Hardy Smith Designs Private Limited

RESINS FOR WPC
Popular polymer resins for WPC are PVC (Polyvinyl chloride), PE (Polyethylene) and PP (Polypropylene). Globally PE and PP based wood polymer composites are widely used. Indian has started with PVC based WPC board manufacturing in last years. With main resins there are several additives and fillers get mixed to create a proper formulation according to the property requirement of the product. PVC is widely used for making WPC boards, WPC Indoor profiles as well outdoor profiles too.

PVC’s properties like lead the material for use into interior products like modular furniture, door frames, window frames, doors and other profiles. Products made with PVC can be printed and painted directly. It has a tendency to work with cyanoacrylate adhesive for faster joineries.

PE/PP are widely used for exterior grade products such as outdoor WPC Deck floors, Wall claddings, Pergolas, Gazebos, Benches, Deck tiles, Fencing and facades. It is heavy material by density as a final products and used for rough and tough outdoor applications. Globally PE/PP are known for their use with natural fibre polymer composites.

NATURAL FIBERS
WPC is known as NFPC (natural fiber polymer composite), globally. WPC is made with the use of natural fibers like wood and other agriculture residues/waste fibers. Saw mill dust is widely used after converting into fine mesh wood powder. This can be of different species of wood e.g. Pine, Teak etc.

Countries like India – where Agriculture is a major activity – has variety of agricultural waste fibers. Rice husk is one of them and can be collected easily compare to other fibers. Apart, jute fibers, wheat straws and bamboo are also termed as fiber resources.

WPC sheets can be used for architectural sculptures and murals. Previously we understood about the application of sheets for heritage design preservations. Moving further towards sculptures and murals architects can create unique formations from WPC boards because of its precision for CNC cutting. WPC boards carry outstanding properties for use if outdoor weather applications as shown in the picture.

Here it is a ‘Whale sculpture’ created by CEPT students of Ahmedabad from Co-extruded white sheets. There is no paint or surface protections used and this structure is placed at the shown premise since almost 4 years now. It has suffered 4 monsoons and 4 winters now. Importantly it has faced 4 scorching summers of Ahmedabad also that goes upto 50 Degree Celsius.

At times you can paint this also for adding more life, not immediately like wood but may be after several years. I would say this as a very important material for architectural creations those need to be made faster, economic, smarter and for long life also. Similar sculptures if designed for interiors, then what to say about its life….may be endless!

‘WPC boards’ – a fastest running product for Indian, Arab and African Infrastructure markets
– By Hardik Panchal, Hardy Smith, India (info@hardysmith.org)

Changing product trend as per the cyclic process of product life cycle, WPC boards are replacing shuttering ply boards with its enduring and highly competitive properties. WPC stands for wood plastic composite and this is a unique and evolutionary product derived from a non conventional extrusion process for wood panel industry which has been using pressing technology. As a fortune product for Indian interior and infrastructure industry which is just enjoying its childhood yet in compare to the other developed countries.

WPC boards are available with various names like ‘Construction boards’, ‘Crust foam boards’, ‘Calcium boards’, ‘WPC shuttering boards’ ‘WPC MDF boards’ in global markets. WPC boards can be produced with flexible density range varies from 400 kg/cum to 900 kg/cum. Another important characteristic is the surface density of this product and which also can be adjusted between a range of 55 shore D to 85 shore D surface hardness.

Formulations play a major role in making WPC boards and that is the master key which allows it to be known by different names as above. Wood wastes, Virgin and recycled plastics are key components for making these composite boards. These boards are covering a large application area starting from interior grade boards being used for making furniture, kitchen cabinets, kitchen shutters. Taking further, these boards are being used for making temporary shelters for government housing projects, construction site pavilions/shelters, low cost housing projects and other road and building projects.

