CW January 2013

January 2013
BUBBLING UP: NEW FOAM FORMULATIONS CONNECTING WITH COUPLING AGENTS LATEST DEVELOPMENTS IN PELLETIZERS
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contents
05 Industry news
PAGE 5
The latest compounding industry news including international acquisitions and alliances, plus new investments and plant openings.
13 Coupling agents make new connections

Coupling agents and compatibilizers are nding new roles in composites and
PAGE 13
blends that are fullling emerging applications. Pat Toensmeier reports.
23 Pelletizing systems: cutting edge technology

Mikell Knights speaks with leading suppliers of pelletizers to nd out about how their latest product developments meet changing market demands.
PAGE 23
37 Blowing up: advances in additives for foaming

Jennifer Markarian examines the latest innovations in additive and masterbatch technologies for foamed plastics applications.
PAGE 37
45 Optimising foamed polyolen formulations

John Krist and Emanuel van der Ven of Sabic describe the optimisation of PE foam formulations using DOE plus validation on production lines.
57 New products: additives

PAGE 45
60 Compounder of the month: IPC 62 Dates for your diary
coming next issue

S Thermally-conductive compounds S Materials handling systems S Additives for polyolens
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www.compoundingworld.com January 2013 | COMPOUNDING WORLD 3
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news
Americhem acquires Infinity Compounding

Global masterbatch supplier Americhem has acquired Infinity Compounding, a producer of filled and reinforced engineering thermoplastics based in Swedesboro, New Jersey, USA. The deal was completed on 28 December 2012. The acquisition expands Americhems activities, adding technical compounding to its core business of colour and additive masterbatch manufacturing. Rick Juve, CEO of Americhem, said: This move broadens the technology base, opens new markets and expands geographical reach for both organisations. Carlos Carreno, president of Infinity Compounding, added: As part of the Americhem Group, Infinity Compounding will be able to offer new products and technologies to our customers including best-in-class colour capabilities. We are also excited about Americhems global manufacturing and marketing reach, in particular China, which is already a growing market for Infinity. Infinity will continue to operate independently with its existing management team. The company serves the medical, electrical/electronics, business machine, disk drive, industrial, aerospace and military sectors. It operates five compounding lines at its Swedesboro plant with a total capacity of around 2,200 tonnes/year. Inifinity Compoundings Carreno is excited about Americhems global reach Carreno told Compounding Americhem is diversifying into technical compounds with the acquisition of Infinity
PolyOne moves into composites

PolyOne has acquired Glasforms, a manufacturer of glass and carbon fibre reinforced polymers and advanced composite products. It paid US$34 million for the company which had revenues in excess of US$50 million in fiscal year 2012. The purchase marks PolyOnes entry into the advanced composites market. Glasforms manufactures standard and custom profiles, tubes and panels using pultrusion, filament winding and continuous resin transfer moulding processes. Its products are used in demanding applications in the electrical, energy, transportation, healthcare, and defence markets. Our acquisition of Glasforms marks yet another important milestone in PolyOnes transformation, as we further broaden our specialty solutions portfolio to include these new and adjacent technologies and applications, said Stephen Newlin, chairman, president and CEO of PolyOne. Glasforms will continue to operate from its Birmingham, Alabama site. The company employs approximately 300 people, and its founder and president, Peter Pfaff, will continue in his leadership role along with other members of the management team.
World that the company plans to add another compounding line in the third quarter of 2013, bringing an additional 600 tons of annual capacity. Infinitys product ranges includes: Instruc structurally reinforced compounds, Inlube internally lubricated compounds, Inelec electrically conductive resins, and Incolor pre-coloured resins. Americhem is a privately owned company with masterbatch plants in the US, the UK and China. Its sales and production in 2010 were estimated at US$190 million and 30,000 tonnes. The companys main markets are automotive, building products, fibres, PET bottles and general moulding.
www.americhem.com www.infinitycompounding.com
Wells Plastics plans expansion

UK masterbatch maker Wells Plastics has received a increase its production capacity by around 25%. It says that one of the drivers for its growth is increasing demand for its Reverte oxo-degradable additive masterbatches which have experienced a 20% rise in sales over the past 12 months. Key Capital made its initial investment in Wells in February 2011. The masterbatch maker employs more than 40 people and has a turnover of E12 million.
E1.8 million follow-on

investment from private equity house Key Capital Partners and its current shareholders. Wells plans to use the funding to invest in new machinery to
www.compoundingworld.com
www.wellsplastics.com
www.polyone.com
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January 2013 | compounding world
news
Invista buys Dutch compounder

Polyamide 66 producer Invista has acquired VSL SiloLogistics compounding and recycling operation located at Born in Sittard-Geleen, the Netherlands. The deal was completed on 21 December 2012. Invista will use the plant to produce its engineering polymer brands, including its Torzen PA 66 resin. It plans to mainly manufacture primebased compounds at the Born site, but the facility also has the capacity and capability to produce high-quality recycled products. Kurt Burmeister, executive vice president at Invista Engineering Polymers said: Europe is a critical region for automotive manufacturers and other global decision-makers within the industry. The Born sites expertise, location, employee values, and position as a trusted compounder made them the right fit for our company. Invista, which claims to be the worlds leading producer of PA 66, was acquired by Koch Industries from DuPont in 2004 and it re-entered the engineering plastics market in 2009 following the expiry of a five-year non-competing clause in the acquisition contract. In 2011 it announced that it was planning to add its own compounding capacity either through acquisitions or investing in new plants. The company uses a network of toll compounders to supply PA 66 grades and it says that it will continue to use these companies alongside its newly acquired in-house production. Our business model now includes internal compounding production as well as contract manufacturers, explained Burmeister. We continue to see opportunities to leverage contractors capacities, locations and competencies while simultaneously extending our reach through this acquisition. The Born plant has approximately 30 employees and they will all transfer to Invista. The facility has been compounding and recycling PA for around 20 years. It was operated by VSL SiloLogistics, which is primarily focused on logistics services for the chemical and food industries.
www.invista.com
NFM picks Jan van Bakergem

US-based extruder manufacturer NFM has appointed Jan van Bakergem as global managing director for compounding systems. He took up his new role on 7 January. Van Bakergem was previously global industry director petrochem at Mac Process, and he was CEO and president of Coperions North American operations from 2003 to 2009. NFM reports strong sales growth for its TEM compounding systems primarily in the US market.It now plans to increase its market share through global sales and it has been increasing its manufacturing capacity.
Epsan increases compounding capacity with Coperion line

Epsan Plastic has added a new twin-screw extruder at its plant in Bursa, northwestern Turkey. It increases its total polyamide compounding capacity from 15,000 to 22,000 tonnes/year. The new line is based on a Coperion ZSK 58 Mc18 twinscrew extruder, taking Epsans total number of Coperion machines to five. In addition to its plant in Bursa, the independent polyamide compounder also operates a separate production facility in the nearby town of Gemlik. Epsan distributes its PA 6 and PA 66 compounds under the Eplamid, Eplon and Epimix brandnames to customers in Europe and North America. The companys global sales director, Arda Efe said: The capacity increase will help Epsan to focus more on fast growing Asian markets as well as strengthen our position in existing ones. Established as a plastics trading firm in 1978, Epsan began PA compounding in 1998. It now employs around 100 people worldwide and produces a range of formulations including flame retardant, reinforced, stabilized and coloured grades. The main target markets for Epsan include the automotive and the electrical and electronic sectors. Epsan has added a new Coperion compounding line at its Bursa plant in Turkey
www.nfm.net
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www.epsan.com.tr
compounding world | January 2013
news
ECHA considers cadmium ban

