Wood Plastic Composite (WPC) Production Line and Factory Setup

A Wood Plastic Composite (WPC) production line is an integrated industrial system designed to mix wood powder, polymer and additives, extrude profiles through a twin-screw extruder, cool, cut and package finished WPC profiles. The line produces durable outdoor profiles for decking, fencing, window frames and outdoor furniture.

From an industrial perspective, WPC manufacturing is important because it combines precise mixing of wood flour (typically 60–80 %), polymer (HDPE, PP or PVC) and additives, controlled melting and extrusion at 170–200 °C, cooling and cutting to produce profiles with consistent cross-section and weather resistance. The process relies on a defined sequence of unit operations that must be correctly engineered and integrated.

Primary raw materials typically include wood powder, polymer granules (HDPE/PP/PVC), adhesives, colorants and stabilizers. Core machinery consists of mixers (500–1000 L), twin-screw extruders (screw diameter 65–92 mm, power 75–110 kW), cooling tanks, cutters and packaging machines. Typical capacity 150–400 kg/h.

The Industrial Department supports investors establishing a new WPC factory as well as existing plant owners requiring repair, overhaul, capacity expansion or automation of current lines. Projects can start from an empty site or from an operating facility that needs technical upgrading.

Whether the goal is a green-field turnkey WPC plant in Iraq, Kurdistan Region, Afghanistan or other regional markets, or the modernization of an existing line in Iran, engineering, machinery supply or manufacturing, installation, commissioning and ongoing technical support can be provided under defined contractual scopes.

Production Line Overview

The WPC production line is engineered as an integrated process system covering raw-material mixing, twin-screw extrusion, cooling, cutting and packaging. Design capacity is determined during the engineering phase and can typically range from 150 to 400 kg/h depending on final product mix and market requirements.

Product types include decking, fencing, window frames and outdoor furniture profiles. The overall process flow follows a defined sequence: mixing of wood powder, polymer and additives; extrusion through twin-screw extruder; cooling; cutting to length; packaging.

Main machinery groups include mixers, twin-screw extruders, cooling tanks, cutters and packaging machines. Supporting infrastructure covers electrical power and process water.

Manpower requirements depend on the degree of automation. Quality control covers profile dimensions, surface quality and packaging integrity. Finished profiles are stored under protected conditions before distribution.

Technical Specifications

The following technical data represent typical ranges for an industrial WPC production line. Final values are defined during basic and detailed engineering and may vary according to selected technology, level of automation, product portfolio and factory layout. For precise project-specific figures, contact the Industrial Department.

Specification	Description
Product	Wood Plastic Composite (WPC) profiles
Production Capacity	150–400 kg/h (depending on project capacity and selected equipment sizing)
Required Area	500–1000 m² (subject to final layout and capacity)
Electrical Power	380 V three-phase, 100–200 kW (depending on equipment selection and automation level)
Water Consumption	10–20 m³/day
Manpower	5–12 persons per shift (depending on automation level)
Main Machines	Mixer (500–1000 L), twin-screw extruder (screw Ø 65–92 mm, 75–110 kW), cooling tank, cutter, packaging machine

All figures are indicative. Detailed utility balances, equipment lists and layout drawings are prepared after process definition and capacity confirmation.

Products

An industrial WPC production line can manufacture decking, fencing, window frames and outdoor furniture profiles of various cross-sections and colors according to market requirements.

Raw Materials for WPC Factory

Raw material selection and quality control are critical for profile strength and weather resistance. The main materials used are described below.

Main Raw Materials

Wood powder (60–80 %) – Provides the wood-like appearance and feel.
Polymer granules (HDPE, PP or PVC) – Bind the composite and provide durability.
Adhesives, colorants, stabilizers – Improve bonding, appearance and UV resistance.

Secondary / Optional Materials

Packaging materials and cartons

Storage and handling conditions must be controlled to preserve material quality and prevent moisture uptake in wood powder.

Sahi Rasa For Factories raw material

The Supply Chain Department is prepared to support identification, evaluation and supply of the main and auxiliary raw materials required by WPC factories. Depending on the contractual scope, services may include supplier identification and evaluation, procurement and purchase coordination, specification control, logistics coordination, supply-chain design for continuous production, ongoing supply arrangements, and supply of materials from Iran for projects located in regional markets.