The high end application of these boards are fall under the category name of ‘Construction boards’, those are effectively being used as a master replacement of ‘Shuttering ply’ and ‘metal templates’. This board can be used more than 20 times in compare to the conventional shuttering ply used for 4-5 times only. Handling, storage and life are key competitive factors above its all other advantages including moisture repellence, non-deformity in shapes and layers, easy to cut, light in weight.

For further information about technology and projects for WPC boards you can write to info@hardysmith.org or visit www.hardysmith.org.

India’s WPC Capacity today

WPC market has actually evolved with really a good pace. In these four years, India has witnessed establishment of more than 50 odd manufacturing facilities for making different WPC products including WPC Sheets and WPC Decking. More players are in pipe line and we are projecting a volume of more than 300 manufacturers in coming 5 years. This subject will go nuclear way. Today, Gujarat is leading the subject with more than 22 players. Ahmedabad is the leader city with more than 7 Lines. We are ahead of Japan as a country manufacturing WPC.

Weather & Cultural issues
We are genuinely facing problems of moisture and termite. Our furniture – be kitchen or bedroom – can be affected anytime due to these two issues. We are carrying culture of cleaning floors with wet clothes or free water. Any culture cannot be changed over the night. This has created a problem of reduced life of furniture – be it with wood or modular with particle board or MDF board.

WPC sheets play a strong and positive role here and it is becoming more and more popular amongst Indian users. Carpenters and Architects have got good understanding about the product and they are using WPC now more effectively in their creations.

Customers’ anxiety
We have always got curious, interesting and positive responses, while we promote or talk about WPC. At initial stage some threw it off just without understanding it. But such cases are very low. More we have got positive and solid interest only. Once one understands the product he/she will say “This is a future product!”

Basic question was coming with two techno commercial challenges – price and screw holding and those answers are also well understood by the market.

Price comparison
Reiterating the same here “Any plywood/MDF/Particle board cannot be used without surface protection. This surface protection is must and required expense for HPL on both the side, glue for that and labour. With WPC you can directly apply the sheets while making furniture. For elevation/shutters only you have to use HPL or Paint or any other substrate which is normally being used with wood panels also. An average cost of WPC sheet match the cost of a wood panel that is ready for application. Importantly, it is 100% recyclable and its user can get at least 15% cost back at any point of time in future.

Screw Holding
Screw holding is moderately perfect and better than MDF and Particle boards. Apart, you can refill the screw gap with PVC grips available in the regular market with use of PVC Solvent Cement.

Mass level awareness
Amongst Other challenges one is the mass level awareness of this product. Still product is not reached to each and every corner of the country. Larger players like Century Ply has started marketing this product and we are waiting for more such players’ entry those can brand this product on TV Media.

Global interest in India
India is becoming popular destination for WPC products. With more than 50 odd manufacturing lines our country is fetching attraction from all over the world. We are targeting equal percentage (50%) turnover from foreign markets. This will include WPC sheets and WPC decking, respectively. WPC actually is well accepted in Global markets. I would say, we are late for understanding and taking interest in this product. Those countries are well developed and they are using WPC as a part of their consciousness about greenness. For us WPC is becoming necessity. We don’t have effective plantation practices, rules and initiatives. We are importing lot of timber and today only Gandhidham has become the largest timber import zone of Asia. Logically, WPC has started being accepted as WPC Sheet first and now we are accepting WPC decking too.

Q1: Why wood polymer composite (WPC) is becoming more and more important for India, even though import of wood is increasing day by day?
A1: Wood plastic composite manufacturing doesn’t need logs or timbers, but this subject is a boon for wood wastes including sawmill dust, plywood sanding dust, bagasse dust, Rice husk, Jute husk and other forms of wood wastes. WPC product formation can use such natural fibre wastes ranging from 10% to 70% of formulation. Thus directly it has no relation with forests and bigger formats of wood and timbers. This way we are saving forests at the first sight and utilizing waste materials at a great instance.

India is being developed as a prominent manufacturing destination for WPC products, globally. Started reversely from international WPC trends India has picked up WPVC panels, rapidly due to all time favourite and upcoming infrastructure developments within the country. India has ‘yet to see’ situation for furniture industry.