The European Commission has asked the European Chemicals Agency (ECHA) to examine the case for expanding REACH restrictions on cadmium to cover all plastics materials. Annex XVII of the chemicals legislation currently list 16 specific plastics materials where cadmium is restricted. The ECHA is asking for evidence to help identify the impact of this potential expansion. Comments from interested parties need to be submitted by 11 February 2013 using an online questionnaire which can be accessed at http://bit.ly/ECHACd. The 16 resins covered by existing restrictions on the use of cadmium as a colorant include PVC, PUR, LDPE, PET, PS, PP and XLPE. However, there is an exemption for LDPE masterbatch. European users of cadmium in plastics should contact the ECHA quickly Further restrictions apply to the use of cadmium as a stabilizer in PVC compounds used in a range of applications including: packaging materials; office and school supplies; furniture fittings; apparel and clothing accessories; floor and wall coverings; textile fabrics; imitation leather; gramophone records; tubes, pipes and their fittings; swing doors; road vehicle components; steel sheet coating; and wiring insulation. For any colorant and stabilization applications which escape the above limitations, there is still a limit of 0.1% cadmium metal by weight in finished plastics articles. The restrictions do not apply to articles coloured for safety reasons. Some cadmium compounds are still used as pigments in plastics, and industry associations say that suitable alternatives may not be available for certain applications, such as colouring engineering plastics. They include cadmium zinc sulphide yellow, cadmium sulphoselenide red and cadmium sulphoselenide orange. Further background information, including the full Annex XVII document can be read at: http://bit.ly/CdPDF.
www.echa.europa.eu
Graphene growth could fall short

Demand for graphene is predicted to grow at 40% per year from US$9 million in 2012 to reach US$126 million in 2020, according to a new report from Lux Research. The study says that this growth is less than some of the hype surrounding the wunderkind material might suggest, drawing potential parallels with the commercialisation of carbon nanotubes. It forecasts that the bulk of the market will belong to graphene nanoplatelets, used mainly in composites and energy storage applications. Despite being a hot research area, the commercialisation of graphene films will be delayed by a large number of technical and economic challenges, says the study. The rocky history of carbon nanotubes shows that a
8
Clariant sells off divisions

Clariant is selling off three of its non-core businesses to the US private investment firm SK Capital for a total of CHF502 million (E405 million). The deal includes Clariants Textile Chemicals, Paper Specialities and
Despite being hyped a wunderkind material, Graphene still faces hurdles to commercial success research and patent boom along with impressive technical performance is far from a guarantee of commercial success, said Ross Kozarsky, Lux Research senior analyst and the lead author of the new report. Major challenges like high costs, processing issues, and competing materials loom large, he added. The report, which is entitled Is Graphene the Next Silicon ... Or Just the Next Carbon Nanotube?, identifies XG and Vorbeck as leading players among the graphene nanoplatelet start-ups. www.luxresearchinc.com
Emulsions businesses. It is expected to be completed by the end of the second quarter of 2013. The company announced in early 2012 that it was considering options for these business lines. It is still carrying out the review process for Leather Services and Detergents & Intermediates.
www.clariant.com
news
UMass Lowell inaugurates new Technovel lab for compounding

The University of Massachusetts Lowell has officially opened the new Technovel Compounding Laboratory as part of its US$80 million Mark and Elisia Saab Emerging Technologies and Innovation Center. The Compounding Laboratory was funded through UMass Lowells partnership with Technovel, the Japanese manufacturer of compounding extruders. It features two Technovel lab-scale lines, one based on a Micro twin-screw extruder and the other built around the companys novel Quad four-screw design. Both extruders have screw diameters of 15 mm. Technovels Micro twinscrew intermeshing co-rotating machine, which can operate at speeds up to 4,400 RPM, boasts a high-torque drive system and a pressureresistant barrel. The modular screw can be configured for an L/D ratio of 45:1 or 60:1. The WDR Quad extruder features four parallel intermeshing co-rotating screws for the improved mixing of materials. It provides longer retention times, lower heat generation and improved venting, according to Technovel. Part of the Universitys Plastics Engineering Department, the new Compounding Laboratory will be used to develop innovative formulations including bioabsorbable polymers and nanocomposites. The Emerging Technologies and Innovation Center also includes a high bay for plastics processing with the ability to run large-scale injection moulding and blown film extrusion. In addition, it features facilities for nanotechnology and biomedical materials R&D. The 84,000 ft2 (7,800 m2), four-storey Emerging Technologies and Innovation Center was officially opened in October and was formerly named and dedicated to benefactors Mark and Elisia Saab in December. Mark Saab graduated from UMass Lowell in 1981 with a degree in plastics engineering. UMass Lowell graduate student Melissa Egan demonstrates the equipment in the Technovel Compounding Laboratory He is president of Advanced Polymers, a manufacturer of medical device components which he co-founded with his wife Elisia Saab and is now part of Vention Medical. The couple live in Lowell and have become the largest individual donors to UMass Lowell. I have always felt strongly about giving back to UMass Lowell and being involved in the plastics engineering program. Im grateful for the specialized education that has led to my success and I want to help todays students discover the path to their own future, said Mark Saab. The faculty, students and staff of UMass Lowells Plastics Engineering Department cannot thank Mark and Elisia Saab enough for their continued and extremely generous support, said Professor Robert Malloy, department chairman. Their support for this building will take our ability to conduct materials and manufacturing research to a new level.
www.technovel.co.jp www.uml.edu
Arsenal Capital invests in Dash Multi-Corp

New York-based private equity firm Arsenal Capital Partners has acquired Dash Multi-Corp, a US manufacturer of formulated polyurethane, vinyl plastisols, specialty coatings and recycled rubber products. The St. Louis, Missouribased company has annual
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sales of more than US$100 million. Concurrent with its acquisition by Arsenal Capital from its founder and owner Marvin Wool, Dashs coated fabrics operations will become a separate entity owned by Marlen Textiles. Dashs MarChem plastics
and chemicals business produces polyurethanes, vinyl plastisols, specialty coatings and adhesives used in a variety of processes ranging from medical device moulding to niche flooring applications. In 2012, Arsenal also invested in IGM Resins,
Plasticolors, Evoniks Colorants business and FluoroSeal Holdings. Its previous investments in the sector include Genovique, IDQ, Novolyte, Sermatech, Velsicol, and Vertellus.
www.arsenalcapital.com www.dashmulticorp.com
PVC Formulation 2013

Market trends and technical developments in PVC additives and compounding
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Coupling agents | additives feature
Coupling agents make new connections

