WPC (PLASTIC COMPOSITE) BOARD
LINE MANUFACTURING
[CODE NO.3386]
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.
COST ESTIMATION
Plant Capacity : 8400.00 KGS/day
land & Building (4000 Sq.Mtr) : Rs. 2.00 Cr
Plant & Machinery : Rs. 1.25 Cr
Working Capital for 2 Months : Rs. 3.50 Cr
Total Capital Investment : Rs. 6.89 Cr
Rate of Return : 37%
Break Even Point : 44%
INTRODUCTION
USES & APPLICATIONS
OURDOOR APPLICATION OF WPC
RAW MATERIALS
POLYMERS
ADDITIVES
ADVANTAGE AND DISADVANTAGE OF WPC
ADVANCE MATERIALS FOR WPC
WOOD MODIFICATION
ADDITIVES
PROFILES
ASPECT OF WPC DURABILITY
WEATHERING STUDIES
FORMULATION OF WPC
FIGURE POLYETHYLENE (PE) – BASED COMPOSITE
DIFFERENT PROCESSES FOR PLASTIC COMPOSITES
EXTRUSION PROCESSING
SINGLE-SCREW EXTRUDER
COUNTER-ROTATING TWIN-SCREW EXTRUSION
COMPOSITE SYSTEM
MISCELLANEOUS POST-EXTRUDER UNIT OPERATIONS
PLASTIC COMPOSITE MANUFACTURING TECHNIQUES
WPC NEW MANUFACTURING TECHNOLOGY
EXPERIMENTAL STAGES
PILOT EXPERIMENTATIONS
PREREQUISITE STAGE
STAGE 1
STAGE 2
PROCESSES EXPERIMENTAL SETTINGS
MARKET SURVEY
NEW MARKET- WPC
FENCING FUTURE
THREAT FROM THE EAST?
FEWER, BIGGER PLAYERS
ADDITIVES CREATE RECIPE FOR GROWTH
EXPORT OF WPC FROM INDIA
GLOBAL TREND IN WOOD PLASTIC COMPOSITES
GLOBAL PRODUCTION OF WPC, AND THE FORECAST
PRESENT MANUFACTURERS OF
WOOD PLASTIC COMPOSITE BOARDS LINE
PROCESS FLOW DIAGRAM FOR PLASTIC COMPOSITE BOARD
THE WPC (PLASTIC COMPOSITE) MANUFACTURING PROCESS WITH EXTRUSION FORMING
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)
BOILER 75
GENERATOR SET (D.G. SET)
MANUFACTURERS/SUPLIERS OF PLANT & MACHINERY
EXTRUDERS
PRESSING MACHINE
COOLING TOWERS
BOILER
GENERATOR SET (D.G. SET)
MANUFACTURERS/SUPPLIERS OF RAW MATERIALS
PLASTIC POLYMERS
COUPLING AGENT
ADDITIVES
RAW MATERIALS CALCULATION
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
