ISSUE-06

APRIL-JUNE 2008

IN THIS ISSUE:

Review: 1. Wood Plastic Composites 2. Twin-Screw Extruders for WPC 3. Contributing to Materials Development 4. Geometry Unraveled Brainstorm: High value end uses for R-PET Question 4 You:
Life Cycle Assessment (LCA)

REVIEW

THE FAST GROWING

WOOD PLASTIC COMPOSITES - WPC

This issue of ET is sponsored by

U N B E A T A B L E E F F I C I E N C Y, U N P A R A L L E L E D V A L U E

USA - JAPAN - EUROPE - INDIA

WAT C H O U T ! I n t h e n e x t i s s u e o f E x t r u d e r Ti m e s t h e main review article would be on C O AT I N G S O N S C R E W S E G M E N T S

To share breakthroughs and happenings in the Polymer & Extruder Industry. To serve as an information sharing platform for STUDENTS, ENGINEERS and COMPOUNDERS. To encourage contributions from scientists, technocrats and teaching community and to generate triggers for new innovations.

The term wood plastic composite (WPC) refers to any composite that contains wood and thermoset or thermoplastic. Thermosets include resins such as epoxies and phenolics. Thermoplastics include resins such as polyethylene, polypropylene and polyvinyl chloride. These new materials extend the current concept of wood composites from the traditional compressed materials such as particleboard and medium density fiber board (MDF) into new areas and more importantly, a new generation of high performance products.

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THE FAST GROWING

WOOD PLASTIC COMPOSITES - WPC

The first generations of WPCs were a combination of recycled wood flour or chips and a binder. These were ideal for relatively undemanding applications. The new and rapidly developing generation of WPCs have good mechanical properties, high dimensional stability and can be used to produce complex shapes. They can be extruded to high dimensional tolerances, are tough and stable products. The new WPCs are high technology products for the most demanding applications. The most common type of the new WPCs are produced by mixing wood flour / fiber and plastics to produce a material that can be processed like a conventional plastic, but has the best features of wood and plastic.

Thermoplastics Materials and Wood Filler

Because of the limited thermal stability of wood only thermoplastics that melt below 200 Deg C are commonly used in WPCs. Currently, most WPCs are made with PE, both virgin and recycled, for use in exterior building components. However, WPCs made with wood PP are typically used in automotive and consumer products and very recently, these materials have been investigated for use in building profiles. Wood filled PVC composites typically used in window manufacture are now being used in decking as well. Polystyrene and ABS are also being used. The plastic is often selected based on its inherent properties, product need, availability, cost and the manufacturer's familiarity with the polymer. The wood used in WPCs is most often in particulate form (wood flour) or very short fibers, rather than longer individual fibers. Products typically contain 50% wood, although some composites contain very little wood. Others contain as high as 70%. The relatively high bulk density and free flowing nature of wood flour compared with wood fibers or other longer natural fibers, as well as low cost, and availability, is attractive to WPC manufacturers and users. Common species used include pine, maple and oak. Typical particle sizes are 10 to 80 mesh.

The most common type of the new WPCs are produced by mixing wood flour / fiber and plastics to produce a material that can be processed like a conventional plastic, but has the best features of wood and plastic.

What is Compounding? Compounding is combining (mixing) different ingredients with a base material and forming a homogeneous mixture. Sometimes a chemical union may be achieved between a base material and the other materials.
Example: Bread dough, Medicines, Glass Filled PC

Processing
Wood and plastic are not the only components in WPCs. These composites also contain materials that are added in small amounts to affect processing and performance. Although formulations are highly proprietary, additives such as coupling agents, light stabilizers, pigments, lubricants, fungicides and foaming agents are all used to some extent. Some additive suppliers are specifically targeting the WPC industry. The manufacture of thermoplastic composites is often a two-stage process. The raw materials are first mixed together in a process called compounding and the compounded material is then formed into a product. Many options are available for compounding; using either batch or continuous mixers. The compounded material can be immediately pressed or shaped or formed into pellets for future processing. Some product manufacturing options for WPCs force material through a die (sheet or profile extrusion), into cold mould (injection molding) , between calendars (calendaring) or between mold halves (thermoforming and compression molding). Combining the compounding and product manufacturing steps is called In-Line Processing.