Silanes and other coupling agents or compatibilizers can be used to molecularly bond organic polymers and inorganic llers and reinforcements. In addition, they can function as surfactants and dispersion agents, as anti-agglomerates, or as adhesion promoters. Such properties make the additives indispensable in a range of established formulations, but recently they have been applied to new and evolving applications with their own performance needs. As a result, the chemistry and use of coupling agents is moving beyond conventional workhorse applications and into markets that are increasing the versatility and variety of grades available. These applications include areas such as: G improving the properties of recycled materials, barrier packaging and advanced composites; G the formulation of new versions of copolymers and terpolymers by compounding normally immiscible resins; G meeting environmental rules for non-halogenated ame retardants and low-VOC (volatile organic compound) processing; G the cost-efcient production of price-sensitive parts through formulation changes; G and efforts to improve rolling resistance in tyres as a fuel economy measure. These developments could, experts believe, promote a degree of innovation in coupling agents that the compounding industry hasnt seen in some time. With
Coupling agents and compatibilizers are nding new roles as the requirements for thermoplastic composites and blends evolve to full emerging applications. Pat Toensmeier reports
the amount of work that is underway to blend materials, the interest in coupling agents as modiers is increasing, says Jose Torradas, senior technical consultant for DuPont Packaging and Industrial Polymers. The number of applications and market segments [they make possible] is growing signicantly all over the world. The materials that DuPont supplies are good examples of the evolving state of coupling agents and related modiers. The company has produced two main product lines in this area for some time, Fusabond and Elvaloy, which are described as compatibilizing resins. Fusabond is based on maleic anhydride-grafted polyolen copolymers, while Elvaloy, a broader product line, comprises polyethylene (PE) terpolymers PE and reactive comonomers and epoxy groups and ethylene acrylate copolymers. When added to compounds at various loadings (3.5 to
January 2013 | COMPOUNDING WORLD 13
additives feature | Coupling agents
where scrap is reintroduced as a structural layer. The grade links the normally immiscible major (up to 90% PE) and minor (PA or EVOH) components to improve dispersion, along with elongation, toughness and other mechanical properties in containers. Meanwhile, compounders use Fusabonds compatibilizing and dispersion properties to reduce the cost of commodity products such as PP containers, while maintaining mechanical properties. Calcium carbonate (CaCO3) is used in these containers for rigidity. According to Torradas, a small amount of Fusabond increases CaCO3 loading, reducing PP use and saving the compounder money, without affecting properties. Elvaloy grades are for neat and glass-reinforced DuPonts Fusabond polymer modiers are used as coupling agents in exible pipe and other end-uses 7% is typical), the materials raise or help maintain select properties of commodity and engineering thermoplastics, and also compatibilize streams of mixed recyclate. Fusabond A560, for example, improves adhesion between glass reinforcements and polyamide (PA) 6 and 66 resins, owing to its maleic anhydride group, which reacts with PA and ethylene-vinyl alcohol (EVOH). DuPont says this can increase the notched Izod impact strength of glass-reinforced PA by 30 to 50%. A560 also contributes to reduced melt viscosity in highly lled compounds and to retention of tensile strength, modulus and heat-deformation temperature. In addition, Fusabond grades reportedly work well as coupling agents in highly lled polyolens. One important area is formulations with ame-retardant mineral llers. Here the use of Fusabond as an additive enhances ller dispersion, improving compound homogeneity, elevating ame-retardant loadings and maintaining tensile strength and elongation-at-break properties. One Fusabond grade, M603, is This blow moulded polyolen agrochemical bottle for Brazil uses a DuPont Fusabond coupling agent touted as a compatibilizer for PE-based recycling streams and production of polymer lumber. In the latter, M603 strengthens the composite and reduces moisture absorption by cellulose bres in the compound. Torradas says that the grade can also be used with polymer lumber materials that are not fully dried, saving compounders time and money. In another reclaim application, Torradas says M603 can improve the in-house recycling of PA or EVOH during the injection moulding or blow moulding of PE-based barrier containers,
14 COMPOUNDING WORLD | January 2013
polyesters polyethylene terephthalate (PET) and polybutylene terephthalate (PBT). The PTW grade is a soft E-nBA-GMA (ethylene/n-butyl acrylate/glycidal methacrylate) terpolymer that bonds to and disperses consistently throughout polyester. It is especially compatible with glass and so toughens reinforced PBT. Elvaloy AC has similar properties in glass-reinforced polyesters, but as a copolymer it increases melt ow over terpolymer versions, thereby improving processability. DuPont tweaks the chemistries of these resin modiers to meet the coupling agent needs of evolving and emerging applications, and to create enhanced formulations with otherwise incompatible polymers and llers. There are fewer new polymers and more interest in blending whats available, Torradas says in explaining this trend. Another company using resin chemistry as the basis for coupling agents is Chemtura. John Yun, technology manager at the company, says Polybond coupling agents are comprised of polyolens and their derivatives, which are grafted with reactive functional chemical groups such as maleic anhydride and acrylic acid. The additives are primarily for blending non-polar polymers like PP, PE and their derivatives with polar llers, such as glass bres, CaCO3, talc, mica, natural bres and others. The coupling agents achieve this, Yun adds, by carrying polar functional groups along the non-polar polymer backbone. This nature of bipolarity in Polybond coupling agents gives rise to afnity at the interface of polymers and llers, he explains. The functional groups form covalent bonds or secondary bonds while the polymer part imparts physical entanglement
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the materials for years, claiming they offer advantages that coupling agents such as silanes do not. Ti and Zr reportedly compatibilize polar and non-polar polymers, and react with all organic and inorganic materials. Conventional silanes, in contrast, work with many reinforcements and mineral fillers, but according to Kenrich they have less effect on materials such as CaCO3, carbon black, carbon fibre and graphene. Ti and Zr are also thermally stable catalysts, says Kenrich president Salvatore Monte. This means they can repolymerize a macromolecule in an extruders polymer melt to rebuild molecular weight a process Monte likens to reactor-based metallocene catalysis. Among the advantages of Ti and Zr when added to thermosets, is a curative function that provides methacrylic, acrylic, amino and mercapto moieties that react with UV light, free radicals, peroxides, sulphur and DuPonts Fusabond Grade M603 is used to compatibilize PE-based recycling streams in Brazil of polymer chains driven by the thermodynamics during the mixing process. As a result, PP, PE and polyolefin derivatives achieve enhancements in such mechanical properties as tensile, flexural, impact and adhesion strength in applications like multilayer film and coatings. According to Yun, Chemtura is supplying these coupling agents for five major applications: PP with short and long glass fibres; PP and PE filled with natural fibres such as wood flours, cellulose, starch and others; PP filled with mineral fillers like CaCO3, talc and colour pigments; adhesive layers between printing ink and PP in flexible packaging; and PP/PA blends. Yun identifies evolving applications for which Polyblend additives have a fit. One is dispersion of colour pigments in automotive and home appliances. Another is flexible packaging for heavy-duty goods comprising a woven PP layer and an ink-print layer. Here the Polybond coupling agents improve adhesion between the ink layer and woven PP. The third is wire and cable compounds with more than a 70% loading of halogen-free flame retardants. To regain the compromised mechanical properties such a formulation creates, Polybond compatibilizes the flame retardant with the polymer, in the process restoring elongation and tensile strength. Yun notes that recycling is another important application, especially in lines where PA can mix with and contaminate PP scrap. A small addition of Polybond coupling agents makes [both materials] compatible and maintains PP integrity, he says. Other materials getting a closer look by some compounders are titanates (Ti) and zirconates (Zr), both organometallics. Kenrich Petrochemicals, which sells liquid Ti grades under KR or LICA brand names, and liquid Zr additives as NZ and KZ brands, has promoted
16 compounding world | January 2013
