Industrial Training MSE31 2019-20

PLANT LAYOUT

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CHAPTER-1

1.1 INDUSTRY PROFILE

Prabitha polymers is a startup company which manufactures xyloid which is a synthetic

wood. xyloid synthetic wood(also known as WPC) is a revolutionary product designed to
compete with the strengths of wood and overcome its weakness. This synthetic wood is used
for making door and window frames, which are long-lasting, eco friendly and value for
money. Its is nature friendly alternative to wood. When it comes to being pro ecological
company has vast experience of about 3 decades where they have been manufacturing an
environmental friendly substitute for fire wood in the form of briquettes using agricultural
waste at GAYATHRI BIO FUELS which is mother company of prabitha polymers . This
new product xyloid is another feather to the company’s hat.

1.2 VISION

To convey that there are infinite ways to develop as a society without harming the
environment.

Prabitha polymers was established in 2018 near Nagaramgere village, Challakere, chitradurga
dist as a manufacturer of XYLOID synthetic wood( also known as WPC). Prabitha polymers
manufacture synthetic wood using the best grade of raw materials procured from reputed
vendors from abroad countries like CHINA, VIENTNUM, JAPAN. Their products are
widely appreciated by their clients for its reliable performance and high quality. The robust
infrastructural facility equipped with the advanced machinery and technologies enabling them
to meet large scale orders of their clients. Prabitha polymers is the only company which
manufactures synthetic wood in KARNATAKA. They supply their products to various states
such as Andhra Pradesh, Telangana, Tamilnadu and Maharastra.

At present it as provided employment opportunities to the rural people, presently there are 40
to 50 workers working in this industry in different sections of manufacturing process.

As seen in the company there is a huge capital that the industry have. They have invested
approximately 40-45lakhs at the time of establishment but now total capital may be
approximately 60-65lakhs. This industry has good financial system that meets all the working
capital requirement.

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CHAPTER-2

2.1 INTRODUCTION

Composite is a material made of two or more constituent materials with significantly

different physical or chemical properties which remain separate and distinct within the
finished structure. Wood plastic composite (WPC) consists of a blend of wood fibers and
matrix polymer.

In recent times, the need for materials with high strength to weight ratio, damping capacity,
chemically inactive, corrosion resistance, high stiffness in such fields as automotive,
aerospace and earthquake resistance structures has spurred the research and development of
high strength materials. Among the different means available to achieve damping and high
strength to weight ratio much importance has been attached to the use of FRP composites

The natural fiber composites have received considerable attention of researcher due to their
abundance, renewability, cost-effectiveness and eco-friendly and better formability. This
workshop will deal with natural fibers and their composites for commercial and engineering
applications. They also find applications in agriculture, biochemistry, chemistry and
environmental sciences. Global warming occurring from carbon dioxide emissions remind us
ecological awareness such as reduce reuse and recycle of products for environmental
protection and saving energy. The number of studies and practical applications on materials
recyclability is being increased, as seen in the many application of green materials and
recycling of petroleum-based materials. Natural fibers are not only light weight and strong,
but also abundantly available and eco-friendly.

Increasing use of composite materials in many fields of engineering has been observed in the
past few decades. The automotive industry is exploiting the usage of composite materials for
structural components construction in order to obtain the reduction of the weight without
decrease in vehicle ride quality and reliability. Fiber-reinforced composite materials and
joints have wide application in aerospace structures such as payload door, remote
manipulator arm, antenna ribs, struts etc. In construction industry it is used in applications
such as bridges, power transmission towers, windows, door panels etc. In automotive
application mainly used for the attachment of suspension composite leaf spring to chassis of a
vehicle, composite propeller shaft attachment to universal coupling etc..

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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 nano cellulose. Recently, the trend of patent registrations for WPCs has
shifted to new products or applications instead of the materials itself.

A wood–plastic composite (WPC) is a common term referring to wood-based elements

such as lumber, veneer, fibers, or particles that are combined with polymers to create a
composite material. It is a broadly used term, and as such, wood elements can be combined
with either thermosetting or thermoplastic polymers. The term wood–plastic composite is
used interchangeably with wood–polymer composites, and the wood composites made from
either thermoplastic or thermosetting polymers are often categorized as separate material
types. Examples of wood–plastic composites made from different polymer types and wood
elements are listed in Table.

