Received: 1 March 2020 Revised: 3 March 2020 Accepted: 4 March 2020

DOI: 10.1002/pc.25570

RESEARCH ARTICLE

Fabrication of highly filled wood plastic composite pallets

with extrusion-compression molding technique

Taijun Jiang | Guangsheng Zeng | Can Hu

Hunan Key Laboratory of Biomass Fiber

Functional Materials, Hunan
International Scientific and Technological
Innovation Cooperation Base of Biomass
Fiber Materials and Application, School of
Urban and Environmental Science,
Hunan University of Technology,
Zhuzhou, China
Correspondence
Guangsheng Zeng, Hunan Key Laboratory
of Biomass Fiber Functional Materials,
Hunan International Scientific and
Technological Innovation Cooperation
Base of Biomass Fiber Materials and
Application, School of Urban and
Environmental Science, Hunan University
of Technology, Zhuzhou 412007, China.
Email: guangsheng_zeng@163.com
Funding information
Hunan provincial scientific research and
innovation project, Grant/Award
Numbers: CX20190843, CX20190844;
National Natural Science Foundation of
China, Grant/Award Number: 51973056;
scientific research projects of Hunan
provincial department of education,
Grant/Award Numbers: 18A258, 18C0524
Abstract
The aim of this study was to fabricate highly filled wood plastic composite pal-
lets with extrusion-compression molding technique and investigate the effects
of processing parameters on mechanical performance and production stability.
The composites were blended in twin-screw extruder and subsequently mea-
sured by weight with an electronic scale. Before compression, it was divided
into pieces and rearranged in the cavities of compression mould according to
the mass distribution. The effects of compression pressure and mould tempera-
ture on flexure strength, density, water absorption, and dimensional deviation
were investigated. The results show that both the flexure strength and density
of the pallets increased with compression pressure and remained higher than
that of extruded deck when compression pressure exceeded 6.5 MPa. Water
absorption and dimensional deviation decreased with compression pressure
and remained lower than that of extruded deck after the compression pressure
exceeded 6.0 MPa. Compression pressure could increase the final passed yield
by improving the composite melt filling state and lowering the buckling defor-
mation, but further increase above 6.7 MPa would result in a decline in final
passed yield. Increase in mould temperature contributed to the production sta-
bility but an excessive value would extend the molding cycle. The insights
gained from this study may be of assistance in optimizing extrusion-
compression processing parameters and expanding the application of highly
filled wood plastic composites in complicated and irregular products.

KEYWORDS
extrusion-compression, flexure strength, pallet, pine fiber, production stability, wood plastic
composites

1 | INTRODUCTION brings about higher biobased carbon content (as a frac-

Wood plastic composite is a kind of biomass materials
widely used in producing extruded outdoor architectural
profiles instead of solid wood and pure plastic.[1,2] Such
popular applications are mainly attributed to its lower
carbon footprint and excellent processability of both ther-
mal forming and machining. As indicated by ASTM
D6866-18 the biobased wood fiber in the composites
tion of total organic carbon) and lower total carbon foot-
print because of its negative value in carbon footprint.
Because the carbon in wood fiber comes from biomass
resources and that in oil-based plastic stems from petro-
chemical resources, the higher content of wood fiber in
wood plastic composites brings about higher biobased
carbon content for the composites. Many researches have
been carried out to investigate the relationship between

Polymer Composites. 2020;1–8. wileyonlinelibrary.com/journal/pc © 2020 Society of Plastics Engineers 1

