fiberEX

The extruder series for

processing wood plastic composites (WPC)
and natural fiber composites (NFC)
Photo: © NATURinFORM GmbH

Setting standards - your partner for successful WPC/NFC production

The fiberEX extruder series was designed especially for the production of wood plastic composites (WPC) and natural fiber composites (NFC). With an output
window of 15 – 1,000 kg/h the machine series exactly meets the requirements of the WPC/NFC industry for maximized process stability for all output ranges.
Based on its long-term expertise, battenfeld-cincinnati offers solutions to process a wide variety of raw material combinations. Maximized flexibility is ensured
by a modular extruder concept for direct extrusion as well as the two-step production process. The fiberEX extruder series is built and designed in Vienna/
Austria, at the group’s competence center for counter-rotating twin screw machines.

At battenfeld-cincinnati a team of specialists is dedicated to continuous, targeted product and process improvement. Together with its worldwide network
of competent partners specialized in raw materials, formulation development, tooling, as well as feeding and dosing solutions, battenfeld-cincinnati is able
to give the best possible support to start-ups and for successfully running a WPC/NFC extrusion business.

Your advantages: Our offer:

Expertise gained from more than 260 lines placed worldwide fiberEX extruder series with screw diameters from 38 to 135 mm
Modular machine concept for direct extrusion as well as extrusion for outputs from 15 to 1,000 kg/h
in the two-step process Diverse screw geometries for processing WPC based on a variety of
Partnerships with leading system suppliers in the market along different raw materials and their combinations
the whole supply chain Modular dosing and feeding solutions for all materials, including
Enhanced lifetime of screws and barrels bulk materials with low or varying bulk density or poor flow behavior
Complete solutions from formulation development to equipment Optimized degassing solutions to maximize the achievable
design processing window
Diverse metallurgical solutions for wear protection with in-house
technology
End products and markets

Definition
NFC are composite products consisting of natural fibers, mainly thermoplastic polymers and addi-
tives to improve and tailor the required properties to the end application. WPC is a sub-category of
NFC, indicating that the fiber originates from a wood source. Formulations using more than 20%
fiber fall under the definition of WPC/NFC (in terms of processing equipment).

End products © NATURinFORM GmbH

WPC/NFC end products are often a substitute for wood products, but are beginning to come
into their own on the international market. 75% of the total market volume is still found in the
outdoor sector, although indoor applications are gaining in importance.

Outdoor applications: Indoor applications: © Plasticwood

Decking, railings and barriers Doors/door frames
Fencing Furniture © Resysta
Siding Skirting
Noise barrier wall panels Window sills
Sight screen shades Decorative sheets © Resysta

Housing systems/shelters

Properties: Properties:
Splinter-free High acceptance in hot climates with
Slow fading/colorfast high humidity, where MDF is not
Flexible in design and surface structure a suitable alternative
Repellent to moisture and organic attack
Low thermal expansion and weather
resistance
© TechWood International

„WPC simply housing“

Photo: © NATURinFORM GmbH

Markets

The biggest and most established market is North America where WPC/NFC products have a long tradition and therefore higher acceptance.

In Europe, the market first took off in 2003, when a volume of over 40,000 tons per annum was reached. In Asia, there are well-known markets like South Korea
and Japan with an established market acceptance of fiber composites. China also shows dynamic growth and a high number of new applications.

The markets in Europe and North America are stable with high innovative strength and are seeking new applications, while in South America, Australia and Africa
there are no market volumes yet and relatively moderate innovative drive.

battenfeld-cincinnati has served the WPC/NFC industry right from the start, and has designed fiberEX, a machine series tailored to meet the specific processing
challenges of this material group.

Examples of surface treatments for end products:

© Photo by courtesy of EINWOOD

© photo courtesy by EINWOOD

Embossing Brushing Sanding

Possible formulation components / project plan

WPC/NFC formulations mainly consist of two components:

1. Natural fibers (all fibers available throughout the year in a constant quality); these normally represent the larger proportion (in terms of percentage by weight)
2. Polymers, which essentially act as the “glue” between the fibers. Apart from very few exceptions, three thermoplastic polymers are used for WPC/NFC formulations:
PP, PE, PVC

The limiting factor in the choice of polymers is their melt temperature which should not exceed 200°C to avoid fiber degradation or burning. Recycled grades of polymers can be
used as well, depending on their availability and quality/purity.

To tune the mechanical and physical properties to the desired application, a variety of additives are available. This is why WPC/NFC formulations always have more than two (up to
ten) components, depending on the complexity of the specifications or end products.

