Composite decking has moved into the mainstream of commercialization. Manufacturers must have a method that can process at high rates for a reasonable capital investment. It must also be able to process a variety of materials so as to take advantage of formulation changes that increase quality and/or reduce costs. A one-step process will be discussed that converts undried cellulosic fibers and polyolefin pellets into finished retail decking. The effect on process conditions, particularly moisture removal, will be presented. Technical as well as commercial issues will be addressed. The focus of the paper will be the need for an integrated manufacturing system to provide the maximum economic return on investment.
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