2 JIANG ET AL.
performance and composite formula in terms of mechan-
ical, thermal, rheological, and morphological
[3–8]
properties. But most of the studies are limited within
injection and extrusion techniques and seldom of them
focused on the performance of finished products of irreg-
ular structure, especially fabricated by extrusion-
compression technique.[6,9]
Wood plastic composites could be processed by extru-
sion, injection, and compression techniques. However,
the poor flowability made extrusion become the most
popular, feasible and cost effective method to manufac-
ture the final products. The structure of the extruded
products was limited to linear ones, which was difficult
to be used in complex and irregular situations.[10] Injec-
tion molding technique can be used to manufacture irreg-
ular products but it required higher melt flow index
compared with extrusion that is difficult to obtain for
highly filled wood plastic composites.[7,11] Hydraulic
compression was a best technique to make irregular
products with materials of poor flowability. It may be
helpful by using hydraulic compression machine to man-
ufacture highly filled wood plastic composite products of
large format, such as pallets.
Pallets were important devices used in logistics trans-
portation and the world consumption for those experi-
enced a rapid growth in recent years.[12] Most of the
pallets were made from solid wood, plastic, steel, and
synthetic materials. The plastic and solid wood took up
more than 60% by volume. The restriction of recycled
plastic import and a ban on logging makes it urgent and
necessary to find out new eco-friendly materials to fabri-
cate pallets. Highly filled wood plastic composites thus
become the best choice as a result of its low cost, recycla-
bility, and excellent mechanical performance. However,
its poor flowability imposed strong restrictions on ther-
mal forming of products of complex and irregular struc-
ture. Long fiber reinforced thermoplastic direct
composites molding (LFT-D) was a newly developed
molding method to manufacture glass fiber reinforced
polypropylene composites by combining twin screw
extruder blending and compression molding
together.[13,14] This method was used to produce building
templates, auto parts, and subplate for pigpen. However,
we cannot use this method directly to fabricate pallets for
the poor flowability and higher moisture content in the
composites. In addition, if the highly filled wood plastic
composites were used in LFT-D production line, the
extruded melt stocks from the exit of the extruder would
swell under the big internal pressure caused by the
heated moisture and make it impossible to be collected
and transferred by the clamping needles.
The aim of this study was to fabricate integrated pal-
lets with highly filled wood plastic composites by a self-
assembled online extrusion-compression molding and
exam the mechanical, dimensional properties, and
processing feasibility. The pine fiber filled polyethylene/
polypropylene composites were blended and melted in
twin-screw extruder and measured by weight with an
electronic scale in a heat-insulated container. The com-
posites were transferred to heated mould cavities in com-
pression mould in hydraulic compression machine to
fabricate the integrated pallets. The flexural strength,
water absorption, dimensional deviation, and final passed
yield of the compressed pallets were investigated to eval-
uate the stability and controllability of online extrusion-
compression molding process. It was proved to be a
feasible method to fabricate complex pallets with highly
filled pine fiber/polyethylene/polypropylene composites
stably. This research could offer a cost effective and con-
trollable processing technique to fabricate products of
irregular structure and large format with highly filled
wood plastic composites.
2 | EXPERIMENTAL
2.1 | MATERIALS
Pine fibers were bought from local wood fiber factory and
its dimensions varied from 30 to 40 meshes. Polyethylene
(grade 5000S) and co-polypropylene (grade K8303) man-
ufactured by Sinopec were used as the plastic matrix.
Maleic anhydride grafted polyethylene (grade M603) from
Dupont was used as the coupling agent to improve the
interface compatibility between polymer and pine fibers.
Ethylene di-stearic amide (Cas No. 110-30-5) purchased
from a local chemical factory was used as the lubricant. The
formula we used for the compressed pallets was listed as
