American Architectural Manufacturers Association

Case Study: Pre-Blended Compound Offers Easy On-Ramp to WPC Production

Sponsored by


Bob Simon, Gossen

According to recent market studies, wood-polymer composites (WPCs) have experienced phenomenal growth over the past decade, and double digit growth continues as more markets recognize the advantages of a WPC-based product. Combining wood and plastic into a different material addresses environmental concerns, such as deforestation and sustainability, but also provides an aesthetically pleasing, low maintenance and cost-effective alternative.

However, diversifying into WPC product lines poses obstacles for extrusion, injection and compression molding companies, primarily in the form of the significant capital expenses involved with establishing the upstream fiber/polymer processing, blending and material handling systems required for wood composites. A manufacturer that decides to become a producer of WPC products would typically need to have a separate plant for such capacity and may not yet have the sales volume to justify the risk.

Now, there are options that eliminate these barriers in the form of pre-made compound in pellet form and finished custom WPC extrusions. A newly-founded (2010) company, Polymera, Inc. (Hebron, OH), offers a unique source for both: 1) a pre-made WPC Compound in a wide spectrum of customer-specified blends that any extruder of polymer fenestration profiles could use with their current equipment to make WPC profiles, and 2) high-output, energy-efficient twin screw WPC extrusion lines offer custom WPC profile production ready for fenestration unit fabrication operations. The company claims it has the capacity to produce some 60 million aggregate pounds of compound or custom-extruded profiles annually at its 160,000 square foot facility.

The company’s three product offerings include.

• A ready-to-use WPC compound for injection molding, extrusion and compression molding applications used for both interior and exterior applications, such as components of windows, doors, furniture and a variety of other markets. Multiple material options are available, such as varying fiber loadings in High Density Polyethylene (HDPE), Polyvinyl Chloride (PVC) and Polypropylene (PP) base polymers.
• Custom produced profiles are extruded on production lines specially configured for maximum flexibility and output and can be supplied either as a bridge until a fabricator brings upgraded manufacturing processes on line or on a long-term supply basis.
• Consultation for companies looking to enter the wood/natural fiber polymer composite market include a technology team to assist with processing, technology development and specification of individual line equipment or customized product lines, such as extruders, colorant feeding, calibration stands and embossing equipment.

To learn more about innovations in the wood and cellulosic composites industry, attend the WCCMC Council meeting on Tuesday, February 28 during the AAMA 75th Annual Conference at Naples, FL.

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