Q2: How WPC can be compared with Wood panels and Softwood in terms of quality aspects?
A2: Please find the following properties of WPC boards made with PVC as the core polymer.

WPC boards are ideal for panel applications in modular furniture. They can withhold screw well. It has dimensional stability. Moisture and termite resistance gives long lasting durability. Surface is printable. You can apply HPL, Veneer and PVC foils. You can perform carpentry jobs just as like as the natural wood and wood panel. It has good machinability on any panel processing machine. Its polymeric structure with PVC makes WPC 100% recyclable and green material. WPC for India-in indoor applications-is the best material than any other wood panel.

Q3: How WPC is termed as “Green” in compare to plywood, MDF and timber?
A3: Green means the product that ‘saves nature – saves natural resources – reduces carbon foot prints – keeps environment clean – uses recycle – can be recycled – has no emission – has no process discharge’.

1. WPC saves trees by not using natural wood from forests – thus it is green.
2. WPC uses the waste wood, wood dust, plywood sanding dust, agriculture waste, and plastic waste – thus it is green as it recycles the natural resources.
3. WPC finished material itself is 100% recyclable and can be reused within the process. WPC products can be recycled anytime during its life cycle – thus is it green.
4. WPC doesn’t emit any gases as a finished product and it is E0 product – thus it is green.
5. Processing of WPC doesn’t create any process waste, waste water or chemical waste – thus it is green.
6. Natural wood, once it is caught up by termite cannot be used again in normal cases. WPC is free from borer and termite – Thus it is green.
7. WPVC like material which is self extinguishing in nature, safe, clean and hygienic-medical grade product – can give a safe and clean life to small children in schools to the employees working in close room conditions. Thus it is green.

All above parameters make WPC more “green” than natural wood.

Q4: How important is the formulation techniques for WPC where agriculture wastes also are used?
A4: WPC is the better material which can use more agriculture waste with polymers. Conventional wood panels cannot use more agriculture waste those have less fibre value and thus bagasse has been the only successful but saturated option today for particle board and MDF board making. Against WPC can use rice husk, wheat straw, just straw, bagasse, coconut powder, bamboo powder etc with more or equal ratio with polymers.

WPC – Wood Plastic Composite – a promising and sustainable green material is being evolved as a fundamental product for India, after being well adopted by the world.

India, a country is having vivid climate conditions, vivid culture, vivid growth patterns and booming infrastructure industry today. Increasing industrial growth is empowering entire India by covering four of its extreme corners, geographically. Increasing human potential is being supported by fascinating employment and business opportunities pan India.

Demand is rapidly increasing for interior and exterior grade materials in building material industry. Modular kitchen are in high demand today, parallel to modular office and home furniture. Timber import is increasing day by day and lot of waste is also being generated in volumes. This waste is coming out of saw mills, plywood mills, veneer units, Particleboard units, MDF units as well as from good quality agriculture residues like Cotton stalks, Sugarcane bagasse, Coir fibers and even Rice husk.

Wood panels are tested and tried to be made out of agriculture residues other than bagasse. At certain level success is achieved but not really promising, thus, question for ‘effective utilization pattern’ of good quality agro residues is still remain. At the same time demand for environmentally appropriate technology is increasing which can really reduce consumption of natural wood. Wood panel technology demands for efficient fiber conversion techniques that can drastically reduce fiber wastage.

WPC, Wood plastic composite, a product with a class, can help meeting global demand of wood products and wood panels. It is a new kind of synthetic material made from waste plastic & wood discharged from mills & factories as well as agriculture residues. It is a natural fit with primary and secondary forest product industries. By construction this product is formulated from – plant fibers as fillers and reinforcements – for polymers. This is one of the fastest growing types of polymer additive.

WPC – Becoming popular amongst Re-sellers and End users

Wood polymer composite and India both are becoming popular for each other nowadays. India, as a country is becoming popular destination for PVC based WPC board’s supply. Country is set with more than 35 odd manufacturing lines for WPVC sheet lines and more than 10 lines for profile production.