follows: pine fiber 50%, polyethylene 24%, co-polypropylene
23%, maleic anhydride grafted polyethylene 1.5%, ethylene
di-stearic amide 1.5% by weight. The addition of polyethyl-
ene into the composites could improve the flexure and
impact performance of the composites.
2.2 | Extrusion-compression equipment
Traditional injection molding technique was unsuitable
for fabricating complex pallets of irregular structure on
account of the poor flowability of highly filled wood plas-
tic composites. Our previous study had introduced an
online extrusion-compression molding method to pro-
duce packaging boxes of irregular structure.[10] In this
study, a modified method was used to fabricate highly
filled wood plastic composite pallets. A photo of the final
compressed wood plastic composite pallet is displayed in
JIANG ET AL.
Figure 1. The dimensions of pallets were 1200 mm
× 800 mm × 110 mm. The schematic diagram of the mod-
ified online extrusion-compression equipment is illus-
trated in Figure 2. The composite melt must be measured
by weight before it was transferred to the cavities of the
compression mould because the weight of the pallet could
vary from 7 to 18 kgs for different carrying capacity and a
wrong weight would result in disqualification during
manufacturing. A precise weighting of the composite melt
could ensure a uniform structure in thickness and stable
compression process. The mass of the composite melt was
measured manually with an electronic scale in this study.
F I G U R E 1 Photo of wood plastic composite pallet made by
modified online extrusion-compression molding technique [Color
figure can be viewed at wileyonlinelibrary.com]
F I G U R E 2 Schematic diagram of modified online extrusion-
compression equipment [Color figure can be viewed at
wileyonlinelibrary.com]
3
The composites were further divided into pieces. The sep-
arated composite melt stocks were transferred and
rearranged in the cavities of the mould according to the
mass distribution of the pallets. The nominal clamping
force of the hydraulic compression machine was 8 MN.
The clamping force was translated into compression pres-
sure as is discussed in the flowing sections.
For comparison of the properties and performances of
the composites between pallets fabricated by extrusion-
compression and deck made by traditional extrusion,
solid composite deck was manufactured with conical
twin-screw extruder and extrusion tools. The dimensions
of the solid deck were 100 mm × 15 mm.
2.3 | Fabrication of the pallets
There were three steps to fabricate highly filled wood plastic
composite pallets. First, dried the pine fiber in a vacuum dry-
ing oven at 120
C until the moisture content lowered than
3% by weight. Mixed all the components of the formula as
listed above in a high-speed mixer for 5 minutes and later
transferred the mixture to the hopper of a twin-screw
extruder. Wood fiber was easy to get burnt at higher temper-
ature during processing, therefore we set the temperature
below 180
C for each zone of the barrel of the extruder. Next,
the composite melt was collected at the end of the extruder
from the outlet with an insulated container. The weight of
the composites was measured with an electronic scale. After
weighting, the collected composites were divided into pieces
within 100 seconds to ensure it was not cooled down. Subse-
quently placed and arranged those separated composite melt
stocks in the cavities of compression mould according to the
pallet mass distribution. More composite melt stocks would
be arranged at the place where it was thicker for the pallet.
Finally, compressed the composite melt stocks at an appro-
priate temperature and compression speed to fill the mould
thoroughly. To improve the flowability of the composites the
mould temperature remained at about 80-110
C.
2.4 | Flexure property and density test
In order to evaluate the flexure properties of the pallets, a
three-point flexure test was performed. The samples for
the test were cut from the top part of the pallet and fur-
ther machined into the standard dimensions of
260 mm × 100 mm × 15 mm. The flexure strength of the
samples was tested according to EN 15534-1:2014. The
thickness of samples was 15 mm and the span between
two supporting bars was 210 mm. Six duplicate samples
were tested for each test conditions. The density test of
the samples was also performed as per EN 15534-1:2014.
4 JIANG ET AL.

