Detailed Project Report (DPR) on wood plastic composite board (wpc)

WOOD PLASTIC COMPOSITE BOARD (WPC)
[CODE NO.3283]  

Wood–plastic composites (WPCs) are a form of composite combining wood-based elements with polymers. The processes for manufacturing WPCs include extrusion, injection molding, and compression molding or thermoforming (pressing). Newer manufacturing processes for WPCs include additive manufacturing via fused layer modeling and laser sintering. An important constraint for polymers used in WPCs is requiring process conditions (melt temperature, pressure) that will not thermally degrade the wood filler. Wood degrades around 220 °C; thus, general-purpose polymers like polyethylene and poly vinyl chloride are typically used for manufacturing WPCs. Wood fibers are inherently hydrophilic because of the hydroxyl groups contained in the cellulose and hemicellulose molecular chains. Thus, modification of the wood fiber via chemical or physical treatments is very critical to making improved WPCs. The most abundant profiles made from wood–plastic composites are boards or lumber used in outdoor decking applications. Although early WPC products were mainly extruded for profiled sections, nowadays, many injected parts made of WPC are being introduced for various industries, including electrical casings, packaging, daily living supplies, and civil engineering applications. Mold and mildew and color fading of WPCs tend to be the durability issues of prime importance for WPCs. Most recent research on WPC durability focuses on studies to better understand the mechanisms contributing to various degradation issues as well as methods to improve durability. Most WPC products in the USA are utilized in building materials with few exceptions for residential and commercial building applications, which means that building codes are the most important national rules for the WPC manufacturers. New developments are being made especially in
the area of nano additives for WPCs including nanocellulose. Recently, the trend of patent registrations for WPCs has shifted to new products or applications instead of the materials itself.

Wood-plastic composites (WPCs) are composite materials made of wood fiber/wood flour and thermoplastic(s) (includes PE, PP, PVC etc.).

In addition to wood fiber and plastic, WPCs can also contain other ligno-cellulosic and/or inorganic filler materials. WPCs are a subset of a larger category of materials called natural fiber plastic composites (NFPCs), which may contain no cellulose-based fiber fillers such as pulp fibers, peanut hulls, bamboo, straw, digestate etc.

Chemical additives seem practically "invisible" (except mineral fillers and pigments, if added) in the composite structure. They provide for integration of polymer and wood flour (powder) while facilitating optimal processing conditions.

In recent years, people in the flooring industry starts referring to WPC as a type of floor that has a basic structure of top vinyl veneer plus a rigid extruded core (the core can be made without any wood fiber). WPC is now an established product category within LVT. This type of WPC is different than the WPC decking and is not intended for outdoor usage.

COST ESTIMATION

Plant  Capacity                                                  :       1024.00 sq.ft./day                  
land & Building (500 Sq.Mtr)                          :        Rented
Plant & Machinery                                             :       Rs. 30.00 Lacs
Working Capital for 1 Month                           :       Rs. 10.69 Lacs
Total Capital Investment                                 :       Rs. 43.69 Lacs
Rate of Return                                                  :       52%
Break Even Point                                             :        61%