PVC (Poly vinyl chloride) is a major raw material for making WPVC products and Reliance has been Instrumental as a major supplier from within the country. Apart from Reliance local manufacturers are importing PVC from abroad. Companies have well understood the subject and gained enough knowledge about raw materials. PVC additives also are being imported directly by the existing players and major supplier is China, again. Recently, Reliance prices are reduced and companies are offering price discount benefit to the Indian market, positively.

At the other end, Gurjan scarcity and increased resin prices are making plywood more and more costly, day by day. WPVC is being controlled by PVC prices and effectively capturing the market, replacing plywood. WPVC decking, exterior cladding, lumbers and fencing are really becoming popular within end users including architects, interiors, builders and retailers. Good demand is being generated and manufacturers are really less!! WPVC is becoming stronger with new experiments in the quality by Indian players. PVC processing needs lot of patience, as it is the subject of formulations. You can make customized WPVC boards, as per your technical need. WPVC sheet can be made 100% Fire retardant by adding Fire retardant additives. E.g. Finolex PVC cables. Mosquito repellents also are being added, based on the application requirement. Most importantly, WPVC boards can be custom made in any colors and you can directly apply it for the end use, without HPL or paint.

There are exclusive WPC displays are coming into action across the country. Recently, WPC CENTRE is launched by HARDY SMITH and there are numerous WPVC applications showcased including Boards, Doors, Door frames, Kitchen carcass, Wardrobes, Shutters, Wall cladding, Flooring, Modular kitchens, Bathroom vanities, Shoe racks, office partitions, Ceiling panels etc.

There is specific demand being generated directly from the end users for PVC WPC solid sheets. WPVC is enjoying replacements for both the ends, where at one end it replaces Marine grade plywood and at second end it replaces hollow PVC profile market. Hollow PVC profile based doors and furniture market is evolved very fast within a few years. It has also captured a considerable market share of wood panel furniture. That market is nowadays started being replaced with solid WPVC boards, as it looks and works similar like a wood panel. Awareness is still a problem and we forecast presence of big ticket players in WPC market very soon.

WPC PVC foam sheets –Replacing Plywood, MDF & Natural wood in furniture applications

Interestingly, WPVC foam sheets are started being used in several new applications in the market. Since its inception in the Indian market PVC foam sheets have been the product of curiosity and questions. It has happened because of the manufacturing technology which was unfamiliar to the wood industry in India. All wood panels – from particle board, MDF, Plywood, Block boards or Door skin- are manufactured with pressing technology. WPC is being produced majorly from the Extrusion technology where polymer processing, formulations, chemical know how and technology understanding are the major areas to be learned and accepted.

WPC as a Polymer with thermoplastic nature gives advantage of ‘Re-cycling’. Thus, we can save lot of natural resources. It gives other natural advantages of Moisture resistance and Termite resistance. Thus, it is being accepted as the ‘Life time Investment product’ by the Indian lower middle class.

Surface of WPVC is quite polished, even, grain less, non porous, clean, calibration free which can be printed, painted and coated directly. It is a ‘ready to use product’ for total carcase applications. WPVC is the best product for ‘Joinery systems’ and it can be joined or sandwiched very fast and solid with ‘PVC Solvent Cements’. This is the fastest technique –played with WPVC boards for making of various product compositions. Whether it’s a 35 to 100 mm thick solid structure or curvilinear chair/tripod or a master piece in children furniture, you can make it quickly possible with WPVC sheet and solvent cement.

With all above advantages WPVC boards are replacing plywood in Kitchen carcases, wardrobes, office cubicles, overhead units as well in bathroom furniture. Density from 550 kg/cum to 650 kg/cum is the perfect fit for screwing and screw holding applications. The regular method of carpentry with PVC foam sheet works well with ‘screw and solvent’ mechanism. Actually it is similar to the plywood and water based adhesive system only but making time will be minutes instead of long hours. And final structure will be moisture proof, termite proof and may be with even ‘Buy back warrantee’ too!