2.5 | Water absorption and dimensional

deviation test

Water absorption test was carried out according to EN

15534-1:2014. The dimensions for water absorption test were
50 mm × 50 mm × 15 mm. The dimensional deviation of
the samples after immersing in water for 72 hours was also
measured as per EN 15534-1:2014 in terms of percentage.
The temperature of the water remained at 20 ± 1
C during
the test. The dimensions of the samples for dimensional devi-
ation test were 100 mm × 100 mm × 15 mm. And the sam-
ples were cut from the corners on the top plate of the pallets.
As all the samples swelled after treatment in water and the
maximum dimensional deviation occurred in the direction
of thickness, therefore, we only considered the dimensional F I G U R E 3 Flexure strength of wood plastic composite pallets
deviation in thickness as the interesting point. The dimen- under different compression pressure and extruded deck with the
sional deviation of the sample can be calculated with same formula
Equation (1).

T = ½ðt 2 −t 1 Þ=t 1  × 100%

Where t1 is the original thickness of the sample and t2

is the thickness of the sample after the treatment in
water. The unit for t1 and t2 is mm and dimensional
deviation is calculated in percentage. We took the cor-
ners as the point of interest because the filling defects
always occurred in the corners of the upper plate of the
pallet. The designed thickness of the upper plate of the
pallet is 15 mm in this study.

2.6 | Production stability evaluation

Good stability and controllability were crucial for mass
production of industrial products. To evaluate the stabil-
ity of the mass production process for fabricating pallets
we took final passed yield and flatness at the feet for
individual pallet as the main influencing factors. The
qualified criterion of the passed pallets must be complete
in structure and flat at four feet. To check the flatness of
the pallet at feet, firstly placed the thoroughly cooled
(24 hours after molding) pallets on the flat floor and
measured the gap between the bottom of each foot and
flat floor. If any gap was bigger than 5 mm, the pallet
was rejected.
3 | R ES U L T S A N D D I S C U S S I O N
3.1 | Flexure strength and density
Flexure strength is significant for the evaluation of carry-
ing capacity of pallets. Figure 3 shows the variation of
F I G U R E 4 Density of wood plastic composite pallet under
different compression pressure and extruded deck with the same
formula
flexure strength of samples cut from pallets with com-
pression pressure and makes a comparison between
extrusion-compression and traditional extrusion molding
techniques. An upward trend in flexure strength with the
increase in compression pressure can be observed in
Figure 3. With the increase of compression pressure, the
growth rate of flexure strength slows at the turning point
of around 7.25 MPa. Compared with extruded deck the
compressed pallet gave a much higher flexure strength.
Figure 4 shows the effects of compression pressure on the
density of compressed pallet and compares it with
extruded deck. The variation of the density exhibited a
similar trend of flexure strength. The maximum density
of the pallets made by extrusion-compression molding
technique reached around 1.3 g/cm3 while that of
extruded deck remained 1.22 g/cm3. Under lower
JIANG ET AL. 5