Composites are materials with distinct layers (parts) of different materials made to work together as one unit. There may or may not be chemical union.
Example: Steel reinforced Concrete, Automotive Tyres, FRP

What is Polymer Compounding? Polymer Compounding is combining a base resin with w w w w w w Pigments Modifiers Performance Additives Reinforcements Fillers Other Polymers

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THE FAST GROWING

WOOD PLASTIC COMPOSITES - WPC

The majority of WPCs are manufactured by profile extrusion in which molten composite material is forced through a die to make a continuous profile of the desired shape. Extrusion lends itself to processing the high viscosity of the molten WPC blends and to shaping the long continuous profiles common to building materials. These profiles can be a simple solid shape, or highly engineered and hollow. Outputs up to 3 mtrs / min are currently possible. Although extrusion is by far the most common processing method for WPCs, the processors use a variety of extruder types and processing strategies. Some processors run compounded pellets through single screw extruder to form the final shape. Others compound and extrude final shapes in one step-using twin-screw extruders.

Equipment manufacturers have set up partnerships to develop complete processing lines for WPCs. The OMEGA 60mm extruder can provide output levels of 300 kg/h of various PP WPC formulations

Why Compound? Compounding is done to modify processing and performance characteristics. It is not conceivable to have a new polymer designed for every nuanced application. w w w w w Enhance Performance Reduce Cost Improve Processing Better Appearance Improve Characteristics

Compounding Equipments Single-Screw Extruders

Some processors use two extruders in tandem, one for compounding and the other for profiling. Moisture can be removed from the wood component before processing, during a separate compounding step (or in the first extruder in a tandem process), or by using the first part of an extruder as a dryer in some in-line processes. Equipment has been developed for many aspects of WPC processing, including material handling, drying and feeding systems, extruder design, die design and downstream equipments such as cooling tanks, pullers and cut-off saws. Equipment manufacturers have set up partnerships to develop complete processing lines for WPCs. Some manufacturers are licensing extrusion technologies that are very different from conventional extrusion processing. Compounders specializing in wood and other natural fibers mixed with thermoplastics have fuelled growth in several markets. These compounders supply preblended, freeflowing pellets that can be reheated and formed into products by a variety of processing methods. These pellets are a boon to manufacturers who do not wish to compound in- line. Other processing technologies such as injection molding and compression molding are producing WPCs, but the tonnage is less. These alternative processing methods have advantages when processing of a continuous piece is not desired or a more complicated shape is needed. Composite formulations must be adjusted to meet processing requirements (e.g.; the low viscosity needed for injection molding can limit the wood content).

w Single screw with Proprietary / Special

Mixing section

w Internal Mixers (Banbury, FCM,

Dispersion kneaders)

w Reciprocating
(Co-kneaders) Twin-Screw Extruders

Single-Screw

w Counter-rotating w Co-rotating

Features of Co-rotating Extruders Narrow Residence Time Distribution

w Lowest operating costs due to reduction

in process steps

w Possible Lower Energy Consumption w Maximum Process Control due to

continuous addition of material in variable sequence without human intervention w Highest Flexibility and Ease of processing w Independence of Extruder Screw Speed and Feed rate

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THE EXTRUDER TIMES / ISSUE 06 / APRIL-JUNE 2008

Applications for WPCs

The greatest growth potential for WPCs is in building products that have limited structural requirements. Products include fencing, industrial flooring and landscape timbers, railings and moldings. Figure is a list of some wood plastic composite products currently available in North America. The decking, window and door profile and automotive markets represent the majority of the WPCs manufactured in the USA.

