A composite film made from rice husk and PVC has been launched by German producer Klöckner Pentaplast (kp, Montabaur; www.kpfilms.com). The “Pentadecor” film, which kp says is the first of its kind, is less than 1mm thick and can be laminated on a variety of surfaces, serving as a wood veneer or alternative to wood plastic composite (WPC) profiles for both indoor and outdoor applications.

While there is a wide variety of extruded natural fibre composite (NFC) and WPC profiles available, kp said the manufacture of films in thicknesses of 300-800 µm has not been possible to date because of the poor rheological behaviour of highly filled compounds. In order to develop a solution, kp collaborated with Resysta International (Pfaffing-Forsting / Germany; www.resysta.de), the producer of a rice husk-based PVC filler. As a result, the companies managed to develop, optimise and patent a stable production process for “Pentadecor” films within just one year.

The new film, said kp, contains high quality additives to provide maximum water and weather resistance, flexibility and robustness, and a direct pigment application on the surface ensures long-lasting UV-resistance. It can also be sanded to a smooth wooden finish and refined in various colours. In addition, kp has developed a new and patented calendaring process to complement existing extrusion, injection moulding and compression moulding technologies.

According to kp, “Pentadecor” films fulfil customers’ demands for a sustainable product with a natural and wood-like appearance that is low-maintenance, long-lasting and splinter-free, and can also be customised with individual designs.