other curing agents to increase cross-linking and other functions, Monte says. In compounding, loadings of 0.2 to 0.4% by weight are typical for unfilled polymers when Ti and Zr are used as adhesion promoters, catalysts or process aids. Loadings range from 0.35 to 0.7% by weight when they are used with mineral fillers, pigments and fibres. Monte says that information about applications is restricted by non-disclosure agreements. Recently developed grades, however, show the types of benefits Kenrich provides with its organometallic chemistry. One grade for unsaturated polyester converts the MEKP (methyl ethyl ketone peroxide) curing reaction to endothermic from exothermic to eliminate micro-bubble formation in parts. New coupling agents for advanced composites are formulated for carbon and aramid materials. The additives even have use in recycling. Because the titanates are in situ catalysts in the melt, they regenerate scissored molecular chains and rebuild mechanical properties, Monte explains. They will also copolymerize, so whereas not more than 5% PP can be blended with high-density PE without having delamination and compatibility issues, [Kenrich] coupling agents will allow a 50/50 PP/HDPE blend that in effect acts as a new polymer. This of course means recycling has to be a melt process, which Monte acknowledges adds cost. But as he notes, these coupling agents will become more viable when the use of recycled commodity plastics become part of a sustainability culture in large markets such as automotive. Silane formulations are also being tweaked for new and evolving needs. The dual functionality of silanes, evident in their ability to achieve molecular bonds between organic resins and inorganic substrates, gives
Xiameter are among the additives used or evaluated for this application. Increasing silica levels and effectively reducing the amount of carbon black [in a tyre] reduces rolling resistance and improves fuel efciency, Hein says. The silane is also necessary because although silica improves tread stock properties, the chemical has low compatibility with elastomers, weakens the rubber matrix and can thus reduce tread life. Loadings of Xiameter silanes for this and other applications can be as low as 0.1% by weight to 10%, though Hein says general levels are in the 0.5% to 3% by weight range. Another additive supplier working on formulations that reduce rolling resistance is Cray Valley. The company uses two basic chemistries: low glass-transition-temperature (Tg) polybutadiene (PBD) oligomers Titanate and zirconate additives from Kenrich react with inorganic and organic materials including graphene, a model of which is shown here formulators a powerful platform on which to add functionality. As a result, silanes are often the go to additives when properties enhancement is required in a various applications. Some of the trends in silanes follow the larger mega-trends in the marketplace, says Travis Hein, technical account specialist for Xiameter silanes at Dow Corning. For example, People are looking to silanes to help them make green materials. Applications here include solar cells, where organic coatings are used to treat the polysilicon cells. The silanes help ensure good adhesion and long-term durability of the coatings, he notes. I think the trends you will see in silane coupling agents will involve adding multiple functionalities to provide a combination of benets such as improved dispersion and water repellency, Hein adds. One new area in which silanes nd increasing use is tyre manufacturing, where they couple silica with tyre rubber. There are several benets to Coupling agents are used to improve silica dispersion in tread stock as tyre manufacturers comply with rolling resistance label rules (Photo: Michelin) this, but a major advantage is reducing rolling resistance in cars and trucks as part of a regulatory effort to minimize fuel consumption. The idea is that decreasing the amount of energy absorbed by tyres will reduce vehicle fuel use. Europe recently started a tyre-labelling program to inform consumers about the rolling resistance of tyres prior to purchase, and the US is expected to eventually implement a similar program. Suldo-brand silanes from
(tradename Ricon) and high-Tg-temperature styrene maleic anhydride (SMA) copolymers (tradename SMA). These materials our starting points, says Jeremy Austin, business development manager permit the company to graft appropriate chemistries onto the molecular backbone of each and start building functionality. The choice as to whether to use low-Tg-temperature PBD or high-Tg-temperature SMA in a formulation is usually determined by the resin or ller it will interact with. Elastomeric polymers generally work better with the low-Tg backbone, while engineering thermoplastics such as PA and polyester function well with a high-Tg backbone. The approach is paying off in rolling resistance. We have seen up to a 30% improvement, says Todd Speece, Cray Valleys marketing director. He believes this reduction in rolling resistance will contribute fuel savings of 3 to 5% in a vehicle. The additives that Cray Valley is working on with several undisclosed customers are in testing, though Speece expects one or two grades to be commercial later this year. The company is not only looking to reduce rolling resistance but improve tyre grip and handling as well. Historically, you could only improve one property at the expense of the other two, he remarks. But in the past several years weve learned enough about properties enhancement to improve [rolling resistance and grip] without affecting [handling]. Speece says the technology is applicable to all vehicles including trucks. The program could be a
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mould release and consistent processing. Compounders and end-users want as much versatility as possible from additives. One recent trend cited by Kerstin Weissenbach, senior technical manager at silane producer Evonik Degussa, is added functionality in coupling agents. The company developed two product lines to meet this need: Dynasylan Oligomers for wire and cable, moisture-cured cross-linked PE and mineral-filled polyolefins; and Dynasylan Silfin for wire and cable, pipe and other thermoplastic applications. Dynasylan Oligomers improve coupling functionality as well as reduce alcohol release, and thus VOCs, during compounding, which is a plus for compliance with environmental regulations. The materials also have a high degree of hydrophobicity, which is especially suited for applications like wire and cable, where Dynasylan Silfin coupling agents from Evonik Degussa are used in silane moisture cross-linking of these PE-X pipes game-changer for major tyre companies that use it to differentiate their products from those of competitors, and for small manufacturers that already produce outstanding tyres and will use the label program for greater market visibility. Either way, the rolling resistance program could shake up the tyre industry, thereby giving coupling agents from Cray Valley, Dow Corning, Struktol (also a silane producer) and others a major role in the ratings competition, albeit behind the scenes. One area Cray Valley works in is non-halogenated flame retardants, where grades permit high loadings of mineral fillers and hydrated flame retardants, reducing resin use and boosting flame resistance, with little trade-off in mechanical properties. Austin says the company took a flame-retardant grade of PP with a 30% loading of CaCO3 and increased that to 55% without giving up a lot in mechanical properties. The decline was only by a single-digit percentage. Recent developments from Struktol include RP 28, a compatibilizer and blending aid that improves the incorporation of regrind or recycled material in a wide range of polymers. The additive is said to deliver improvements physical properties and processability. It can also be used as an alloying agent for engineered plastics, providing improved dispersion of the discreet phase polymer as well as mechanical bonding characteristics that can result in better physical performance. Struktol has also introduced TR 451, which it describes as a special combination product for improving the incorporation of fillers into polyolefin compounds. Studies show that it allows higher loadings of CaCO3 in PP without sacrificing processability or performance. Alternatively, compounders using treated fillers may be able to switch to untreated fillers in combination with TR 451 to reduce overall costs. In addition, the additive can provide viscosity reduction,
external layers must resist water and other forms of moisture. Dynasylan Silfin grades are described as easy-todose liquids with all ingredients for grafting and cross-linking polyethylene. The materials contain vinyl silanes and initiators, cross-linking catalysts and additives such as antioxidants, metal deactivators and processing aids. Weissenbach says that these materials meet the needs of compounders who want additives that widen process windows, thereby helping to reduce scrap and keeping production costs down; help comply with environmental workplace rules; and of course meet their needs for coupling agent functionality. To achieve these and other benefits, Evonik Degussa is pushing the boundaries of applications, she remarks. In the future, coupling agents will play a greater role with other additives in building properties and expanding performance in new and traditional applications. Weissenbach says that her companys coupling agents are already used in such areas as alternative energy (wind turbines), corrosion protection and in replacement of environmentally suspect materials, and that developments will continue as users seek to optimize their processes. An observation that all makers of coupling agents will doubtless agree with. Click on the links for more information:
www.dupont.com www.chemtura.com www.4kenrich.com www.xiameter.com www.crayvalley.com www.struktol.com www.evonik.com