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Wood–plastic composites (WPCs) are materials comprising polymers and wood elements

Polymer type Wood elements WPC types

Thermoplastic Lumber, veneer, fibers, Extruded lumber, injection-molded

polymers particles, flour, etc. automotive components

Thermosetting Lumber, veneer Polymer impregnated wood (impreg,

polymers compreg)

The earliest wood–plastic composites appeared nearly a century ago where wood flour was
combined with phenol–formaldehyde resin to create a composite material used as an
automobile gearshift knob. An excellent overview of composites made by combining wood
with thermosetting polymers was provided by Rowell and Konkol. An early reference to
combining wood sawdust with thermoplastic resin via extrusion processing appeared more
than 60 years ago. More recent references on wood–plastic composites from thermoplastic
polymers.

Wood-plastic composites (WPCs) are composite materials made of wood fiber/wood

flour and thermoplastic(s) such as PE, PP, PVC, or PLA.

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 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).

Wood-plastic composites are still new materials relative to the long history of natural lumber
as a building material. The most widespread use of WPCs in North America is in
outdoor deck floors, but it is also used for railings, fences, landscaping timbers, cladding and

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siding, park benches, molding and trim, window and door frames, and indoor
furniture. Wood-plastic composites were first introduced into the decking market in the early
1990s. Manufacturers claim that wood-plastic composite is more environmentally friendly
and requires less maintenance than the alternatives of solid wood treated
with preservatives or solid wood of rot-resistant species. These materials can be molded with
or without simulated wood grain details. Wood-plastic composite material contains plastic,
which has a good elastic modulus.

In addition, due to the inclusion of fiber and fully mixed with the plastic, which has a
comparable hardwood and hardwood, bending and other physical and mechanical properties,
and its durability is significantly better than ordinary wood materials. Surface hardness is
high, generally 2 - 5 times the wood.

Some of the artificial zeolites can be added to the polymer. This aluminosilicate molecule
captures the powder to absorb the odor in the material. Through the powder in a large number
of crystal voids, the adsorbent can capture the odor of organic small molecules. Molecular
trapping adsorbents have been successfully applied to polyolefin extruded tubing, injection
and extrusion blown containers, isolated packaging materials, extruded packaging and sealing
materials. The molecularly adsorbed powder can also be added as a dehumidifier to the
plastic to remove water vapor.
Extruded products of different sizes and shapes increase the diversity of wood-plastic
composites
When the profile is not required to have a continuous sheet structure or the parts have a
complex structural design, the wood mold can be molded by injection or molded. Processors
are sometimes faced with the problem of how the wood-plastic material is fully charged
during processing. To solve this problem, they need to reduce the amount of wood fillers to
increase the melt flow.
Since 200 ° C is the upper limit of the operating temperature of the wood-plastic composite,
some resins with a melting point of more than 200 ° C, such as PET, can not be used in
wood-plastic composites.
Water vapor will degrade the properties of the composite and also contribute to the breeding
of microorganisms, so water vapor must be removed before using wood fillers. Before
processing the wood filler to be dried, the general requirements of the treated water vapor
content is less than 1 ~ 2%.
Now the wood-plastic composite processing machinery is equipped with feeding equipment,
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drying equipment, extrusion equipment and molding equipment, there are some necessary
downstream equipment such as cooling water tanks, traction equipment and cutting
equipment.

Appropriate additives are required to modify the surface of the polymer and wood flour to
enhance the interface affinity between the wood powder and the resin.
The high-filling wood powder has poor dispersibility in the molten thermoplastic, making the
melt flow poor and difficult to be extruded. The surface treatment agent can be added to
improve the flowability to facilitate extrusion molding.
Plastic matrix also need to add a variety of additives to improve its processing performance
and the use of its products performance.

2.2 WPC PROPERTIES

1. The product has the same processing performance as the logs, can be nailed, drillable, can
be cut, bonded, fixed with nails or bolts, smooth and delicate surface, no sanding and paint,
the paint adhesion is good, Like paint.

2. Products have better physical properties than logs, better stability than wood size, noisy
cracks, warping, no wood knots, twill, adding colorants, coated or composite surface can be
made of colorful Various products, so no need for regular maintenance.

3. Can be a variety of specifications, size, shape, thickness and other needs, which also
includes a variety of design, color and grain of finished products, to customers more choices
.
4. Products with fire, water, engage in corrosion, resistance to moisture, not insects, not long
fungi, non-toxic, non-polluting and other excellent performance, low maintenance costs.