Decking
Although WPC decking is more expensive than pressure-treated wood, manufacturers promote its lower maintenance, lack of cracking or splintering and high durability. The actual lifetime of WPC lumber is currently being debated; most manufacturers offer a 10-year warranty. Compared with unfilled plastic lumber, the advantages of WPC lumber include increased stiffness and reduced thermal expansion. However, mechanical properties such as creep resistance, stiffness and strength are lower than those of solid wood. Hence these composites are not currently being used in applications that require considerable structural performance. For example, WPCs are used for deck boards but not the substructure. Solid, rectangular profiles are manufactured as well as more complex hollow and ribbed profiles. Wood fiber, wood flour and rice hulls are the most common organic fillers used in decking. About 50% wood is typically used in decking and some products contain as much as 70% wood. A polyethylene matrix is used most often, but manufacturers of decking made with PVC and PP have recently entered the market. At least 20 manufacturers produce decking from WPCs.

The decking, window and door profile and automotive markets represent the majority of the WPCs manufactured in the USA.

Fig: Source : www.toolbase.org

Window and Door Profiles

Window and door profile manufacturers form another large industrial segment that use WPCs. Fiber contents vary considerably and can range anywhere from 30 to 70%. PVC is most often used as the thermoplastic matrix in window applications, but other plastics and plastics blends are also used. Although more expensive than unfilled PVC, wood filled PVC is gaining favor because of its balance of thermal stability, moisture resistance and stiffness and strength. Patent activity is very high in this area. Several industry leaders are offering wood-plastic composites in their product line, but their approaches vary. One leading manufacturer co extrudes wood filled PVC with an unfilled PVC capstock for durability. Another manufacturer co extrudes a PVC core with a wood filled PVC surface that can be painted. A third manufacturer offers two different composites: 1. Highly wood filled PVC for stiffness and 2. A composite with a foamed interior for easy nailing and screwing.

Fig: Wood PVC composites Source: www.ptonline.com

Automotive Applications
Wood-filled PP sheets for interior substrate is still made in the USA by several manufacturers. However, manufacturers are beginning to investigate the use of other natural fibers such as kenaf, flax and hemp in air laid processes. Growth in the use of natural fiber filled thermoplastics, rather than unfilled plastics have been rather slower in the USA than in Europe, where environmental considerations are a stronger driving force.

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THE FAST GROWING

WOOD PLASTIC COMPOSITES - WPC

One market analyst cites the lack of delivery channels and high transportation costs as major factors that slow growth in the USA. One major U.S. Company has used German technology to produce automotive door quarter panels from natural fiber composites with PP and polyester. A number of other automotive components are being made with similar technology. Nonwoven mat technology is being used to make rear shelf trim panels with flax reinforced PP. Other products being tested include instrument panels; package shelves, load floors and cab back panels.
Fig: www.nolimitaudiocar.com

Conclusion:
Wood and natural fibers are one of the fastest growing fillers-reinforcements in the United States. For the next five years, a 50% growth rate has been projected for WPCs in the building products sector. In the automotive sector, growth for WPCs is estimated at around 15% over the next five years. WPCs are being investigated for more demanding applications with concurrent developments in processing and product design.

The WPCs are Fast Growing Indeed!

This article is contributed by Dr. Y.B. Vasudeo & Dr. R. Rangaprasad, www.byinnovationsconsultancy.in

Dr. Y.B. Vasudeo Ph.D President & CEO BY Innovations Consultancy (India) Pvt Ltd

Dr. R. Rangaprasad Ph.D Leader - Innovations Practice BY Innovations Consultancy (India) Pvt Ltd

This issue of ET was sponsored by STEER ENGINEERING Pvt Ltd. www.steerworld.com

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I N V E S T M E N T O P T I O N I N A WO R L D TH AT I S D E M A N D I N G A N D D Y N A M I C .

THE EXTRUDER TIMES / ISSUE 06 / APRIL-JUNE 2008

NEW GENERATION CO-ROTATING TWIN-SCREW EXTRUDERS for Wood Polymer Compounding (WPC) The

