木塑复合材料的技术和经济（印度）分析
摘要
木塑复合材料是由木粉/木纤维和塑料混合加工而成,不仅具有传统塑料的加工特性,而且还具备了木材和塑料的优点。
从国际制造业的前景来看,印度错过了一次发展高新技术制造业的机会,现正决心提高高新技术制造的能力。木材加工业会产生很多剩余物和社会上也会产生很多废旧塑料,这些都没有被很好的利用。木塑复合材料的生产会使印度制造商进入高科技制造业,并且利用这些原材料生产出环保的产品。
本研究主要包括两个部分:木塑复合材料技术分析和经济(印度)分析。技术部分主要分析了木塑复合材料的原材料,工艺过程,以及所需要的设备。经济部分分析了木塑复合材料的市场前景和在印度采用由当地现有原材料加工而成的木塑复合材料来作为地板材料的趋势。
技术分析方面,我们回顾了各种文献,进行工厂访问,与不同的学者或研究人员进行面对面的交流,以及参加挤出成型试验,全面了解了木塑复合材料对原材料的要求以及对不同应用领域所采用的不同配方。在上述分析基础上,设想了在印度投资生产木塑复合材料。
经济分析主要基于经济学的基本概念如利润和损失,人事规划,风险预测,收支平衡,设备成本,运营资金要求,折旧,关键投资,起步资金要求。
基于如上的研究,得到以下结论:
所有木塑复合材料的纤维素基填充物,比如木粉,锯屑,稻壳都是天然材料,它们含有纤维素,半纤维素,木素。木粉是碾磨而成的、细细的粉料。通常用于木塑复合材料中的木粉的网孔尺寸为400μm。尽管聚乙烯的力学性能没有聚丙烯,聚氯乙烯,丙烯腈-丁二烯-苯乙烯和尼龙好,但是高密度聚乙烯是木塑复合材料户外地板中最常见的塑料原材料。由于偶联剂可以提高纤维素纤维和聚合物母体的兼容性,有助于纤维的分散,提高热熔物的流动性,提供木塑复合材料的力学性能,因此,是木塑复合材料生产中最重要的添加剂。挤出是木塑复合材料生产工艺中最常见的环节,通过挤出可以生产出高尺寸精度,稳定性很高的的产品。对大部分的高要求应用领域来说,新型的木塑复合材料是一种高科技产品。
木塑复合材料生产的毛利为29.66 %,净利13%。工厂一般可以在2.5到3年内就可以收回投资成本。投产时最主要的投资是厂房。根据经济分析时列出的投资,厂房投资和设计费总共需要26万美元。当使用高密度聚乙烯新料时,木塑复合材料的原材料价格为915美元/吨。预计到2011年,木塑复合材料的市场份额将增长到30%。因此,对印度的厂家来说,现在是开始木塑复合材料生产的最好时期。
THE FAST GROWING‘WOOD PLASTIC COMPOSITES’– WPCs are produced by mixing wood flour / fiber and plastics to produce a material that can be processed like a conventional plastic, but has the best features of wood and plastic.
Viewed from the perspective of international manufacturing, the Indian economy is seeing a dramatic resurgence. India sees itself as having‘missed-out’on high technology manufacturing and is determined to build its capabilities. A lot of wood residue from wood processing industry and waste plastic is generated, which is not put to good use. The production of WPC enables Indian manufacturers to engage in high technology manufacturing and utilize raw materials to produce eco-friendly products.
This thesis is broadly divided into two parts consisting of WPC Technology and Economics. The technology part explains fundamentals of raw-materials, processing and equipment required for WPC. The economics part deals with the market opportunities and trends of WPC products with special focus on availability of raw-material and cost of manufacturing WPC decking in India.
The research was carried out by review of literature, factory visits and face-to face dialogues with various scholars, participation in WPC extrusion experiments and researchers for complete understanding of raw-material requirements and their formulations for different applications. Understanding of the existing situation and need for new developments related to machinery and equipment from machine manufacturers. Analysis of the information gathered in the above phases is used to draw an economically profitable business plan for the manufacturing of WPCs in India.
The economic analysis is based on fundamental of economics such as profit and loss statement, personnel plan, risk assumptions, break-even, equipment costs, working capital requirements, depreciation, key investments and startup capital requirements.