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HANDBOOK OF PLASTICIZERS, 2ND EDITION
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COST MANAGEMENT IN PLASTICS PROCESSING: STRATEGIES, TARGETS, TECHNIQUES AND TOOLS

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UNDERSTANDING PLASTICS ENGINEERING CALCULATIONS HANDS-ON EXAMPLES AND CASE STUDIES

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Order online or by telephone, fax or email. Contact Matt Wherlock, Tel: +44 (0)117 924 9442 Fax: +44 (0)117 9892128 email: mjw@amiplastics.com All prices are correct at the time of publication but may be subject to change. Please check the Plastics Information Direct website for current prices and shipping charges.
Pelletizers | machinery feature
Mikell Knights speaks with leading suppliers of pelletizers to nd out about their latest product launches and the changing market demands that they are designed to meet
Pelletizing systems: cutting edge technology

Pelletizer manufacturers have been busy developing new products and technologies to meet the evolving requirements of the compounding sector. They include systems designed to reduce energy consumption and improve process control and quality levels. Other innovations have been introduced to increase the speed of machine start-ups, product changeovers and maintenance operations. In addition, pelletizers are being developed to successfully handle increasingly complex formulations, including high ller loadings, high-temperature polymers or sensitive bio-based materials. Over the following pages, we look at the latest developments and news from a range of suppliers, including Automatik, Bay Plastics Machinery, Berlyn, BKG, Coperion, Davis-Standard, Econ, Gala and Reduction Engineering Scheer. Automatik Plastics Machinery recently rolled out its Sphero 50, an upgraded version of the smallest model in its Sphero line of underwater pelletizing systems. The unit processes a range of polymers, masterbatches, compounds and technical plastics at ow rates from 70 kg/hour up to 600 kg/hour, says Andreas Voemel, who is product manager for the line.
www.compoundingworld.com January 2013 | COMPOUNDING WORLD 23
The systems components, including the Centro 50 pellet dryer, process water system, hydraulic unit and electric control cabinet, are all mounted on a solid mobile frame. This helps to minimize the footprint while keeping all components accessible for maintenance and adjustment. Other relevant components, including start-up valves, die-plates, water basins and drives, are suspended from a T-bar on the mobile frame. A new cutter head is designed to provide better
Above: Automatiks latest Sphero 50 underwater pelletizer has its components mounted on a mobile frame
Below: Automatiks Primo 200E strand pelletizer features a large cutting width
machinery feature | Pelletizers
alignment of the blades with the die-plate as well as optimizing the pellet flow inside the cutting chamber. These changes help to ensure the production of consistent high-quality pellets, says the company. An ergonomic design approach allows for easy cleaning and quick changes of the die-plate, blade carrier and blades, adds Voemel. The Sphero 50 joins six other models in the Sphero line which deliver throughputs up to 32 tonnes/hour. Automatik, a subsidiary of the gear pump and filtration system maker Maag (which itself recently became part of Dover Corporation), has also enhanced its Primo line of single-side dry-cut strand pelletizers with its new Primo 200E that features a large cutting width. The cantilever-style model is suitable for the production of thermoplastic compounds, additive masterbatches or colour concentrates at throughputs up to 1.5 tonnes/hour. The model features cutting tool sets for hard, abrasive, soft or flexible plastics, all of which use a special geometry with a very short unguided length between the feed rolls and the cutters. This enables optimum straight cutting of hard or soft strands. The feed geometry does not subject the strands to pretensioning prior to cutting. The low-deposit cutting chamber is easy to clean, and overall retooling time is claimed to be quick and simple. With its 200 mm operating width, the Primo 200E is the largest in the product line which also includes the Primo 60E and 120E. Another recent development from Automatik is its EBG belt conveyor system for pelletizing highly-filled or high-temperature polymers as well as sensitive biopolymers or compounds containing natural fibres. The belt system supports and conveys the material
from the die to the dry cut pelletizer automatically. We cool the material with air while it is on the belt, then we cut the polymer while it is at 150 to 200oC, generating high-quality pellets with no dust, fines or waste, says Joachim Scheurich, product manager for dry cut systems. Special high-flow air nozzles cool the belt and material from above. A water spray or water bath are also offered as options. Automatik supplies the EBG in two model sizes, the EBG 250 with a maximum throughput of 1 tonne/hour, and the EBG 450 with 2 tonne/hour maximum throughput. Each unit can be ordered with belt lengths of 3, 5 or 7 metres. Automatik has built these special units for about 18 months and there are approximately 30 installations in the field processing glass-filled nylons, WPCs and carbon-filled high-temperature polymers.
www.automatikgroup.com
Bay Plastics Machinery (BPM) says that it is advancing the control of its strand pelletizing lines, moving from turn-knobs and speed-pots, via closed-loop systems with PLC controllers, through to recent additions to its advanced Digital Pellet Length Control (DPLC) technology. The DPLC system relies on software algorithms and control of the feed rollers and rotor motors to determine cutter speed. The PLC adjusts the lower speed roll to maintain pellet length, says Jason Forgash, executive vice president at BPM. If the extrusion line speed changes, a user enters the desired pellet length through the control panel and the system adjusts the pelletizer accordingly. The company says that the DPLC can deliver material savings by dialling in the process more quickly, and reducing waste of polymers during start-up. The closed-loop DPLC system now has an optional control feature that measures the pressure of the polymer in the die, then uses that reading to control the operating speed of the pelletizer. Die pressure tracking
BPMs new XVAK vacuum air knife system dries 15-25 strands
adjusts the pelletizer speed in real-time. Users requiring pellets of varied lengths can reset the pellet diameter and length mid-process. BPM is now looking to take the control a step further, enhancing the system to allow for a pellet-per-gram spec to be entered, with machinery adjustments executed automatically. In a related development, the company is working with a customer on the design of a system to read the output of the material feeders to control the extruder. The pelletizer will track the extruder rate and follow it step-for-step. DPLC costs approximately US$2,000 plus the cost of a dual drive to control the pelletizer, and can control lines with up to 250 strands. Even lines running just five to ten
24
Pelletizing & Pulverizing Technology

Strand Pelletizing
l Precision grinding of cutting rotors l Maintenance, Repair and Refurbishment of cutting rotor assemblies l New cutting rotors in several materials and designs, bed knives etc.
Under Water Pelletizing