compression pressure, both the flexure strength and den-

sity of the compressed pallet were lower than those of
extruded deck. When the compression increased up to
6.5 MPa the density of pallets manufactured by
extrusion-compression molding started to exceed that of
extruded deck.
Highly filled wood plastic composite is a kind of heat
sensitive biomass materials and should not be processed
at higher temperature. Higher temperature would lead to
the burn of wood fibers and reduction of mechanical
strength of the composites.[15,16] Before the traditional
extrusion process for deck the composites were blended
and pelletized with a twin-screw extruder. In the extru-
sion process for deck, the composites experienced two
heating processes, which would bring about serious burn F I G U R E 5 Water absorption of wood plastic composite pallet
of wood fibers. In the second extrusion process the com- under different compression pressure and extruded deck with the
same formula
posites melt was firstly separated in the spiral grooves
and later converged in the extrusion tools. The newly
converged composites gained the inborn defects because
of the continuous separation and convergence of compos-
ite melt in the barrel and extrusion tools. Both two fac-
tors resulted in lower flexure strength of traditional
extruded deck. The extrusion-compression molding tech-
nique removed the second heating process and changed
the second higher shear-based extrusion process with a
lower shear-based compression process. As is believed,
the higher shear could result in higher local temperature
and even destroy the internal structure between wood
fibers and polymer matrix. It can be drawn from this
comparison that the online extrusion-compression mold-
ing is an appropriate technique to process heat shear sen-
sitive materials and avoid declines in performance
mainly caused by multiple heating processes. F I G U R E 6 Dimensional deviation of wood plastic composite
pallets under different compression pressure and extruded deck
with the same formula after immersing in water for 72 hours
3.2 | Water absorption and dimensional
deviation
when the compression pressure reached a limit of about
Water absorption for highly filled wood plastic compos- 7.2 MPa. Compared with extruded wood plastic compos-
ites determines the durability and mechanical and ite deck the water absorption of compressed pallet
dimensional stability. The absorbed water could induce remained at a lower value when the compression pres-
the wood fiber to expand in volume and further destroy sure went up 5.8 MPa. Figure 6 presents the variation of
the connection at the interface between wood fibers and dimensional deviation for composite pallets and extruded
polymer matrix under internal stress caused by variation deck after immersing in water for 72 hours with the
in volume.[8] The mechanical strength of the inflated increase in compression pressure. A similar trend in
fiber always declined quickly with moisture content.[8] dimensional deviation with respect to water absorption
The wood fiber concentration remained as high as 50% could be observed. At higher compression pressure
by weight in this study and such a high wood fiber con- (higher than 6 MPa), the water absorption of compressed
tent was easy to absorb water if the it was not tightly pallets held lower that of extruded deck. That means
compressed. The effect of compression pressure on water there is a positive correlation between dimensional devia-
absorption is presented in Figure 5. An obvious decrease tion and water absorption.
tendency was illustrated and from the variation trend we Water absorption reflects the interface compatibility
could infer that the water absorption obtained a balance between wood fibers and polymer matrix and the degree
6 JIANG ET AL.
of emersion of wood fiber from the polymer matrix. If a
higher compression pressure was applied on the compos-
ite melt during processing the polymer matrix would
transfer the load to wood fiber and make a close contact
between the two phases. The transferred pressure would
also compact the porous wood fiber to form a dense
structure, which could be reflected by the density
increase in Figure 4. The density of polyethylene and
polypropylene polymer matrix was not sensitive to the
compression pressure as indicated by other study.[17] The
moisture content in wood plastic composites mainly
came from two sources: wood fibers and surrounding
environment. In extrusion-compression molding the
moisture in wood fiber would be released not only from
the vacuum vent but also during the open composites
melt collecting process. The composite melt in the col-
lecting container was exposed in the air for a period and
the moisture had enough time to release. This may be the
main reason online extrusion-compression molding tech-
nique is superior to continuous extrusion in fabricating
highly filled wood plastic composite pallets.
3.3 | Final passed yield and production
stability
To evaluate the possibility and stability to fabricate
highly filled wood plastic composite pallets with the
online extrusion-compression molding technique, final
passed yield and thickness deviation at different compres-
sion pressure and mould temperature were measured
and considered. The variation of final passed yield and
thickness deviation with compression pressure and
mould temperature is presented in Figures 7 and 8,
respectively. The final passed yield of wood plastic
F I G U R E 7 Final passed yield of wood plastic composite
pallets under different compression pressure and at different mould
temperature
composite pallets increased with the compression pres-
sure firstly and began to decline at the peak of around
6.7 MPa, as is showed in Figure 7. While the final passed
yield of the pallets increased and later decreased with the
mould temperature. Figure 8 provides the relationship
between thickness deviation at four corners of the upper
plate of wood plastic composite pallets and compression
pressure at different mould temperature. It was shown
that the thickness deviation declined with the increase
both in compression pressure and mould temperature.
And the descent rate of thickness deviation of the pallets
