Detailed Project Report (DPR) on Wood Plastic Composite Board Line

WOOD PLASTIC COMPOSITE BOARD LINE

[EIRI/EDPR/1543] J.C.: 337INR, 338US$

INTRODUCTION

Plastic and wood wastes have been a main environmental concern. Plastic is the biggest problem due to its high amount of waste generated, non biodegradability and the fastest depletion of natural resources regarding its short life cycle, therefore increased amount of material utilized in its production, and waste generated. The same applies to wood with lesser degree where it is depleting trees and forests and the wastes mainly are either burned or disposed; resulting in extra consumption, depletion, and pollution of nature. Several worldwide attempts have been adopted; especially in the developed countries, to take advantage of these types of waste especially with the raised need for alternatives to virgin materials. Wood plastic composite (WPC) is a product which could be obtained from plastic and wood. WPC is a composite with a rapid growing usage consisting of a mixture of wood waste and polymeric material . Many trials of obtaining a WPC product were basically built on the concept of a Cradle to Cradle approach where the material is recycled at the end of its life cycle to produce a Cradle (new) product and thus close the loop and imitate the natural ecosystem. As a consequence, this minimizes the solid waste content and conserve the natural resources. Therefore, costs, energy, and depletion of virgin materials are reduced. In addition, it assures the sustainability over the incoming years for future generations' use.

WPC has become currently an important address of research that gained popularity over the last decade especially with its properties and advantages that attracted researchers such as: high durability, Low maintenance, acceptable relative strength and stiffness, fewer prices relative to other competing materials, and the fact that it is a natural resource . Other advantages have been strength points including : the resistance in opposition to biological deterioration especially for outdoor applications where untreated timber products are not suitable, the high availability of fine particles of wood waste is a main point of attraction which guarantees sustainability, improved thermal and creep performance relative to unfilled plastics where It can be produced to obtain structural building applications including: profiles, sheathings, decking, roof tiles, and window trims. On the other hand, WPCs are not nearly as stiff as solid wood; however, they are stiffer than unfilled plastics. In addition, they do not require special fasteners or design changes in application as they perform like conventional wood.

As mentioned, the reasons for using WPC are many; however, there are other causes that menforced many countries to tend for using alternative sources to virgin materials. In the United States, for example, the U.S. Environmental Protection Agency, by the beginning of 2004, has phased out the usage of wood treated with chemicals such as the chromate copper arsenate (CCA) to prevent environmental and microbial degradation. As this type of wood was used in the building products' market concerned with residential applications such as decking, the need for the alternative survived the WPC market. In Europe, environmental concerns are focused on limiting the use of finite resources and the need to manage waste disposal; therefore, the tendency to recycle materials at the end of their useful life has increased tremendously. Recycling polymers in Europe was less preferred than other types of materials such as metal; however, illegality of land filling and waste management priority in many European countries were the motive to do so . In addition to the enforced environmental policies, the growth of environmental awareness led to a new orientation to use wasted natural materials for different applications and industries such as the automotive, packaging and construction industries.

COST ESTIMATION

Plant Capacity            5000 sq.ft./Day

Land & Building (1500 sq.mt.)    Rs. 1.57 Cr

Plant & Machinery                    Rs. 3.30 Cr

Working Capital for 3 Months    Rs. 2.35 Cr

Total Capital Investment          Rs. 7.58 Cr

Rate of Return                          51%

Break Even Point                      44%

CONTENTS

INTRODUCTION

APPLICATIONS

RAW MATERIALS

LUBRICANTS AND RHEOLOGY CONTROL ADDITIVES FOR THERMOPLASTIC COMPOSITES MANUFACTURING

WPC NEW MANUFACTURING TECHNOLOGY

EXPERIMENTAL PROCESSES

MARKET POSITION

ADDITIVES CREATE RECIPE FOR GROWTH

PRESENT MANUFACTURERS OF WOOD PLASTIC COMPOSITE BOARDS LINE

MANUFACTURING PROCESS

FLOW SHEET DIAGRAMS OF WPC

DETAILS OF RAW MATERIALS

PLANT & MACHINERY COMMERCIALLY USED

COMPOSITION FOR WOOD-POLYMER COMPOSITE AND WOOD-POLYMER COMPOSITE MADE FROM THE COMPOSITION

MANUFACTURING OF THE WOOD PLASTIC COMPOSITES

PENETRATING TREATMENT FOR WOOD PLASTIC COMPOSITES

PROCESS FOR THE PRODUCTION OF COMPOSITES OF CO-MINGLED THERMOSET RESIN BONDED WOOD WASTE BLENDED WITH THERMOPLASTIC POLYMERS

ADVANCED POLYMER/WOOD COMPOSITE PELLET PROCESS

POLYVINYL CHLORIDE HOMOPOLYMER, COPOLYMERS AND POLYMERIC ALLOYS

TECHNICAL/TURNKEY CONSULTANT FOR SETTINGUP WPC PLANT

COMPLETE PLANT SUPPLIERS FOR WOOD PLASTIC COMPOSITE BOARD LINE

MANUFACTURERS/SUPLIERS OF PLANT & MACHINERY

MANUFACTURERS/SUPPLIERS OF RAW MATERIALS

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)