Materials for WPC and Processing Any virgin or recycled plastic that can melt and process below the degradation point of wood (200 C) is usually suitable for manufacturing wood polymer compounding materials. Based on existing WPC technology, the polymer materials that are more suitable for use in the production of these materials are PP, PE and PVC. Among these, PP has the highest melting temperature and therefore requires more careful control over the process of compounding. Deep flighted High-Torque Co-rotating twin-screw extruders are ideal for wood-PP compounding. The flexural strength (stiffness to weight) is superior to polyethylene and PVC based WPC materials. Currently, most WPCs are made with PE, both virgin & recycled and PVC, for use in exterior building components. However, WPCs made with Wood-PP composites have diversified the range of application at lower cost and availability, since it lends itself to post-processing treatment and as a large amount of recycled feed stock is also available in plenty. The competition among WPC producers has shifted focus toward improving the ways products are formulated and manufactured to reduce costs and add value through product differentiation. The product aesthetics and quality are the key areas of focus. Recent advances in WPC material and compounding and processing technologies include: 1. 2. 3. 4. 5. Improved pellet quality and surface Improved bonding and composite uniformity More realistic wood-like appearance More vivid colors and shine with improved fade resistance Use of Recycled Plastic Feed stocks suitable for composites

Optimizing Screw Design and Maximizing Output Quality and Quantity in WPC For twin screw compounding extruders, an important goal is to optimize screw design in order to transfer energy to mixing most efficiently. Different screw element designs are used depending on the material processed. Higher speed in Twin-Screw Extruders (TSE) allow higher throughput on smaller extruders.

OMEGA Series has a larger outside-diameter/ inside-diameter ratio

(Do/Di) of 1.71 compared to traditional extruders with a Do/Di of about 1.55, which increases the free volume by about 30-40 %. This feature is achieved without sacrificing the available torque. It becomes an important factor in providing enhanced process capability. This becomes crucial while processing Wood flour with Polypropylene.

STEERs OMEGA series extruders has the required process capability to extrude strands with required surface appearance with varied levels of wood content such as 35%, 45% and 55%. A 60mm extruder can provide output levels of 300 kg/h of various PP WPC formulations.
[This article was possible with the contributions from Mr. Prakash Hadimani, Manager STEER Application Development Center (ADC) Bangalore, and Dr. Babu Padmanabhan.]

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MATERIALS DEVELOPMENT

Contributing to materials development that is sustainable and environment friendly is SCS vision.

We do not inherit the earth from our ancestors, We borrow it from our children.
Mahatma Gandhi.

ET is pleased to publish here, the key note address of Dr. Babu Padmanabhan on the occasion of SCS Annual Foundation Meet.

The people of any land would like to have harmony in their midst and enjoy a well-developed quality of life. To realize the Vision 2020 for India, a vision put forth by our former President Dr. Abdul Kalam, a number of us have to dedicate ourselves to various missions. SCS has a mission to contribute to sustainable materials development, specifically carbon- based materials, in this land. No development can arise without professionalism and leadership. Therefore, SCS has started gathering the best professionals in the industry who are also leaders in this field. Leadership is about handling problems with grace and Professionalism is about getting things done in an accountable manner. What is a well-developed quality of life and how materials development can help?
Some of us may have noticed that, we (humankind) have a natural ability and interest in Language & Literature Science & Philosophy Religion & Culture Arts & Crafts Sports & Entertainment Earth & Space Exploration

Great strides in these areas are necessary to attain the status of a fully developed society. These leaps are only possible through renewable and therefore sustainable and environmentally friendly (toxin free) materials development.

Application of Materials
ENERGY FOOD : Fuel cells, cellulose ethanol, polymerbased batteries : Green houses, packaged ready to eat hygienic and nutritive food for busy professionals : Drip irrigation : Modular toilets, paints : Climate control : Colored polyester threads, thermally sensitive and chromic fabrics : Diapers and female hygiene products, : Contact lenses; spinal bio material; heart valves : Heat and electrical insulators; Glow-in-the-dark helmets and signage

WATER HOME HOME CONVENIENCE CLOTHING ACCESSORY HEALTH -5SAFETY

A developed society offers time for man to pursue these aspects of

life in full. To understand the purpose of life on this planet seems to be an endeavour that has puzzled scholars for many centuries. A simpler question to address is the purpose of our own life. The quest for knowledge and its understanding binds all of humankind together.