Natural fibers Polymers Project plan

Wood, rice husks, PP, PE, PVC (virgin or To ensure a high quality end product and a lean process, the follow-
palm, cork, etc. recycled) ing three key project phases are recommended for an initial invest-
ment:

1. Exact product definition:

a. Product placement in the market
b. Specifications of mechanical and physical properties

2. Formulation development:
a. Based on the requirements under point 1.

Additives Fillers 3. Equipment:

Lubricants CaCO3 (calcium carbonate), a. Designed for the formulation developed under point 2.
UV-stabilizers, talcum, etc.
coupling agents
colorants, etc.
Photo: © Deceuninck

Processing WPC/NFC – producing high quality end products

Not only the right formulation, but also the way it is processed and homogenized, are crucial for producing a first class end product whith enhanced properties. There are several
methods to manufacture WPC/NFC products. battenfeld-cincinnati offers system solutions for both the process itself and process support. In the industry, two basic extrusion pro-
cesses are distinguished. Due to its higher process stability as well as higher output capacities and easier operation, the 2-step process has largely superseded the 1-step process.

Raw materials
Wood fibers Polymers Additives

Material preparation Step 1: Compounding

Gravimetric Heating-cooling Counter-rotating Co-rotating
1-STEP PROCESS

2-STEP PROCESS
Drying dosing mixer twin screw extruder twin screw extruder

Direct extrusion Intermediate product

Mixing Homogenizing
Plasticizing Venting Agglomerate Powder Granulate
Dispersing Pressure build-up

End product Step 2: Form giving extrusion

Calibrating Cooling
Plasticizing Homogenizing Pressure build-up

Calibrating End product Cooling

Post extrusion surface treatment (inline)

 Processing trends

In recent years, a strong international trend towards co-extrusion has developed. Co-extrusion technology reduces material costs, which often constitute 70% of production costs.
In particular, the reduction of high-priced formulation components (e.g. colorants, UV stabilizers) is a major concern, with a high-quality outer layer (co-ex layer) to ensure optimal
product attributes and looks. While “cap stock” (a pure polymer layer) is the most popular variant in the USA, WPC formulations with “wood aesthetics” are being used in the rest
of the world.

Inner layer/core layer: Outer layer:

Higher ratio of recycled material Virgin material

Lesser/no content of pigments Lower fiber ratio
Lesser/no UV-stabilizer High content of UV-stabilizers
etc. High pigment ratio
© Photo by courtesy of Fiberon Pure polymer layer (cap stock)

battenfeld-cincinnati offers a high variety of co-extrusion solutions and retrofits to optimally equip new and existing lines:

© Foto mit freundlicher Ge-

nehmigung von EINWOOD

Conventional system – both extruders standing side by “Space saver“ version: co-extruder on a pedestal “Piggyback” version: co-extruder mounted on top of the main extruder
side
Photo: © Correct Deck

Dosing:
Tailored and patented dosing solutions even for raw
materials which tend to aggregate and bridge
(Pat. Nr. DE 103 16 232)

Crammer feeder of a fiberEX 114 extruder Horizontal dosing unit

Wear protection:
As standard, screws and barrels are coated with tungsten carbide to Schematic sketch of possible metallurgical solutions:
ensure enhanced lifetime
To compensate for the corrosive and abrasive nature of WPC/NFC
materials, battenfeld-cincinnati offers a wide variety of wear protection
solutions using in-house technology as well as wear monitoring/
measurement
Legend:

High-grade steel, hardenend Molybdenum layer

and tempered
Nitrided layer Tungsten carbide layer

“BC“ layer “Superior TC“ tungsten carbide,

hard metal layer

System solutions:
With its wide network of partners, battenfeld-cincinnati offers complete Gear box:
extrusion solutions – from conveying the material into the extruder, to Sturdy gear boxes provide high security
shaping the product with an adapted tool, calibrating and finally cutting and torque for maximized efficiency and
it into a marketable product. optimal energy transfer into the material
 Barrel and screw tempering:
As standard, barrels are fully insulated using
the apc® cooling system to ensure homogeneous
temperature distribution
Screws are tempered with the maintenance-
free, closed Intracool® system
Schematic barrel sketch Optional for special applications, primarily used Screw geometries:
with apc® (Air Power Cooling) system for Cimitherm applications (vacuumed copper battenfeld-cincinnati’s screw geometries are based on more than
pipes) 25 years of experience in the market and more than 260 machines
sold
Tailor-made concepts focusing on gentle plasticizing, maximized
venting and homogenization at high output levels
Screws are designed and manufactured in Europe
Schematic sketch of
Intracool® screw core
thermo-regulation Venting port:
system A specially engineered venting port provides enhanced degassing
capacity to ensure maximum process stability and low maintenance
with high outputs
Two separate venting ports are used for larger output ranges