Registering an order for raw materials for the factory Wood Plastic Composite (WPC)
Sahi Rasa Supply Chain Department

Raw-material supply chain support can be examined for industrial projects located in Iran, Iraq, the Kurdistan Region of Iraq (including Erbil, Sulaymaniyah, Duhok), Baghdad, Basra, Mosul, Afghanistan (Kabul, Herat, Mazar-e-Sharif), Uzbekistan, Turkmenistan, Tajikistan, Syria, Oman, Jordan, Turkey, Armenia and Georgia.

Manufacturing Process

The industrial WPC process follows a defined sequence of unit operations.

Mixing – Wood powder, polymer and additives are mixed in a mixer to a homogeneous blend.
Extrusion – The blend is melted and shaped in a twin-screw extruder at 170–200 °C and forced through a die to form the desired profile.
Cooling – The extruded profile is cooled in a cooling tank to solidify.
Cutting – The continuous profile is cut to standard lengths.
Packaging – Finished profiles are packaged.

Machinery & Equipment

Each main machine performs a specific function. Support is available for design, manufacturing or procurement, customization, installation, commissioning, repair, overhaul, refurbishment, automation and spare-parts supply according to the agreed project scope.

Mixer – Homogenizes wood powder, polymer and additives (capacity 500–1000 L). Position: first stage. Importance: uniform composition. Quality impact: mixing quality affects final strength. Maintenance: agitators and seals. Sahi Rasa support covers design and spare parts.
Twin-Screw Extruder – Melts and shapes the composite (screw diameter 65–92 mm, power 75–110 kW). Core machine of the process. Position: after mixing. Quality impact: temperature profile and screw design determine profile quality. Maintenance: screws, barrels, dies and heaters. Sahi Rasa provides specialized extruder support and overhaul.
Cooling Tank – Solidifies the profile. Position: after extrusion. Quality impact: cooling rate affects dimensional stability. Maintenance: pumps and water systems.
Cutter – Cuts profiles to length. Position: after cooling. Quality impact: length accuracy. Maintenance: blades and drives.
Packaging Machine – Packages finished profiles. Position: end of line. Quality impact: pack integrity. Maintenance: sealing and handling systems.

Factory Layout & Building Requirements

Typical functional areas include raw-material storage, mixing and extrusion hall, cooling and cutting area, packaging, finished-goods warehouse, quality-control laboratory, utility rooms, maintenance workshop, staff facilities and loading docks. Layout must respect process flow and dust control for wood powder. Exact area allocation is determined during the engineering phase according to capacity and product range.

Utilities

Electricity: 380 V three-phase, typically 100–200 kW
Water: 10–20 m³/day
Compressed air as required
HVAC and drainage according to hygiene and local regulations

Turnkey Factory Setup

An investor can start from an empty site. Depending on contractual scope, the project can be accompanied through: Idea → Feasibility → Engineering → Factory Design → Machinery → Procurement → Manufacturing → Installation → Commissioning → Training → Raw Material Supply → Packaging → Trial Production → Commercial Production. The objective is an operational factory ready for production.

EPC & PMC

Projects can be executed under EPC (Engineering, Procurement, Construction) or PMC (Project Management Consultancy) approaches. Engineering, machinery supply or manufacturing, installation supervision and commissioning are coordinated within the defined contract boundaries.

Machinery Repair

Existing WPC factories can request inspection, troubleshooting, mechanical and electrical repair, component replacement, spare-parts supply and line maintenance support for mixers, extruders, cooling systems and cutters.

Machinery Overhaul & Refurbishment

Older equipment can be evaluated for comprehensive overhaul, replacement of worn screws and barrels, control-system upgrades, improved reliability and modest capacity or quality improvements where technically feasible.

Capacity Expansion

Capacity of an existing line can often be increased by addressing bottlenecks, upgrading key machines (extruder, cutter) or introducing selective automation.

Industrial Automation

Typical applications include PLC sequence control, temperature and speed monitoring, automatic dosing, HMI, data logging and optional SCADA integration.

Supply Chain

Factory = Machinery + Raw Materials + Utilities + People + Process + Supply Chain + Market. The Supply Chain Department supports supplier sourcing, procurement, logistics and ongoing material supply for WPC projects.