Based on above research I give the folllowing Results:
All cellulose-based fillers for WPC, such as wood flour, sawdust, and rice hulls, are natural materials, containing cellulose, hemicellulose, and lignin. Wood flour is finely divided ground wood having a flour-like appearance. Wood flour that is typically used in WPC has mesh size of about 40, that is, about 400μm. Despite unfavorable mechanical properties of polyethylene compared to Polypropylene, PVC, ABS, and Nylon, HDPE is the most popular plastic for WPC decking. Coupling agents are the most important addives in WPC manufacturing as they improve the compatibility between cellulose fiber and polymer matrix, aid in fiber dispersion, hence, provide a better flow ability of hot melts and enhance mechanical properties of WPCs.
Extrusion is the most common processing technology and WPC can be extruded to high dimensional tolerances, are tough and stable products. The new WPCs are high technology products for the most demanding applications.
WPC manufacturing has a Gross Profit margin of ~29.66 % and a net profit margin of ~13%. The unit will most probably recover initial investments within 2.5 to 3 years of production. Our largest Start-up Requirement is the building of the storage, palletizing and extrusion facility. Its final value at completion is listed below as a long-term asset of US$ 260,000. Raw Material Cost of Wood Plastic composite per ton using virgin HDPE is US$ 915 / ton. This is the best time for Indian companies to start manufacturing of WPC decking as the share of WPC decking in the market is forecasted to grow to more than 30% in 2011.
从国际制造业的前景来看,印度错过了一次发展高新技术制造业的机会,现正决心提高高新技术制造的能力。木材加工业会产生很多剩余物和社会上也会产生很多废旧塑料,这些都没有被很好的利用。木塑复合材料的生产会使印度制造商进入高科技制造业,并且利用这些原材料生产出环保的产品。
本研究主要包括两个部分:木塑复合材料技术分析和经济(印度)分析。技术部分主要分析了木塑复合材料的原材料,工艺过程,以及所需要的设备。经济部分分析了木塑复合材料的市场前景和在印度采用由当地现有原材料加工而成的木塑复合材料来作为地板材料的趋势。
技术分析方面,我们回顾了各种文献,进行工厂访问,与不同的学者或研究人员进行面对面的交流,以及参加挤出成型试验,全面了解了木塑复合材料对原材料的要求以及对不同应用领域所采用的不同配方。在上述分析基础上,设想了在印度投资生产木塑复合材料。
经济分析主要基于经济学的基本概念如利润和损失,人事规划,风险预测,收支平衡,设备成本,运营资金要求,折旧,关键投资,起步资金要求。
基于如上的研究,得到以下结论:
所有木塑复合材料的纤维素基填充物,比如木粉,锯屑,稻壳都是天然材料,它们含有纤维素,半纤维素,木素。木粉是碾磨而成的、细细的粉料。通常用于木塑复合材料中的木粉的网孔尺寸为400μm。尽管聚乙烯的力学性能没有聚丙烯,聚氯乙烯,丙烯腈-丁二烯-苯乙烯和尼龙好,但是高密度聚乙烯是木塑复合材料户外地板中最常见的塑料原材料。由于偶联剂可以提高纤维素纤维和聚合物母体的兼容性,有助于纤维的分散,提高热熔物的流动性,提供木塑复合材料的力学性能,因此,是木塑复合材料生产中最重要的添加剂。挤出是木塑复合材料生产工艺中最常见的环节,通过挤出可以生产出高尺寸精度,稳定性很高的的产品。对大部分的高要求应用领域来说,新型的木塑复合材料是一种高科技产品。
木塑复合材料生产的毛利为29.66 %,净利13%。工厂一般可以在2.5到3年内就可以收回投资成本。投产时最主要的投资是厂房。根据经济分析时列出的投资,厂房投资和设计费总共需要26万美元。当使用高密度聚乙烯新料时,木塑复合材料的原材料价格为915美元/吨。预计到2011年,木塑复合材料的市场份额将增长到30%。因此,对印度的厂家来说,现在是开始木塑复合材料生产的最好时期。
THE FAST GROWING‘WOOD PLASTIC COMPOSITES’– WPCs are produced by mixing wood flour / fiber and plastics to produce a material that can be processed like a conventional plastic, but has the best features of wood and plastic.