WPVC sheets are being used for Door frame and Children furniture making also because of its easy to cut, easy to mould nature. The structure doesn’t carry in long fibres, thus it is safe for little kids during use. Applications shown in the images can give enough idea about the end use of the material with solvent joinery, curvature shapes and painted surfaces……but with NO WOOD.

Hardik Panchal,
CEO (MBA, BEng Polymer Technology)
HARDY SMITH WPC CENTRE

Best practices witnessed in last years for modular kitchen manufacturing is with MDF or Plywood panels because of its engineered structure and dimensions. These panels are in practice to be used with mandatory laminations of HPL/Paint on front and back surfaces. This is not only for decoration but also to protect the wooden material from moisture and termite. For high end applications PU laminations are in practice. But the basic structure of the panel is still wood and cannot be considered 100% water proof or termite proof. WPC BOARDS a new generation panels derived technically from Polyvinyl chloride polymer and natural fibre (saw mill dust or agriculture fibre e.g. rice husk) composite. Globally it is termed as natural fibre polymer composite or wood polymer composite.

These panels are made with a vast thickness range from 5 mm to 40 mm. Furniture makers can ask for any odd or even thickness to us for the same. WPC BOARDS are available in different density range e.g. 500 kg/cum, 600 kg/cum, 700 kg/cum and 800 kg/cum. 700 kg/cum and 800 kg/cum is the best product from HARDYPLAST known as HYPER WPC boards. It carries higher wood contents for best screw holding and dimensional stability.

Apart WPC BOARDS are available in 3 layer variant for ready to fix applications in furniture like ‘WPC Prelam boards’. Made with co-extrusion technology 3 layer WPC Boards are having surface density of 1400 kg/cum and shore D hardness more than 85. Plain colour furniture requirements e.g. Hospital furniture can be completely made with 3 layer WPC boards in any colour. These panels are available in any colours based on MOQ.

Most upcoming application and markets for WPC boards are into Digital printing Panels for designer kitchen segment. Same format will become popular for office & home furniture, cabins, toilet cubicles, partitioning systems etc. for designer furniture. Complete interior can be conceptualised with WPC boards with digital printing technology. WPC boards can be directly printed with flat-bed printing technology with high resolution and long lasting UV ink based.

Thus a versatile water proof and termite proof WPC BOARD is ready to fit to your kitchen furniture requirement.

WPC CARCASS – An application becoming ‘mandatory’…

CARCASS becomes a very critical application, while it is placed adjacent to a wall. Depending on the atmosphere and weather pattern of surroundings, seepage/moisture gets accumulated in the walls.

This also happens due to Transpiration. The major mechanism for long-distance water transport is described by the cohesion-tension theory, whereby the driving force of transport is transpiration. The evaporation of water from the exposed surfaces of a furniture in room side. Water molecules cohere (stick together), and are pulled up the wood body by the tension, or pulling force, exerted by evaporation at the exposed surface of a furniture. This is unavoidable and uncontrollable phenomenon.

Apart, Indian system for floor cleaning uses ‘mopping with water’ and it leaves water particles on the furniture panels. This also incurs into well-known problems of decay, fungus, delamination of HPL, bubbling, bending, de-layering etc.

It becomes dangerous when termite comes into picture. Termite in major cases attacks from within the furniture body and we have heard many cases where wardrobes, cupboards falls down leaving the back walls. Wardrobe carcasses, kitchen carcasses, overhead units, storage units, shoe racks etc… are sensitive to termite attacks when placed adjacent to walls.

In coming days, majority of Indian homes will start using WPC PVC boards for this application, as mandatory.

WPC CNC GRILLS – A modern material for preserving heritage…

WPC can be routed with CNC and hand routing machines, just like conventional MDF and wood. Importantly it can be used without surface protection, paints or coatings. WPVC can be available in custom colors and it can help in making versatile creations for designers.