TRANSPORTATION : Railway coaches, bus interiors INFORMATION : Digital Paper; scanner

Materials development contributes to all aspects of society

including the development of arts & crafts, sports & entertainment, exploration of earth & space, although, the effects are felt at a maximum when addressing the primary needs of man. The primary needs of our society are in the areas of Energy & Food Earth & Water Home & Home Convenience Clothing & Accessories Health & Safety Transportation & Information (including communication)

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THE EXTRUDER TIMES / ISSUE 06 / APRIL-JUNE 2008

India can currently boast of, as one of the lowest CO2 emissions in the world given our population size. India releases just one quarter of the world average of one ton per person per year. Compare this, to the USA whose emissions are five times the world average. Our materials development effort should not contribute to an increase in India's greenhouse gas emissions or a negative impact on the environment. On the other hand, it should contribute positively to minimize our ecological footprint. A potential crisis looms ahead of us due to overexploitation of earth's resources rather than conservation and protection.
We need to use our experience to look deep into the future and anticipate potential calamities and ecological problems. Being prepared is the only way to handle problems gracefully. When people have health problems or get injured due to environmental damage, it is not acceptable. We would need science and technology to act with a sense of purpose in conserving our natural world.

While the imagination runs wild, there is a need to ensure that leapfrogging is not only about superior abilities with more efficiency and lower costs but also to curtailing environmental pollution. An example is Ni-Cd Batteries from previous-generation mobile phones are being carelessly disposed into the environment and Cadmium is a heavy-metal toxin. We respect our elders. On the other hand, we also have a tendency to take them for granted. We display this same tendency in dealing with Mother-Nature. We are not indifferent to her, however, we are abusive and we should stop that. Mahatma Gandhi said, We do not inherit the earth from our ancestors, we borrow it from our children. We have a responsibility to conserve and protect. While contributing to materials development, SCS will shoulder this responsibility.

India can leapfrog over old generation technology.

Is it possible that there were not enough land-line phones, because it would have been an unnecessary waste of resources with the advent of mobile telephony? Possibly, we do not have proper power supply, because, every building whether residential or industrial will produce renewable energy without accessing the power grid. Probably, there is no need to have proper roads because it may be easier to fly using a buoyant air-bus.

By believing in the Vision 2020, SCS will work towards the development of this land and contribute towards making the vision a reality.
Dr. Babu Padmanabhan, Ph.D www.steer.in www.drbabupadmanabhan.com

SCS

STEER CONSULTANCY SERVICES

REQUIRES POLYMER TECHNO-PROFESSIONALS with PASSION Polymer Technologists / Polymer Engineers / Polymer Consultants
You will enjoy being a part of SCS if you have the required experiences, flair and knowledge in any of the following:

SCS NEEDs...

a) Polymer Testing Services b) Polymer Turnkey Projects c) Plastic Compounding d) New Applications and R&D E) Technology Development

f) Certification Services and CDM g) Life Cycle Assessment (LCA) h) Techno Marketing i) Techno Writing Skills j) Techno Consulting

Get in touch. E Mail : scsinfo@steer.in, Tel : 91 80 41137350 Visit: www.steer.in

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THE EXTRUDER TIMES / ISSUE 06 / APRIL-JUNE 2008

TECHNOLOGY UPDATE ON TWIN-SCREW EXTRUSION

Title

- Geometry Unraveled

Dr. Babu Padmanabhan Ph.D, presented a paper at the International Conference: Plastic Extrusion Asia 2008 March 2008, Bangkok, Thailand
For complete viewing of the presentation you may visit

www.extruderprocessingzone.com

Co-rotating Twin-screw extruders

CD

are versatile devices that allow work to be done efficiently on plastic materials. The work done generally

Do

Di

raises the temperature of the material being processed, resulting in a partial or complete fusion of the mixture, chemical an increase in the the the uniformity of the composition, a union between components constituting

mixture and finally a reduction in the size of particles in that mixture. Work done on the material is the result of application of shear forces, extensional forces that cause elongation or stretching of material, compressive forces that results in pressure build-up and squeezing of the material and bending forces that causes fibers and layers to fold and interact. These forces occur in three dimensional space inside the extruder defined by the Axial Plane, Longitudinal plane for each screw and several Radial planes. Flow of material between elements in different radial planes creates lateral shear in the material. In general, radial and lateral shear rates are 10 to 100 times greater in magnitude compared to axial or longitudinal shear stress. -10-

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THE EXTRUDER TIMES / ISSUE 06 / APRIL-JUNE 2008

Readers Queries on Extruders, Elements, Polymer-Compounding etc are answered by ETs Expert Group

Apart from creating new PET bottles & containers, what are the best three 'high value end uses' of recycle PET plastics?