l Re-sharpening of UWP knives and Surface grinding of die-plates l Repair and Refurbishment of die-plates l New die-plates and UWP knives
Pulverizing
l Precision grinding of discs and segments l New discs and segments in different materials and designs l Special wear resistant coatings
Rue Jean Koch 4 B-4800 Lambermont Belgium Phone: +32 8731 0906 E-Mail: pelletizing@bks.be Internet: www.bks.be
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BKS Malaysia
No.12, Jalan High Tech 5 Kawasan Perindustrian High Tech 43500 Semenyih, Malaysia Phone: +60 3 87 23 36 29 E-Mail: sorna@bks.com.my Internet: www.bks.com.my
strands can see a return on investment, says BPM. DPLC was conceived as a way to improve the processing of recycled materials, which tend to be crammed into an extruder due to their low-bulk density. The cramming can cause surging out of the die, which in turn creates processing fluctuations during pelletizing, says Forgash. In addition to low bulk density materials, it can also be used for high-performance polymers, compounds and pigments. BPM has also introduced a new low-cost version of its vacuum air knife system. The new XVAK series is a low noise pelletizer that controls 15-25 strands. The system effectively dries strands from a water bath or water spray.
a web strand process for a customer that produces 19 strands held together by a web of material stretching from one strand to the next. They did not want the operator to have to babysit the line, so we created the web strand which eliminates web dropping, says Cassidy. The trial application was a success. Berlyn ECM can build web stranding systems for customers with projects requiring up to 50 strands. Berlyn ECM is updating its standard die-face plate technology to a more wear-resistant design. The new die-face plate moves away from a clad face plate configuration, which partially covered the die face, to a solid carbide matrix material that is used across the entire die face.
www.bayplasticsmachinery.com
Berlyn ECM, a supplier of lab-scale and production systems using company-built extruders and underwater or strand pelletizers is adding its first hot-face pelletizer model to its product line. The air-cooled hot-face cutting approach targets processors using material that should not come in contact with water. Polymer is pelletized on the face of a waterless die that is then transferred by air to a cooling table. The hot-face die is offered individually or as part of a system with throughputs from 500 to 6,000 lb/hour (230 to 2,700 kg/hour) says Jay Cassidy, vice president of sales. In 2004, Cassidy and several other partners purchased the extrusion and pelletizing product line from Berlyn Extruders, where he worked before the company went out of business. The company offers complete systems including the extruder, screen-changer, continuous filter and pelletizing die, with a choice of BKG has been focusing on the design of more energy efficient pelletizing systems water bath/air knife/hot face cutting. Berlyn ECM creates a single, customised control system based on a Eurotherm Maco, Siemens or Allen Bradley platform. Berlyn ECM has developed
www.berlynecm.com
Bruckmann & Kreyenborg Granuliertechnik (BKG) has focused on delivering energy savings with the development of its special insulated die-plate design and its rethinking of the water circulation system for its underwater pelletizing systems. Each development aims to deliver energy savings up to 33% compared conventional components, says Ralf Simon, BKGs managing director. The insulated die-plate is designed to process high-temperature resins in an underwater pelletizing system where die-plate temperatures often reach 350 to 380oC, while the water temperature can hover between 60 to 90oC, explains Simon. In order to minimize heat loss and maintain good thermal distribution between the die and die face, high-temperature steels are used for the die-plate surface and special materials are specified to insulate the hot die body from the cold cutting surface. BKG says that the design reduces the risk of die-hole freeze-off, which can occur with heat loss and poor temperature distribution. The problem generates increasingly irregular flow in the die as more holes close, while at the same time the die holes that remain open experience higher pressure and varying material flow velocity. This can lead to serious problems for downstream processes, says Simon. With its special systems, BKG says that the hydraulic pressure used to hold the blades in contact with the die-plate surface is kept as low as possible to reduce wear and energy losses. The company is also optimizing the water filtration and recirculation system of its underwater pelletizers to reduce energy consumption. We have eliminated some of the water pumps that we normally install for water filtration, and we have improved the insulation of the system, says Simon. BKG reports growing sales of underwater pelletizing
26
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systems for processing bio-based resins, with around 10 lines supplied in the past two years. It is also supplying equipment for the pelletizing of compounds featuring natural reinforcements. These include around 20 lines for processing wood-plastic composites capable of handling filler loadings of 40% or more. Another area of growth is the pelletizing of hightemperature resins, with three or four commercial lines installed over the past two years, including a polysulphone line in the Far East. BKGs CrystallCut underwater in-line PET crystallization system is now being widely used for the production of spherical pellets for PET bottle production. The single-step technology was introduced eight years ago as an alternative to strand pelletizing. This shows a change occurring worldwide for PET pelletizing, and it is even being seen in Western Europe, reports Simon. The spherical pellet yields approximately 8% higher bulk density than conventional shapes.
Pell-Tecs new SP500HD strand pelletizer matches up with specific Coperion ZSK extruders
www.bkg-de
Coperion has several developments in strand pelletizing underway following its purchase of Pell-Tec in January 2012. The relationship between the two companies goes back to 2002, when Pell-Tec began delivering strand pelletizers to Coperion, says Michael Schuler, Pell-Tecs CEO. Coperion produces its UG line of underwater pelletizers at its main facility in Stuttgart, Germany, and will keep the Pell-Tec manufacturing operations in Niedernberg, Germany. Both operations are sharing process know-how and investigating approaches that can support and advance their respective technologies, says Schuler. Pell-Tec is adjusting the throughput capabilities of its pelletizer line to exactly match the production rates of Coperions new MC18 twin-screw compounding extruders. The intention is to offer a complete system including the compounder and pelletizer where the customer does not worry about interfaces or interlinking the controls. Pell-Tec is also developing two high-throughput strand pelletizing models designed to match Coperions ZSK 70, 82 and 92 extruders. The new SP500HD and SP700HD are heavy duty designs featuring working widths of 500 mm and 700 mm respectively. The SP700HD unit is designed to handle materials with high filler contents. It is offered
with drive power ranging from 30 to 45 kW delivering the ability to pull 150 strands of 3 mm diameter at rates of 5,600 or 6,300 kg/hour. The SP500HD comes with drive power from 22 to 37 kW and the ability to draw 125 strands at throughputs of 4,500 or 5,000 kg/hour. Like the 700 model, the heavy duty unit has upsized bearings and bearing joints, a more robust cutter and a more rugged puller. In the field of engineering plastics, Pell-Tecs customers are moving towards higher loadings of glass fibre in polyamides. Schuler says that compounds with 50-60% glass loadings are being produced to meet demand from the automotive and aircraft industries for parts that withstand heat and dampen vibration. They present pelletizing challenges as they are very stiff, very tough to cut and very abrasive. The heavy duty design of the new SP units has been developed to meet these challenges. The new strand pelletizers will feature an automated water-assisted strand conveyor that catches the strands at the die then guides and supports them to the cutting knife. Instead of a quench tank, the strands are cooled and handled through a combination sluice- and- watercooled conveying system. The sluice and conveying belt restrands broken polymer strands automatically. The system is useful in high-throughput operations with many strands, where strand breakage can
January 2013 | compounding world 29
The latest strand conveyor from Pell-Tec is designed to overcome strand breakage problems
says Crumb. Davis-Standard has developed special location formats to optimize the hole patterns in the die-plate design. The company builds its own die-plates and offers tailored die hole geometries and patterns for different materials, viscosity ranges and applications. The X series new or retrot machines with the optimized die-plate pattern are an option for the companys Universal Pelletor line which is designed to operate as an underwater, water-ring or air-ring system. This design can run with the cutting knife in contact with the die-plate face or in gap mode, depending on the polymer, to greatly improve knife and die-plate life. Davis-Standard is also creating a new hard-face die made to handle highly-lled material formulations, targeting compounding applications that generally run at rates under 40,000 lb/ hour (18,000 kg/hour). Above: Davis-Standard has improved the product throughput of its X series of pelletizers Right: DavisStandards MicroDie technology for small pellet production is being upgraded happen often. The new conveyor design provides cooling similar to a quench tank while minimizing operator involvement. This creates an opportunity for one operator to monitor multiple lines. Sluice strand conveyors have previously been available from Pell-Tec, but only for smaller pelletizing units with working widths of 300 mm. Pell-Tec also now offers a new FlexSize option on its strand pelletizers that allows users to vary the length of the pellet produced without exchanging gear wheels. It is particularly aimed at masterbatch projects running 500-600 kg/hour, but it is an option for all pelletizer models. In addition, the companys MicroDie technology for small pellet production is being upgraded. Crumb says that the new design offers improved cleanability, reduced pressure drop, enhanced geometry, improved insulation and optimised orientation of the heating media to the orices. Davis-Standard is also improving an option that doubles the life of the cutting knife assembly. The blade material, blade position, blade geometry and the alignment of the blade to the die face help to extend knife life while trimming maintenance costs and downtime.
S www.davis-standard
Econs newest underwater pelletizing unit, the EUP50, is a lab-scale model built to handle high-performance polymers. It is designed as an alternative to strand units for product development or small batch production applications, including those involving hard-tohandle materials. The EUP50 has a throughput ranging from 2 kg/h to 100 kg/h, which is relatively low for an underwater pelletizer says Alexander Datzinger, sales manager at the companys headquarters in Austria. He adds that the unit can handle ller loadings up to 80%, which can cause problems with strand pelletizers. Its patented thermally insulated die-plate also helps when processing high-performance compounds such as lled PEEK, lled PTFE or LCP. The die-plate design is the same as that used on Econs larger models. This separates the die-plate from the nozzle to provide thermal insulation and deliver a range of benets. These include quick and easy
S www.coperion.com S www.pell-tec.com
Davis-Standard has further improved the capabilities of its X series of pelletizers by offering new and retrot debottlenecking kits. These are designed to improve product throughputs of its Universal Pelletor line by up to 25% or more, while maintaining the same equipment footprint and high pellet quality. The die-plate boasts the next generation of hole patterns, says Charles Crumb, business group manager of extrusion pelletizing systems. The size, shape and placement of the die-plate orice holes have been improved, allowing 4 to 5% more holes in a given die-plate. Hole location must be such that the heel and the toe of the cutting blade sees exactly the same amount of resin from one end to the other in order to achieve uniform cutting blade and uniform die-plate wear,
start-ups, while a very wide range of materials can be processed without any freezing at the die-plate. Econ describes the EUP50 as a compact, mobile and fully integrated unit that is particularly suited to small batch production with frequent material and colour changes. For, example it can be used to produce masterbatch with specic carrier resins in relatively low quantities. Cleaning is both quick and efcient; the integrated centrifugal dryer can be cleaned out in a few minutes, claims the company. The EUP50 and the larger EUP150 model are now offered with an optional PLC controller, which costs around 10-15% extra compared to a conventional control system. In addition, Econ has added continuous band water ltration as an option for all of its underwater models. The system continuously lters out nes and contaminants in the circulating process water, eliminating the need to clean the tank at every product change. With the addition of the latest model, Econs EUP underwater pelletizers are now offered in seven standard sizes covering throughputs from 2 to 6,500 kg/hour. Gala has developed its Heat Flux die-plate to allow its underwater pelletizing systems to handle temperature-sensitive materials more efciently. The special die-plate is designed so that it insulates the heated body of the die-plate from the process water contacting the die face. It has demonstrated energy cost savings of up to 70%, as well as increased production Econs EUP50 underwater pelletizer is designed for development or small batch production
S www.econ.eu
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THER M O P L A S T I C Template CONCENTRATES 2013