WPC can be grilled for the best artistic creations like following image. Here in image is a world famous heritage site of ‘Sidi Saiyad’s Mosque and popularly known as ‘Sidi Saiyad’s Jali’ from Ahmedabad. It is carved on WPC sheet without paint and applied with LED backlighting. Such many architectural and heritage derivations can be developed for interiors. Surely this will long last than wood or MDF as its moisture and termite proof.

You can work with 5 mm WPC single layer sheet for minor and major carvings, without any stability issue. 3 layer WPC sheets can be a better option for such a work. As WPC sheets can be made with lower and higher density architects can choose the right substrate based on the requirement on Grill work. 3D routing also can be efficiently done on higher thickness – higher density sheets. This can be done well on 28/30/35/40 mm sheets. There are unique applications of WPC Grill works in luxurious look outs of home, hotels, hospitals, temples, apartments, villas and farm houses.

WPC DOORS | WPC SOLID DOOR FRAMES

Wood polymer composites is evolving as a great material for India. Popularly known as ‘WPC’ – fetches attention and becoming material of attraction for architects, interiors, project engineers and contractors. Because of its core technical properties of 100% water proof, 100% termite proof, 100% borer proof and 100% recyclable. HARDY SMITH with its known product brand of ‘HARDYPLAST’ is the single largest supplier of WPC products in the country.

WPC Doors and WPC Door frames are becoming essential part of new projects and government departments are also including WPC products into tenders. HARDYPLAST Doors are supplied in different thicknesses from 24 mm to 35 mm. WPC Doors are available in Plain solid door format, 3 layer Flush door format and Profile Door format also. WPC Solid door frames are made in different dimensions to fit to the main door, internal doors and bathroom doors. WPC Door frame is a unique product that is becoming favourable amongst carpenters and installer because of its ‘ready to fix’ design.

One can paint, polish or coat to the WPC Door and Door frame surfaces. WPC products are maintenance free, while being used in its natural form itself. Hotels, hospitals, hostels, temples, farm houses, village sites, clubs, restaurants, villas are the best suitable places for all WPC materials. HARDY SMITH has rendered the WPC arena in India and as a techno-commercial advisor serve to foreign territories also. ‘WPC CENTRE’ – a retail chain is coming soon across India for a complete WPC product solution. For more details kindly check www.wpc-centre.com.

WPVC board – it was brown actually. Now it is white as well as colorful too!

HARDY SMITH, India.

Poly vinyl chloride – is an instrumental material behind the making and formulating of wood polymer composites, in case of India. India is becoming popular destination for PVC based WPC. Country is witnessing a continuous growth with addition of new players regularly since last 4 years now. Indian exhibitions are adding stalls for WPC products now for new brands. A lot of activities are going on for this product and its promotion, carpenter meets, and architect meets etc at different levels are on. Product showcasing also is in action and you can find exclusive ‘WPC CENTRE’s in action.

WPVC board as a popular product is set for quality, supply and varieties. At inception wood PVC board was woody brown. Now it is available as WHITE PVC foam sheet. Recently it is being available in all the colors with beautiful surface luster. WPVC sheets can be available in different colors and can be applied to the end use without HPL or Paint. A few standard colors are Brown, Grey and Ivory. These boards are replacing MDF and Corian type materials in CNC designer panel applications. Apart from this Ivory and grey colored sheets are becoming fit for kitchen carcass and wardrobe carcass. For office furniture and partitions such colored sheets are replacing compact HPL. Toilet cubicles are also being made with this.

PVC is resistant to ignition. The temperature required to ignite rigid PVC is more than 150oC higher than that required to ignite wood. The high chlorine content of PVC polymer reduces its ignitability and also the heat it contributes to a fire. High concentrations of organic materials will increase flammability; high concentrations of inorganic materials will reduce it.

Ignition Temperatures for Various Materials (ASTM 1929)