Packaging

Primary packaging, secondary packaging, labeling, coding, cartoning and palletizing are integrated according to product format and market requirements.

Branding & Product Development

When required, support can be provided for product development, packaging design, graphic design, industrial design, branding and related marketing preparation.

Market & Country Sections

Engineering, machinery, installation, overhaul and supply-chain support are available for WPC projects in Iran, Iraq, Kurdistan Region (Erbil, Sulaymaniyah, Duhok), Baghdad, Basra, Mosul, Afghanistan (Kabul, Herat, Mazar-e-Sharif), Uzbekistan, Turkmenistan, Tajikistan, Syria, Oman, Jordan, Turkey, Armenia and Georgia.

Sahi Rasa Services

Service	Application in This Project
Feasibility Study	Technical and economic assessment of capacity, product mix and investment
Factory Design	Layout, process flow and utility design
Machinery Design / Manufacturing	Specification and coordinated supply or manufacturing of process equipment
Procurement	Sourcing of machinery, components and materials
Installation & Commissioning	Mechanical/electrical installation, start-up and performance testing
Automation	PLC, HMI, process control and optional SCADA
Raw Material Supply	Coordination via Supply Chain Department
Repair / Overhaul / Refurbishment	Restoration and modernization of existing machinery
Capacity Expansion	Engineering and implementation of throughput increases
Staff Training	Operational and basic maintenance training

Why Sahi Rasa

Process engineering, machinery-related capabilities, procurement support, supply-chain coordination, installation, commissioning, training, maintenance support and automation are combined. The practical advantage is a more integrated execution path from concept to an operating production line.

From Empty Land to Production

Typical sequence: Feasibility → Engineering → Factory Design → Equipment Design → Machinery Manufacturing/Procurement → Logistics → Installation → Commissioning → Staff Training → Raw Material Supply → Trial Production → Commercial Production. Operational support for a defined initial period can be examined as a contractual option.

Who Should Contact Sahi Rasa?

Investors – planning a new WPC factory or production line
Existing Factory Owners – needing repair, overhaul, refurbishment, modernization, automation or capacity expansion
Industrial Buyers – requiring machinery, spare parts, raw materials or engineering services

Final CTA

If you intend to set up a Wood Plastic Composite (WPC) production line or factory, if your existing plant needs repair, overhaul or capacity expansion, if you require new machinery or automation, or if you need coordination of raw-material supply, contact the Industrial Department.

Submit your request for: Factory Setup / Machinery / Repair / Overhaul / Refurbishment / Automation / Capacity Expansion / Raw Materials.

Registering an order for raw materials for the factory Wood Plastic Composite (WPC)

FAQ

What is the typical cost of setting up a WPC factory?
Cost depends on capacity, product range, automation level, building and utility scope. A detailed estimate is prepared after process definition.
Which main machines are required?
Mixer, twin-screw extruder, cooling tank, cutter and packaging machine.
What production capacity can be designed?
Typical capacity ranges from 150 to 400 kg/h, determined during the engineering phase.
How much space is needed?
Typical process area ranges from approximately 500 to 1000 m², subject to final layout.
What are the main raw materials?
Wood powder, polymer granules (HDPE/PP/PVC), adhesives, colorants, stabilizers and packaging materials.
Can raw materials be supplied?
Yes, via the Supply Chain Department according to project scope.
Is machinery manufacturing or procurement supported?
Design, manufacturing or coordinated procurement according to the agreed scope.
Can existing machines be repaired?
Yes – inspection, troubleshooting, mechanical/electrical repair and spare parts.
Is overhaul or refurbishment possible?
Yes – comprehensive restoration and control upgrades.
Can capacity of an existing line be increased?
Often yes, by addressing bottlenecks and upgrading key equipment.
Are turnkey projects executed?
Turnkey or partial turnkey scopes can be offered under defined contracts.
Are services available in Iraq and Kurdistan Region?
Yes, including Erbil, Sulaymaniyah, Duhok and other locations.
Are services available in Afghanistan?
Yes, including Kabul, Herat and Mazar-e-Sharif.
Can raw materials be supplied from Iran for regional projects?
Yes, coordination of material supply is part of possible supply-chain scope.
Is installation and commissioning included?
They can be included according to the selected contractual package.