5. Product use similar to the appearance of wood, plastic hardness than high, long life, can be
thermoplastic, high strength, energy conservation.

6. Product quality is good, light weight, insulation, smooth surface, free of formaldehyde and
other harmful substances, non-toxic, non-polluting.

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CHAPTER-3

3.1 RAW MATERIALS FOR WPC PRODUCTION

 Polymers
 Polyethylene(PE)
 Polypropylene(PP)
 Polyvinyl chloride(PVC)
 Polystyrene(PS)
 Polymethyl methacrylate(PMMA)
 Calcium carbonate(CaCO3)
 Wood powder
 Lubricants
 Wax
 Glycerol
 Fatty acids
 Foaming agent

 Stabilizers
 Lead salt
 Ca-Zn
 UV stabilizer
 Impact modifiers
 Propylene
 Ethylene
 Diene terpolymers
 Butylene-styrene
 Coupling agent
 Maleic anhydride
 Silane

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 POLYMERS

Polyvinyl chloride (PVC) is the widely used polymer because it can be made into
products with a wide range of propertied from soft and flexible to light and rigid. The
outcome is often determined by additives. Other ingredients must typically be added
to convert those resin into a finished product. These can include heat stabilizers,
lubricants, foaming agents, impact modifiers and coupling agents.
Usually 50% PVC is added in production of WPC.
The polymer PVC used is shown in fig 3.1

Fig 3.1- PVC

 CALCIUM CARBONATE (CaCO3)

The use of Calcium Carbonate is mainly for increasing the toughening effect on
polymer and effectively fill in WPC for the best tensile, flexural and impact properties of
WPC and also reduces the energy consumption for processing. Calcium carbonate which is
used in production of WPC is as shown if fig 3.2

The appropriate additive amounts of calcium carbonate added is 30%.

Fig-3.2-CaCO3

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 WOOD POWDER

The colour of the WPC produced mainly depends on the type of wood powder used
The appropriate amount of wood powder added is 10%.
The wood powder used in production of WPC is as shown in fig 3.3

Fig 3.3-Wood powder

 LUBRICANTS

Lubricants are essential because it increases throughput and improve WPC surface
appearance and it also prevents the edge tearing of WPC boards
The different lubricants used are wax, glycerol, fatty acids
Approximately 1-2% of lubricants are used in production of WPC.
The wax used in production of WPC is as shown in fig 3.4

Fig 3.4 - Wax

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 FOAMING AGENTS

Foaming agents are used to reduce density and improving machinability.

Approximately 1-2% of foaming agents are used in production of WPC.
The foaming agent used in production of WPC is as shown in fig 3.5

Fig 3.5- Foaming agent

 STABILIZERS

Stabilizers are used to slowdown the reaction,maintain chemical balance,reduce

surface tension,prevent light and thermal decomposition
Approximately 1-2% of stabilizers are used in production of WPC
The stabilizer calcium zinc and lead salt used in production of WPC is as shown in fig
3.6 and 3.7 respectively.

Fig 3.6 Calcium zinc Fig 3.7 Lead salt

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 IMPACT MODIFIERS
Impact modifiers are used to improve strength and toughness and increase the screw
holding strength of WPC. It also reduce the stiffness
Approximately 1-2% of impact modifiers are used in production of WPC.
The impact modifiers Propylene and Ethylene used in production of WPC is as shown
in fig 3.8 and 3.9 respectively.

Fig 3.8-Propylene Fig 3.9 Ethylene

 COUPLING AGENT

Coupling agents bond the wood powder to the resin matrix. they boost the
structural strength and stiffness. It also increases the dimensional stability , impact
resistance and fiber dispersions.
Approximately 1-2% of coupling agents are used in production of WPC.
The coupling agents Maleic anhydride and silane used in production of WPC is as
shown in fig 3.10 and 3.11 respectively.

Fig 3.10 Maleic anhydride Fig 3.11 Silane

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CHAPTER-4

4.1 PROCESSES OF WPC

1
• PULVERIZATION OF PVC

2
• FEEDING SYSTEM

3
• HOT MIXING

4
• COLD MIXING

5
• EXTRUSION

6
• COOLING

7
• CUTTING

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1. PULVERZING:

Pulverizer machines are used to smash materials into tiny shards or granules. Pulverizer
machines can crush all types of items, including plastic, glass, aluminum, concrete, coal,
rock, resin, tires, and medical waste. Pulverizer machines come in a number of different
forms. Hammer mills, ring mills, double roll crushers, granulators, impactors, and
shredders are all forms of pulverizer machines. Pulverizer is used in plastic industry
for Plastics Pulverizing Including PVC Recycling, Rotational Molding, Compounding
and Master batching.

