Plastic wood floor

Wood-plastic composite (WPC) materials have emerged as revolutionary, eco-friendly alternatives, finding versatile applications in flooring, wall panels, fences, and more.  Widely embraced in outdoor spaces such as courtyards, landscapes, parks, and commercial areas, these materials have become an integral part of our daily lives.

What Exactly is WPC?

W – The wood fibres contribute between 30% and 70% of the total composite mass. Sourced primarily from sawdust, wood shavings, or recycled wood products, these fibres are responsible for the material’s mechanical fortitude and natural aesthetic qualities.

P – Making up the balance, thermoplastic polymers like polyethylene (PE), polyvinyl chloride (PVC), or polypropylene (PP) act as binding agents. These polymers envelop the wood fibres, creating a composite material that possesses enhanced water repellency, long-term durability, and resistance to microbial decay.

C – In some formulations, WPC may also incorporate a range of functional additives (composite). These could include UV stabilisers for better sunlight resistance, colour pigments for visual appeal, and antimicrobial agents to further deter mould and bacterial growth.

How Is WPC Made?

The manufacturing process of Wood-Plastic Composite (WPC) is a crucial factor in determining its structural integrity, durability, and application versatility. There are primarily two methods used to manufacture WPC: extrusion and injection moulding.

Extrusion Process

Material Preparation: Wood fibres, usually in the form of wood flour, are first dried to remove any moisture. These dried fibres are then mixed with thermoplastic resins, along with optional additives like colourants and UV stabilisers.

Blending: The mixture is blended thoroughly in a high-speed mixer to ensure uniform distribution of wood fibres and thermoplastics. This is essential for achieving consistent mechanical properties in the final product.

Extrusion: The blended material is fed into an extruder, where it is melted and forced through a die under high pressure. The die is designed to shape the molten composite into the desired profile, be it planks, sheets, or other forms.

Cooling and Calibration: As the material exits the die, it goes through a cooling tank filled with water or air-cooled, which solidifies the material. Calibration tools might be used to maintain the desired dimensions and tolerances.

Cutting and Finishing: Once cooled, the extruded WPC is cut to specified lengths. Surface treatments, such as sanding or embossing, can be applied to enhance aesthetic qualities.