What are the main steps that are to be taken in an LCA - Life Cycle Assessment?
The best answer will be published. Readers are INVITED to send-in their answers with appropriate drawings / pictures / illustrations to etec@extrudertimes.com The ET expert panel, would SELECT the most appropriate answer. ET's decision is final. The participant to send full name and address particulars along with their answers. LAST DATE to receive the entry is August 15th, 2008.

Recycled PET is a desired secondary resource. PET, the abbreviation for Poly Ethylene Terephthalate, is fully recyclable and may be used for manufacturing new products in many industrial areas such as packaging for detergents, cosmetics, high-quality carpets, strapping tape, car spare parts, pillow fillings for allergic persons and fabrics. Its versatility in the many industries therefore makes it irreplaceable. Recycled PET is manufactured into numerous products. The five major generic end-use categories for recycled PET plastic are 1) packaging applications (such as new bottles), 2) Sheet and film applications (including some thermoforming applications, such as laundry scoops), 3) strapping, 4) engineered resins applications (such as reinforced components for automobiles) and 5) fiber applications (such as carpets, fabrics and fiberfill). There are a number of emerging technologies that are generically referred to as depolymerization processes. These processes -- like glycolysis and methanolysis -break down the PET plastic into its individual chemical components, which can then be recombined back into PET plastic. While not used extensively, these technologies are employed when the economics warrant and offer yet another market opportunity for post-consumer PET plastic containers. One of the highest value end-uses for recycled PET plastic is to manufacture new PET bottles and containers. However, recycled PET can be made into numerous other products including: Belts, blankets, boat hulls, business cards, caps, car parts (bumpers, distributor caps, and exterior panels), carpets, egg cartons, furniture, insulation, landfill liners, overhead transparencies, paint brush bristles, pillows, polyester fabric for upholstery, T-shirts, sweaters, backpacks, athletic wear and shoes, recycling bins, sails, scouring pads, strapping, stuffing for ski jackets, cushions mattresses, sleeping bags and quilts, tennis ball cans, tennis ball felt, twine and welcome mats. Answer provided by : Mr. Goutam Bhattacharya.
Answer for ET 5

Action is not made right by the rules of society or the codes of behaviour approved by convention. Right action issues from a mind which has discarded the notion of I, the false personality, and shed the fetters forged by self-seeking.
- Radha Burnier Brainstorm invites questions Please send your questions etec@extrudertimes.com

to

QUESTION

YOU

What would be the ideal 'residence time in a Co-rotating Twin-Screw Extruder ? How does this actually influence the outcome of the final product? Actually, this depends a lot on the task that is being performed. Generally speaking, the shortest possible residence time to do the task well is ideal. Reason is that excess residence time does NOT necessarily improve the mixing effect, as many tend to believe. In fact, there is good evidence that excess kneading actually worsens dispersion. Also, any extra residence time goes into building up heat history of the polymer, taking it closer and closer to the point where it begins to degrade. Just for the sake of bouncing some numbers, an average compounding task with a 32 L/D machine normally has a residence time in the order of 8-30 seconds. Response received from : Dr. Pradeep Bakshi.
All rights reserved: Reproduction without prior permission of the publisher is expressly prohibited. The publisher makes every effort to ensure that the ETs contents are correct. However, we accept no responsibility for any errors or omissions and accept no responsibility for any loss or damage caused as an effect thereof. The opinions expressed by experts are their own and in no way reflect that of the publisher. Printed and Published by: Mr. K.S. Ram, Director and Principal Consultant SCS, on behalf of STEER CONSULTANCY SERVICES, #204, Esteem Plaza, Bashyam Circle, Sadashivnagar, Bangalore 560 080, India. Contact: etec@extrudertimes.com, ksram@steer.in. FOR PRIVATE CIRCULATION ONLY

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