The Naroto range of pulverizer ensures the production of pulverized material from
plastic granules for the manufacturing of high quality final products. Pulverizer can
pulverize LDPE, LLDPE, HDPE and various thermoplastic materials and other kinds of
pulverize for different materials.

Pulverizers has fully automatic operations with predetermined sequence of operations

such as Automatic granule lifter, Automatic on and off feeder, Automatic controls of mill
temperature etc. The Pulverizer constitutes of high quality, maintenance-free, efficient
components.

Pulverizers are available in various configurations like Single Mill

Pulverizer, Twin Mill Pulverizer (Dual Mill Pulverizer) with various designs, sizes and
shapes of pulverizer blades.

The pulverizer used in production of WPC is as shown in fig 4.1

Fig 4.1- Pulverizer

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2.FEEDING SYSYTEM

Feeding system involves feeding of all the raw materials required for the production of WPC
in powder form into the feeder. The different raw materials fed are

 Polymers
 Polyethylene(PE)
 Polypropylene(PP)
 Polyvinyl chloride(PVC)
 Polystyrene(PS)
 Polymethyl methacrylate(PMMA)
 Calcium carbonate(CaCO3)
 Wood powder
 Lubricants
 Wax
 Glycerol
 Fatty acids
 Foaming agent
 Stabilizers
 Lead salt
 Ca-Zn
 UV stabilizer
 Impact modifiers
 Propylene
 Ethylene
 Diene terpolymers
 Butylene-styrene
 Coupling agent
 Maleic anhydride
 Silane

The feeding system used in production of WPC is as shown in

fig 4.2

Fig 4.2 Feeding system

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3.HOT MIXING

In the stage the powdered raw materials is mixed at a temperature of 1100 C where the
different raw materials melt and form paste like material and mix thoroughly at the high
temperature

The Hot mixing unit used in production of WPC is as shown in fig 4.3

Fig 4.3- Hot mixing unit

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4.COLD MIXING

In this stage the paste mixture is mixed at room temperature and regains its powder form after
cold mixing. This process takes place at a temperatutre of about 250C.

The cold mixing unit used in production of WPC is as shown in fig 4.4

Fig 4.4 Cold mixing unit

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5.EXTRUSION

This process starts by feeding mixed raw materials from a hopper into the barrel of the
extruder. The material is gradually melted by the mechanical energy generated by turning
screws and by heaters arranged along the barrel. The molten mixture is then forced into a die,
which shapes the mixture into a shape that hardens during cooling.

The material enters through the feed throat (an opening near the rear of the barrel) and comes
into contact with the screw. The rotating screw (normally turning at e.g. 120 rpm) forces the
plastic beads forward into the heated barrel. The desired extrusion temperature is rarely equal
to the set temperature of the barrel due to viscous heating and other effects. In most
processes, a heating profile is set for the barrel in which three or more independent PID-
controlled heater zones gradually increase the temperature of the barrel from the rear (where
the plastic enters) to the front. This allows the plastic beads to melt gradually as they are
pushed through the barrel and lowers the risk of overheating which may cause degradation in
the polymers

The Extrusion unit used in production of WPC is as shown in fig 4.5

Fig 4.5- Extrusion unit

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6. COOLING (CURING)

The WPC after extrusion process is very hot and is at a temperature of approx 1700 therefore
cooling is required, hence continuous extruded WPC is passed through the cooling track
which water is used to carry away the heat and reduced the temperature of extruded WPC to
around the room temperature

There are 2 stages in cooling of extruded WPC

1. Indirect cooling- in this stage extruded WPC is passed through the cold dies to cool
the WPC without any direct contact of cooling medium with the surface of WPC.
2. Direct cooling- In this stage WPC which is cooled by indirect cooling is passed
through the cooling tract where in the cooling medium which is commonly water is in
direct contact with the extruded WPC thus reducing the temperature of WPC to room
temperature.
The Cooling system used in production of WPC is as shown in fig 4.6

Fig 4.6 – Cooling tract

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7. CUTTING AND DUST COLLECTION

In this stage the continuously extruded WPC is cut to desired length using automated cutting
blade and the cut WPC is ready to pack.