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efciency as a result of improved pellet quality and uniformity. It is not a material of any kind that insulates the die, rather, it is an insulating cavity designed in the style of a double- or triple-pane of glass, says John Roberts, director of sales and marketing at Gala Industries in Eagle Rock, Virginia. The cavity within the die provides the insulation from the water and will not rob the heat from the die-plate. The cavity design also minimizes pressure drop while maintaining a uniform temperature on the heated side of the die-plate, reducing the potential of polymer solidication in the die face. The trick is to make the die-plate robust and exible enough to handle the constant thermal cycle that a die-plate goes through and not destroy the insulation properties or the integrity of the die-plate for long- term performance. Gala says that its conventional die-plate designs can process most grades of highly engineered materials, but the Heat Flux die-plate opens an entirely new arena of engineered materials and generally higher-temperature or high-performance material formulations to its pelletizers.
The company has also launched a new fully automated underwater pelletizing unit that processes a wide range of materials at rates up to 15,000 kg/h while maximizing blade and die face life. Its Electronically Adjustable Pelletizer (EAC) joins Galas line of automated, spring-loaded and manually adjustable underwater pelletizers. It features a servo stepper motor that is positioned, adjusted and monitored by PLC. The cutter blades can be positioned in increments down to less than 0.001 inch (0.025 mm). We know, through the use of pelletizer automation and monitoring, that spinning cutter blades in an underwater pelletizer are subject to a force that can draw the blade into the die face, potentially increasing blade and die face wear on certain applications, says Roberts. A processor might assume that they have to push the The Heat Flux die-plate from Gala can handle temperaturesensitive materials more efciently
designed to make each strand thermally uniform, from surface to centre, for clean cutting. The conditioning system section shrinks the temperature difference between the skin of the strand and its molten centre, which can be up to 150oC across an unconditioned pellet fresh from a water bath or spray nozzles, says Chris Case, vice president, market development. Several commercially installed units are being used to improve the pelletizing of glass-lled PA 66 with black pigment, a common formulation used by the auto industry. The lines are producing temperature-uniform strands, eliminating the shrink voids, angled cuts, jagged edges and nes typically generated with strands having a wide skin-to-centre temperature difference. A good spot for cutting a strand is 10oC below the Tg of the polymer, explains Case. At that point the strand has the ability to keep its shape through the cutting Reduction Engineering Scheers new conveyor improves the temperature distribution across strands blades to hold it to the die face but in some applications, linear force from the turning blades actually draws the blades forward. The design of the EAC brings absolute control of blade position. The PLC allows the user to set the blades adjustment amount and frequency, thereby maintaining an optimal blade-to-die-plate distance during operation. An optional integrated blade position measuring system alerts the user when a blade change is required. PLC control also allows a user to move the cutting blades briey into contact with the die-face then away as a self-cleaning die-kiss step that prevents material build-up. The PLC can store hundreds of recipes. EAC is currently being used on systems processing a wide range of materials, including glass-lled polymers, bio-resins, hot-melt adhesives and high-temperature resins, says Roberts. It features a rotational clamp that allows operators to close, clamp and lock with one hand instead of two. Another new product from Gala is the Melt Conditioning Device which cuts up the blocks of scrap polymer diverted onto the shop oor during process Galas EAC system helps to maximize the working life of the blade and die face start-up. It has a pneumatically operated cutter blade that is positioned underneath the material diverter valve of an extruder in order to slice the melt blocks into smaller pieces for ease of handling. An operator can set the cutting frequency of the blade. process while remaining warm enough to generate the fewest number of nes. Cutter wear may be reduced, as the overall strand temperature is warm, making it is easier to cut. Processors of the glass-lled pigmented polyamide are discovering that reducing ne generation, dust and angled cuts in the nal product yields a cleaner pelletizing system that runs longer with fewer housekeeping issues. It also reduces the need for a special equipment to separate nes, says Case. Friable polymers that offer good clarity, such as PS or PMMA, could yield an optical defect or chip and break if nes or angled cuts appear in the product. The Flash-off system is offered with a water bath or water tray, with vacuum or blowers, and in lengths of 3, 5 and 7 metres.
S www.reductionengineering.com
S www.gala-industries.com
Reduction Engineering Scheer reports commercial projects for its Flash-off conveyor, a strand pelletizing conditioning system that was introduced in 2011. It features a special temperature compensation section
34
COMPOUNDING WORLD | January 2013
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Polymer foams | additives feature
Blowing up: advances in additives for foaming

Foaming offers several benets to polymer processors and is used in a wide variety of applications, including automotive and packaging products. Primarily, foaming is used to reduce weight, which saves material costs. Less weight can also lead to fuel savings, for example in light-weight vehicles or in lighter packaging to transport. Foamed plastics can also provide insulation to increase energy efciency. So it is no surprise that foaming is gaining interest as a sustainable technology because of its ability to bring fuel and materials savings. Polymers can be foamed by injecting gas directly into the melt using a physical blowing agent, or by creating a gas in the melt using a chemical foaming or blowing agent (CFA). Blowing agents can also act as processing aids in the melt to improve throughput, as viscosity reducers to improve ow and reduce moulded-in stress, and to improve mould lling and reduce warping. Processes for direct gas injection, such as Trexels MuCell microcellular process, have been growing in use. Several new process technologies for physical foaming were discussed in Compounding Worlds August 2012 article on Expanding interest in lightweight parts (see http://bit.ly/CWfoam). These new technologies include Wittmann Battenfelds direct nitrogen injection technology, R&D Factorys water injection system, and Trexels and Mazdas core-back expansion moulding technology. In addition to these process improvements, developments
Jennifer Markarian examines the latest developments in additive and masterbatch technologies for foamed plastics applications
in additives for both chemical and physical foaming are also progressing.
Chemical foaming agents

