Wood/Plastic Composites (WPC) Wood/Plastic Composites (WPC) for Outdoor Livingfor Outdoor Living

WPC: Where did it start?

• Subsidiary of BB&S Treated Lumber Co.

• Use of CCA (Chromated Copper Arsenate)

• Late 1980’s/early 90’s WPC began

• WPC natural direction

1998

6000

sq

m, 9

00

lb/h

r

Current

36,0

00 s

qm,

30,0

00 lb

/hr

Fiberon growth over 10 years

The Market (US)

Acceptance of pressure treated wood in early 1980's

WPC products about 10%-12% of the market (46 million square meters) with market value of about $1 billion.

1980 - 1996 market for PT wood grew at annual rate of 20%. It is now a 5 billion feet market (460 million square meters).

Until 2009 downturn, WPC decking, railing, & fencing market growing in excess of 20% per year.

The European market is estimated to be 2.6 million sqm with majority coming from European producers along with imports from U.S. & China.

Use of wood molders to create surface effects for better appearance.

Fiber Composites became known - innovative products.

True tropical hardwood colour effects.

Capstock on decking to improve scratch, stain and fade resistance.

New techniques for coextruded rail products.

Double embossing techniques for “rough sawn” appearances.

Best Decking & Fencing Solutions

Composite Decking, Railing & Fencing

Fiberon LLC registered in 2010

1 of 3 largest producers of WPC in US

Best Decking & Fencing Solutions

Composite Decking, Railing & Fencing

Raw materials

US producers use primarily Polyethylene/Wood for decking & PVC/Wood for railings.

The wood species used varies by regional location of producer & the types of wood available.

European market ~ Polypropylene/Wood or PVC/Wood compounds to extrude the decking or other WPC products

Best Decking & Fencing Solutions

Composite Decking, Railing & Fencing

UK/European trend

“The market in Europe is expected to increase from virtually nothing at the moment to somewhere in the region of £500 mill ion to £1 bil l ion over the next f ive years. In volume terms, this equates to up to 1.3 mil l ion tonnes of WPC material. It has even been suggested that the European market for WPCs will eventually exceed that in the USA …..”

~ Wood Plastic Composites study – Technologies & UK market opportunities, published by WRAP, 2003

Best Decking & Fencing Solutions

Composite Decking, Railing & Fencing

UK/European trend

“Although there are conflicting views as to which application will offer the greatest opportunity for WPC manufacturers in the UK and the rest of Europe, the applications most likely to emerge and achieve significant growth in the short to medium term are outdoor products (decking, fencing and garden/outdoor furniture), doorframe profiles and window profiles.”

~ Wood Plastic Composites study – Technologies & UK market opportunities, published by WRAP, 2003

Best Decking & Fencing Solutions

Composite Decking, Railing & Fencing

UK/European trend

“It is generally accepted that the lower-value, outdoor products will be the first to make an impact on the UK market …...”

~ Wood Plastic Composites study – Technologies & UK market opportunities, published by WRAP, 2003

One and one-half acres of rainforest are lost every second with tragic consequences for both developing and industrial countries

~ http://www.rain-tree.com/facts.htm

Best Decking & Fencing Solutions

Composite Decking, Railing & Fencing

Use of Recycled materials

“ (Outdoor products) will, however, be very important in introducing the consumer to WPC materials and the benefits that they can offer over competing materials.”

~ Wood Plastic Composites study – Technologies & UK market opportunities, published by WRAP, 2003

Best Decking & Fencing Solutions

Composite Decking, Railing & Fencing

UK/European trend

“There is, however, a general reluctance amongst potential manufacturers and end-users, in the UK especially, to consider plastic recyclate as a feedstock for WPC materials….

the preference would be to use virgin polymer and wood flour or fibre from traceable sources…..

These will have an impact on the cost of the final product.”~ Wood Plastic Composites study – Technologies & UK market opportunities, published by WRAP, 2003

Best Decking & Fencing Solutions

Composite Decking, Railing & Fencing

Solid Core Board

No pest gets in

No water trapped within

No end caps needed

Best Decking & Fencing Solutions

Composite Decking, Railing & Fencing

No staining or painting ever needed

Benefits compared to wood

Deck not slippery when wet

No splitting or splintering

Use of recycled materials

No rot or decay

How is it made?

Recycled Wood in flour form HDPE or PVC in pellet form

Dried from 6% moisture to 2%

Hoppers Hoppers

Extruder

Transported via bulk trucks (20 MT) or bulk rail cars (100 MT)

The wood arrives every 4 hours and the polymers on a similar schedule.

Both the eastern (North Carolina) & western (Idaho) plants run 24 hr/7 days for 360 days per year.

Lubricants, color, moldicides, and aging stabilizers are also added directly to the extruder.

The extruder mixes the materials together dispersing & distributing the wood and minor ingredients into the polymer matrix.

At the end of the extruder is a die that gives the WPC its desired profile.

The profile is cooled in a series of water baths, sawn to length, molded to give a surface appearance, and embossed to get a grain effect.

The boards, rails, & fence products are stacked into bundles, packaged, & moved to the storage area.

Long Live Beauty!

Best Decking & Fencing Solutions

Composite Decking, Railing & Fencing

Hidden Fasteners for Stunning Finish