Degassing:
Engineered filter systems can be
quickly serviced without tools and
during production
Depending on the extruder size, the Degassing: triple filter system
types and number of filters can (above) and twin filter system
be adapted with by-pass switch (right)
Photo: © Resysta

Schematic drawing of a complete line / possible line configuration:

Tipping table Saw Surface treat- Haul-off Calibration Shape-giving Extruder

ments: and cooling tool including
Brushing tanks upstream
Sanding
Embossing

Upstream:

Surface treaments: When conveying WPC/NFC

Downstream / calibration materials, it is crucial to avoid any
Brushing (predominantly in & cooling: Extruder: segregation of the material blend
Europe and Asia) The gravimetric dosing unit has
Sanding (mainly in Japan) Compared to other extrusion Tooling: The extruder’s task is to process to be designed for WPC/NFC
Embossing (wide-spread in the processes, WPC/NFC do not have the material very gently to avoid formulations and has to com-
USA and China) to be calibrated extensively The tool’s task is to shape the fiber degradation pensate the potentially fluctua-
At battenfeld-cincinnati, co-ex- The cooling length is often shorter melt to an end product with The extruder must provide the ting bulk density and poor flow
truded surface finishes are sup- than in conventional PVC defined dimensions within best possible melt quality for the behaviors
plied by competent specialist extrusion processes due to diffe- tolerances, and with the desired next process step: shaping the Extensive network of sub-sup-
partners rent flow behaviors surface quality product pliers
fiberEX outputs
The extensive output range of battenfeld-cincinnati’s WPC/NFC extruder series

Output range* kg/h Output range* kg/h

Extruder Extrusion of compound/pellets Direct extrusion/compounding Extruder Extrusion of compound/pellets Direct extrusion/compounding
fiberEX 38 20 - 60 15 - 40 fiberEX 93 200 - 400 100 - 350
fiberEX 50 60 - 120 30 - 90 fiberEX 114 250 - 600 200 - 450
fiberEX 72 90 - 275 60 - 200 fiberEX 135 500 - 1,000 350 - 750

WPC high performance

Extrusion of compound/pellets extrusion
Direct extrusion/compounding Twin strand extrusion
WPC sheet
1,000 2,000
Solid profiles,
Conical extruders panels

Output range*
Output range*

Hollow decks > 3 kg/m meter

< 3 kg/m meter weight
weight
Standard
WPC co-extrusion applications
500 Laboratory applica- 1,000
< 2,5 kg/m
tions meter weight
Small profiles
WPC co-extrusion
Laboratory applications
220
100
Parallel extruders
kg/h lbs/hr
fiberEX 38 fiberEX 50 fiberEX 72 fiberEX 93 fiberEX 114 fiberEX 135
„flex vent“ system „flex vent“ system „twin vent“ system

* Actual achievable output depends on residual moisture content, formulation, wood content, bulk density, tooling and downstream;
reference outputs are achieved with standard compounds available on the market (> 500 gll; < 1,5% r.h.)
Our production locations We offer you energy-efficient equipment and production solutions. Find out more in our brochure or online.

battenfeld-cincinnati
Austria GmbH
P +43 (1) 61006-0 fiberEX extruders are used in lines for the production of WPC/NFC and profile.
[email protected] Here you see schematic line layouts with the fiberEX in green.

battenfeld-cincinnati (Foshan)
Extrusion Systems Ltd.
P +86 (757) 2997 5318 / 2238 0110
[email protected]

battenfeld-cincinnati
Germany GmbH
fiberEX compounding line and water ring pelletizer (other pelletizing systems available on request)
P +49 (5731) 242-0
[email protected]

battenfeld-cincinnati
USA
P +1 620 241-6843 fiberEX WPC/NFC profile line (fiberEX 93 & winBEX downstream)
[email protected]

Visit us online: In the list below you will find all of our equipment for WPC/NFC processing and production of profiles.

Conical twin screw extruders

www.battenfeld-cincinnati.com Parallel twin screw extruders
www.battenfeld-cincinnati.com/china Single screw extruders

www.battenfeld-cincinnati.com/usa Profile downstream

www.youtube.com/BattenfeldCincinnati

Edition 04/en: 2016-09

Subject to technical alterations.