INTRODUCTION    
USES & APPLICATIONS    
OURDOOR APPLICATION OF WPC    
RAW MATERIALS    
POLYMERS    
WOOD    
ADDITIVES    
ADVANTAGE AND DISADVANTAGE OF WPC    
ADVANCE MATERIALS FOR WPC    
WOOD MODIFICATION    
ADDITIVES    
PROFILES    
ASPECT OF WPC DURABILITY    
STRUCTURAL    
WEATHERING STUDIES    
FIGURE  POLYETHYLENE (PE) – BASED COMPOSITE    
DIFFERENT PROCESSES FOR WOOD PLASTIC COMPOSITES    
EXTRUSION PROCESSING    
SINGLE-SCREW EXTRUDER    
COUNTER-ROTATING TWIN-SCREW EXTRUSION    
COMPOSITE SYSTEM    
WOOD RUDER    
MISCELLANEOUS POST-EXTRUDER UNIT OPERATIONS    
WPC MANUFACTURING TECHNIQUES    
WPC REPROCESSING    
WPC NEW MANUFACTURING TECHNOLOGY    
EXPERIMENTAL STAGES    
PILOT EXPERIMENTATIONS    
PREREQUISITE STAGE    
STAGE 1    
STAGE 2    
STAGE 3    
PROCESSES EXPERIMENTAL SETTINGS    
FIG. ILLUSTRATIVE PROCESS FLOW CHART OF WPC MANUFACTURING    
COMPONENTS OF WPC    
MATRIX COMPONENT    
THERMOSETS    
THERMOPLASTICS    
WOOD COMPONENT    
WOOD SPECIES    
WOOD PARTICLE SIZE    
MARKET SURVEY    
MARKET SHARE    
QUALITY OF WPC IN INDIA    
DESPITE BEING A PLASTIC COMPOSITE, WHY IS WPC CALLED
A GREEN MATERIAL?    
FUTURE OF WPC IN INDIA    
MARKET SURVEY (GLOBAL)    
NEW MARKET- WPC    
FENCING FUTURE    
THREAT FROM THE EAST?    
FEWER, BIGGER PLAYERS    
ADDITIVES CREATE RECIPE FOR GROWTH SUMMARY FIGURE GLOBAL MARKET FOR APPLICATIONS OF WPCS, CELLULOSICS, PLASTIC
 LUMBER, AND NATURAL FIBER COMPOSITES, 2008-2016 (METRIC TONS)    
EXPORT OF WPC FROM INDIA    
DETAILED IMPORT DATA    
OF WOOD PLASTIC COMPOSITE    
PRESENT MANUFACTURERS OF    
WOOD PLASTIC COMPOSITE BOARDS LINE    
FORMULATION OF WPC BOARD    
COMBINATION OF WPC BOARD    
MANUFACTURING PROCESS OF WPC BOARD    
PROCESS FLOW DIAGRAM OF WPC BOARD    
PRODUCTION OF WOOD PLASTIC COMPOSITE    
TECHNICAL DETAILS OF WOOD PLASTIC COMPOSITES    
THE ROLE OF RESINS:-    
VARIATION IN PLASTIC FEEDSTOCK:-    
PROCESSING CONSIDERATION    
OF WOOD PLASTIC COMPOSITES    
MOISTURE AND TEMPERATURE    
THE WPC MANUFACTURING PROCESS    
WITH EXTRUSION FORMING    
DETAILS OF RAW MATERIALS    
TABLE 2.0: FUNCTIONS OF ADDITIVES USED IN THERMOPLASTIC COMPOSITES    
MECHANICAL PROPERTIES OF WOOD-POLYPROPYLENE COMPOSITES*    
TECHNICAL DETAILS OF PVC WPC FOAM BOARD LINE    
TECHNICAL/TURNKEY CONSULTANT FOR SETTINGUP WPC PLANT    
SUPPLIERS OF PLANT & MACHINERIES (IMPORTED)    
SUPPLIERS OF PLANT & MACHINERIES (INDIAN)    
MANUFACTURERS/SUPLIERS OF PLANT & MACHINERY    
EXTRUDERS    
PRESSING MACHINE    
COOLING TOWERS    
BOILER    
GENERATOR SET (D.G. SET)    
MANUFACTURERS/SUPPLIERS OF RAW MATERIALS    
WOOD FLOUR    
PLASTIC POLYMERS    
COUPLING AGENT    
ADDITIVES    
                        
            
        
APPENDIX – A:

 1.      COST OF PLANT ECONOMICS      
 2.      LAND & BUILDING                                      
 3.      PLANT AND MACHINERY                                  
 4.      FIXED CAPITAL INVESTMENT                             
 5.      RAW MATERIAL                                         
 6.      SALARY AND WAGES                                     
 7.      UTILITIES AND OVERHEADS                              
 8.      TOTAL WORKING CAPITAL                                
 9.      COST OF PRODUCTION                                   
10.      PROFITABILITY ANALYSIS                               
11.      BREAK EVEN POINT                                     
12.      RESOURCES OF FINANCE                           
13.      INTEREST CHART                                       
14.      DEPRECIATION CHART                                   
15.      CASH FLOW STATEMENT                                   
16.      PROJECTED BALANCE SHEET