speeded up at higher mould temperature.
The rejected pallets came from two aspects: defects cau-
sed by imperfect filling and buckling deformation espe-
cially at the feet of the pallets. The gap between the foot
and flat floor was critical for pallets quality control because
the uneven foot of the pallets would result in the drop of
goods and unevenness on store shelves. The highly filled
wood plastic composite melts would fail to be fully filled
into confined cavities under lower compression pressure
for the poor flowability. By raising the compression pres-
sure and mould temperature, the composite melt would be
easily squeezed into the narrow corners in the mould cav-
ity and make a complete pallet structure. On the other
hand, the higher compression pressure could bring about a
higher density and a shorter compression molding cycle.
And a compact internal structure and shorter molding
cycle would give a superior stability in structure and
dimensions. However, excessive compression pressure
would give a rise to internal stress within the pallets, which
could lead to unexpected buckling deformation especially
at the feet of the complex and irregular pallets.
The thickness deviation was considered as an impor-
tant factor influencing production stability because the
F I G U R E 8 Thickness deviation at four corners of the upper
plate of wood plastic composite pallets under different compression
pressure and at different mould temperature
JIANG ET AL.
uneven thickness would cause imbalanced stress distribu-
tion across the upper plate of the pallets. And it was
mainly caused by imperfect filling and excessive com-
pression pressure. If the composite melt was not thor-
oughly compressed under enough compression pressure
an uneven filling would take place. From our experi-
ments, it could be found that the imperfect filling parts
always appeared at the corners of the compressed pallets.
Deviation in thickness at the corners of the upper plate of
pallets would occur at the front of the composite melt
flow during processing. Compression pressure and mould
temperature were two important and controllable
processing parameters during the fabrication. Both
higher compression pressure and mould temperature
were benefit to improve the composites filling and make
a uniform structure. However, excessive compression
pressure could result in negative effects on the final pas-
sed yield and thickness deviation. Higher mould temper-
ature was advantageous to improve the flowability and
reduce the internal stress, but too high a mould tempera-
ture would result in inadequate cooling and extend the
molding cycles. Only an appropriate compression pres-
sure and mould temperature could make flawless wood
plastic composite pallets in both structure and mechani-
cal performance with an acceptable final passed yield.
Some splay mark could be observed on the surface of
the pallets as illustrated in Figure 1, which was caused by
the moisture from the composites and too many pieces of
composite melt stocks. The composite melt collecting and
measuring equipment was beneficial to the release of the
moisture but would result in many weld surfaces, where
a weak strength occurred. Therefore, heat sensitive com-
posites with low moisture content can be selected to
manufacture products with the online extrusion-
compression molding technique. And the surface and
mechanical properties would be improved dramatically
by extruding the composites in a continuous manner and
maintaining the extrudate at a stable temperature before
transferred to the cavities of the mould.
4 | C ON C L U S I ON S
A self-assembled online extrusion-compression molding
production line was used to fabricate highly filled wood
plastic composite pallets and the mechanical perfor-
mance, dimensional properties, and production stability
were measured and investigated. The results from this
investigation show that the compression pressure had a
positive impact on both the flexure strength and density
of the composite pallets. The flexure strength and density
would exceed that of extruded deck when compression
pressure went higher than 6.5 MPa. Water absorption
7
and dimensional deviation decreased with the compres-
sion pressure and remained below that of extruded deck
after the compression pressure exceeded 6.0 MPa. Com-
pression pressure could increase the final passed yield
but further increase (above 6.7 MPa) could result in a
decline. Although the increase of mould temperature
could improve the production stability, an excessive
mould temperature would lead to an extension of the
molding cycle.
It can be drawn from this study that the extrusion-
compression molding technique combined both compos-
ite blending and compression molding process together
can be used to fabricate industrial products of irregular
structure and large format with highly filled wood plastic
composites. Compared with injection molding method it
saves much more energy and makes a low shearing mold-
ing at relatively lower temperature available especially
for heat sensitive composites. It indicates that the online
extrusion-compression molding technique is a feasible
and cost-effective technique to fabricate irregular and
large format industrial products stably. And the insights
obtained from this study can offer valuable references to
optimizing extrusion-compression processing parameters
and expanding the application of highly filled wood plas-
tic composites.
ACKNOWLEDGMENTS
This work was sponsored by national natural science
foundation of China under grant 51973056, scientific
research projects of Hunan provincial department of edu-
cation under grant 18A258 and 18C0524, and Hunan pro-
vincial scientific research and innovation project under
grant CX20190843 and CX20190844.
ORCID
Taijun Jiang https://orcid.org/0000-0003-2922-2988
Guangsheng Zeng https://orcid.org/0000-0003-0223-
5017
Can Hu https://orcid.org/0000-0002-9046-572X
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How to cite this article: Jiang T, Zeng G, Hu C.
Fabrication of highly filled wood plastic composite
pallets with extrusion-compression molding
technique. Polymer Composites. 2020;1–8. https://
doi.org/10.1002/pc.25570