Viewed from the perspective of international manufacturing, the Indian economy is seeing a dramatic resurgence. India sees itself as having‘missed-out’on high technology manufacturing and is determined to build its capabilities. A lot of wood residue from wood processing industry and waste plastic is generated, which is not put to good use. The production of WPC enables Indian manufacturers to engage in high technology manufacturing and utilize raw materials to produce eco-friendly products.
This thesis is broadly divided into two parts consisting of WPC Technology and Economics. The technology part explains fundamentals of raw-materials, processing and equipment required for WPC. The economics part deals with the market opportunities and trends of WPC products with special focus on availability of raw-material and cost of manufacturing WPC decking in India.
The research was carried out by review of literature, factory visits and face-to face dialogues with various scholars, participation in WPC extrusion experiments and researchers for complete understanding of raw-material requirements and their formulations for different applications. Understanding of the existing situation and need for new developments related to machinery and equipment from machine manufacturers. Analysis of the information gathered in the above phases is used to draw an economically profitable business plan for the manufacturing of WPCs in India.
The economic analysis is based on fundamental of economics such as profit and loss statement, personnel plan, risk assumptions, break-even, equipment costs, working capital requirements, depreciation, key investments and startup capital requirements.
Based on above research I give the folllowing Results:
All cellulose-based fillers for WPC, such as wood flour, sawdust, and rice hulls, are natural materials, containing cellulose, hemicellulose, and lignin. Wood flour is finely divided ground wood having a flour-like appearance. Wood flour that is typically used in WPC has mesh size of about 40, that is, about 400μm. Despite unfavorable mechanical properties of polyethylene compared to Polypropylene, PVC, ABS, and Nylon, HDPE is the most popular plastic for WPC decking. Coupling agents are the most important addives in WPC manufacturing as they improve the compatibility between cellulose fiber and polymer matrix, aid in fiber dispersion, hence, provide a better flow ability of hot melts and enhance mechanical properties of WPCs.
Extrusion is the most common processing technology and WPC can be extruded to high dimensional tolerances, are tough and stable products. The new WPCs are high technology products for the most demanding applications.
WPC manufacturing has a Gross Profit margin of ~29.66 % and a net profit margin of ~13%. The unit will most probably recover initial investments within 2.5 to 3 years of production. Our largest Start-up Requirement is the building of the storage, palletizing and extrusion facility. Its final value at completion is listed below as a long-term asset of US$ 260,000. Raw Material Cost of Wood Plastic composite per ton using virgin HDPE is US$ 915 / ton. This is the best time for Indian companies to start manufacturing of WPC decking as the share of WPC decking in the market is forecasted to grow to more than 30% in 2011.
引文
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[2] S. Hatzikiriakos, and J.M. Dealy. Wall slip of molten high density polyethylenes. II. Capillary rheometer studies. J. Rheol. 1992.
[3] R.J. Castillo, D. Strutt, and J. Vlachopoulos. Proceedings of Experiments and Simulations with Barrier Screws, ANTEC, Society of Plastic Engineers, Brookfield, CT, San Francisco, CA, 2002.
[4] R.K. Gupta. Polymer and Composite Rheology, 2nd edition, Marcel Dekker, New York, 2000
[5] S.J. Park and R.G. Larson. Modeling the linear viscoelastic properties of metallocene-catalyzed high density polyethylenes with long-chain branching. J. Rheol. 2005.
[6] U.S. Pat. No. 5,082,605. J.G. Brooks, B.D. Goforth, and C.L. Goforth. Method for making composite material. January 21, 1992
[7] U.S. Pat No. 5,539,027. M.J. Deaner, G. Puppin, and K.E. Heikkila. Advanced polymer/wood composite structural member July 23, 1996
[8] U.S. Pat. No. 5,746,958 . K.-A. Gustafsson, J.J. Muller, and R.A. Wittenberg. Method of producing a wood-thermoplastic composite material. May 5, 1998
[9] U.S. Pat. No. 6,758,996 . Y.A. Monovoukas, S.J. Anderson, D. Leeman, A.A. Klyosov, and G.P. Philippidis. Cellulose-reinforced thermoplastic composite and methods of making same. July 6, 2004
[10] U.S. Pat. No. 6,702,969. L.M. Matuana and J.A. King. Method of making wood-based composite board. March 9, 2004.
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