replace even Aluminium/other metals/Marble/Stone as well.

Manpower crisis in labour jobs is becoming a very much sensitive issue and in this case whole nation needs to be switched over to the alternative raw material. We have to use materials and products those are user friendly, takes less time in assembling and project completion. It is a time to use Smart materials like WPC.

An education and awareness drive is responsibly managed since last 8 years by HARDY SMITH. It is a green initiative of HARDY SMITH for promoting the sustainable material WPC, which can save lot of trees. We are trying to promote the maximum possible applications of WPC that can minimize the use of WOOD in all the aspects. We urge the entire nation to give their hands in promoting and using WPC as a next generation material.

USE WPC. Save trees. Save earth.