The powder obtained while cutting WPC is collected by dust collector and this powder is
again reused.

The Cutting and dust collection system used in production of WPC is as shown in fig 4.7

Fig 4.7- Cutting system and Dust Collector

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CHAPTER-5

5.1 PRODUCTS

The WPC products as shown in fig 5.1

Fig 5.1 Door and window frames

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The modern applications of WPC are as shown in fig 5.2

Fig 5.2 Modern application of WPC

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The Different sizes of WPC door frames are as shown in fig 5.3

Fig 5.3 Different Sizes of WPC door frame

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CHAPTER-6

6.1 ADVANTAGES OF WPC:

WPCs can produce the final shape through extrusion processing, this maximizes resource
efficiency and gives flexibility for improved fastening, stiffening, reinforcement, finishing,
joining. WPCs are wood plastic products that need no further processing. WPCs are weather ,
water and mould resistance for outdoor applications where untreated timber products are
unsuitable. WPCs are plastic products with exceptional environment credential and performance.
WPCs have a wide range of applications. They can cost effectively replace wood products in
applications such as furniture, doorframes, and decorative profiles, in fact anywhere wood
shapes are used. They can cost effectively replace plastic products in applications such as
window frames, roofline products and cladding, in fact anywhere that plastics shapes are used.

 The material is very easy to maintain and clean.

 The material is resistant to ultra violet light and its colour does not fade easily.
 Wood Plastic Composite is highly durable and is not affected by rain, snow or
peak summer conditions.
 The material is slip resistant hence is a very good material when used as deck
flooring especially near swimming pools.
 WPC cladding Panels is highly weather resistant. It is available in many colours
and textures which add to the beauty of the building.
 It is safe to use as this material is environment-friendly. It has the resistance to
bear strong climatic conditions and offers security from water, chemicals. This is
best and promising substitute to plywood.
 AS the WPC material can be molded into diverse shapes and sizes, it is the best
material option to make designer windows, almirahs, doors, and other home
furnishing items.
 It also has resistance to termite and fungus.

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6.2 DISADVANTAGES OF WPC:

1) CHEMICAL PROPERTIES: It contains a plastic polymer and wood fibres so the

shortcomings of both the materials will be present in it.

2) RESITANCE: The resistance of WPC to the extreme temperature is low as

compared to wood

3) COST: The cost of WPC material is higher as compared to the other materials
used for the same purpose

4) APPEARANCE: It lacks the natural wooden texture due to which the feeling of
natural wood missing when furniture or doors of this material is prepared.

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6.3 APPLICATIONS OF WPC:

Current applications for WPCs are largely in finished products such as decking, cladding,
and window frames. A particular growth area is in structural engineering applications that
use the physical properties of WPC to the limits.

 Outdoor deck floors,

 Railings
 Fences
 Landscaping timbers
 Cladding and siding
 Park benches
 Molding and trim
 Window frames and components
 Door frames and components
 Indoor furnitures
 Kitchen cabinets and worktops
 Sound proofing cladding
 Office furniture
 Exterior vertical and horizontal cladding
 Garden furniture and architecture

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6.4 WOOD V/S WPC

Traditional wood Synthetic wood (WPC)

Water proof
☻ ☻
Environmental friendly
☻ ☻
Shrinking
☻ ☻
Bending
☻ ☻
Maintaienece
☻ ☻
Installation
☻ ☻
Wastage
☻ ☻
Fabrication expenses
☻ ☻
Recycling
☻ ☻
Bacteria and fungus
attack
☻ ☻
Smooth surface
☻ ☻
Durability
☻ ☻

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REFERENCES:
 International journal of waste sources

 Wikipedia on Wood plastic composites

 A research paper on physical and mechanical properties of WPC board from sengon
sawdust and recycled HDPE plastic from science direct – 175(2017)695-704.

 A research paper on Investigations on ageing of Wood plastic composites for outdoor

applications: A meta analysis using empiric data derived from diverse weathering trials
from science direct ( construction and building materials-vol24).

 Web: www.greendotbioplastics.com

 A research paper on Manufacturing of Wood plastic composite from completely recycled

materials from Research gate ( 471-472:62-66)

 Web: www.crodapolymeradditives.com

 Text book on Wood plastic composite by Anatole. A. Klysov

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