The most commonly used CFA is azodicarbonamide (ADCA or AZO), an exothermic CFA that produces nitrogen on decomposition. There are also other exothermic CFAs and endothermic CFAs, such as carbonates that release carbon dioxide. Exothermic CFAs have a high gas yield, which maximizes density reduction. Endothermic CFAs typically produce a smaller cell structure, which can improve physical properties and surface appearance. Blends of both types are also used. CFAs are added during extrusion or moulding of the nal part either as a powdered additive or as a masterbatch. Although CFA technology is well-established, customers and suppliers continue to look for further improvements in density reduction, physical properties,
additives feature | Polymer foams
Clariants Hydrocerol CFA formulations allow much smaller cells for example, the average cell size shown on the right is 91 microns compared to 181 microns for the traditional formulation on the left
quality of appearance, and cost savings. In the past, foaming has been often used as a band-aid for moulded parts with thick walls and difcult ow paths, but now we see optimization of chemical foaming usage in automotive and other markets as a substantial cost and raw materials reducer, says Peter Schroeck, technical director of Reedy International. New patented processes are taking advantage of the easy implementation of chemical foam in composites and glass lled polymers and are achieving substantial performance and process improvements while inching closer to lofty Corporate Average Fuel Economy goals, he adds. Reedy, which supplies endothermic and endothermic/exothermic blends, recently introduced Safoam PN-40E, an endothermic chemical nucleating and foaming agent compatible with both styrenics and olenics. The new product has improved bubble size and gas retention, which can result in improved ex and compression in thermoformed parts, says the company. Clariant Masterbatches discussed its improved Hydrocerol CFA masterbatches in a presentation at AMIs Polymer Foam 2012 conference held in Newark, New Jersey, USA, in October. Frank Neuber, applications development manager at the company, explained that the new masterbatches use carrier systems that create earlier polymer fusion onset. This enables better distribution in the mix, improved cell-wall integrity, and improved encapsulation of the gas that is generated to create a better foam structure.
processing conditions to obtain the best possible foaming. These new Hydrocerol masterbatches are optimized for specic resins, processes, and applications. The goal is to create the most effective foam cell structure to maximize both density reduction and physical properties and surface appearance, says Kirk Jacobs, product line director for additives at Clariant Masterbatches North America. Different resin types and grades perform differently in the foaming process and thus require not only compatible carriers but different types and levels of blowing agents, nucleating agents, and other additives, notes Neuber. The end application also needs to be taken into account. For example, thin-walled, thermoformed cups require very small cell sizes. Several new Hydrocerol CFA masterbatches are now commercial, including products for: automotive applications involving TPO, PP, and nylon; thermoformed polystyrene packaging; injection-moulded polyolen closures; and exible lm and tube polyolen packaging. In extrusion blow moulding (EBM) applications, Hydrocerol masterbatches are being used successfully in non-appearance parts such as vehicle ductwork. Appearance-sensitive EBM applications in food and personal-care packaging require better surface aesthetics, and Clariant is working with several customers on masterbatches ne-tuned for these applications. ColorMatrix, a subsidiary of PolyOne, supplies
ColorMatrix says its Excelite liquid foaming agent creates very smooth PVC sheets suitable for digital printing
In addition, Clariant has optimized nucleation to create smaller and more uniform cells that allow the use of additional CFA to achieve greater density reductions without signicant loss of physical integrity or appearance. Processors can incorporate best practices, such as using accurate feeding systems, ensuring consistency between shifts, incorporating stabilizers when adding regrind, and using a consistent resin to further improve their cost savings. These practices are not always used, said Neuber, but they can have a positive effect. Clariant works with customers on their shop oors to improve practices and optimize
38
additives feature | Polymer foams
Chris R&P Compounding is targeting Vistamaxx PBE at a variety of applications including footwear
foam structure that maintains the barrier, chemical, and temperature resistance of PVDF resins with the light-weighting and cost-saving advantages of foam. Foamed wire and cable jacketing, for example, is not only lighter weight and lower cost than solid jacketing, but has an improved, lower dielectric constant, is more flexible, and is easier to strip, claims Seiler. Other foamed applications, such as foam-core PVDF piping, are in development.
Nucleating and coupling agents

Particles such as calcium carbonate and talc can be used to nucleate bubble formation in chemical foaming
Improving foam properties

ExxonMobil Chemicals metallocene-catalyzed Vistamaxx propylenebased elastomer (PBE) is finding use in foaming applications. Chris R&P Compounding of Guangdong Province in China recently developed a special formula for foaming with Vistamaxx PBE that uses existing equipment but creates foams with improved properties. Vistamaxx PBE has a semi-crystalline structure of propylene and ethylene that contributes to making foams softer, with better elongation, more flexibility, and better slip resistance than ethylene vinyl acetate (EVA) and polyolefinic elastomer (POE) alternatives, says Chris R&P. The Vistamaxx PBE-based foams are also more weather resistant than EPDM rubber and lower in cost than polyurethane and rubber-based alternatives, adds the company. Chris R&P has used Vistamaxx PBE successfully in a range of products, including footwear, toys, and sporting goods.
applications. Direct gas extrusion systems can use mineral particles as passive nucleators or endothermic CFAs as active nucleating agents. In general, nucleating agents act to reduce cell size and increase cell density, which helps maintain physical properties and thus allow further weight reduction. Smaller cell sizes typically lead to improved surface finish and thermal insulation. In polypropylene (PP) foam, talc acts as both a reinforcing filler and a cell nucleator. Studies investigating talc as a nucleator of cell formation found that a microcrystalline talc morphology performs better than the more conventional macrocrystalline, lamellar morphology, explains Dr Gilles Meli of Imerys Talc. Meli and his team presented this work at the Society of Plastics Engineers Foams 2012 conference held in September in Barcelona, Spain. Meli explained that the energy barrier required to initiate heterogeneous nucleation depends on the surface geometry of the nucleating site. Microcrystalline talc nucleates cells more effectively because it is has a higher surface area, which enables it to entrap more gas, thereby generating a higher number of nuclei. PP foam containing microcrystalline talc displayed cell density more than two times higher than that of PP foam containing lamellar talc, reported Meli. Applied Minerals Dragonite halloysite, a natural aluminosilicate clay with a hollow tubular morphology, provides effective reinforcement and nucleation because of its high aspect ratio and surface area. Dragonites surface area is 65 m2/g or higher, compared to about 10-20 m2/g for typical talc and approximately 5 m2/g for calcium carbonate, notes Dr Chris DeArmitt, the companys CTO. In a presentation at AMIs Polymer Foam 2012 conference, DeArmitt showed that using halloysite to nucleate cell formation improved production speeds by 30-40% in a foamed extruded HDPE sheet. In addition, the formulation required 30% less endothermic blowing agent, and it improved mechanical properties and surface finish compared to an existing commercial
www.exxonmobilchemical.com
liquid foaming agents, including what it says is the worlds first liquid foaming agent for PVC sheet. The Excelite product creates a finer, more consistent cell structure within the extruded polymer to create a smoother surface finish. This aesthetic quality is important in applications such as digital printing, says Bjoern Klaas, director of new product and technology development at the company. Liquid foaming agents, like liquid colorants, bring improved dispersion, highly accurate dosing, and reduced waste, notes Klaas. Arkema recently introduced a patent-pending CFA in a masterbatch designed for foaming its polyvinylidene fluoride (PVDF) resins during extrusion (eg wire and cable jacketing, profiles, pipes, film, sheet) or injection moulding. For years, no foaming agent was available that could make a consistent structure with fully-closed cells in PVDF, and PVDF applications were primarily served with solid products rather than foamed products, notes Dave Seiler, Americas business manager and global advisor for fluoropolymers at Arkema. The new technology, however, yields a closed-cell
compound used by the customer. In foamed, injection-moulded PP parts, nucleation of cell formation with halloysite can be used to maintain mechanical properties while further reducing density. Halloysite differs from other nucleating agents, such as talc and calcium carbonate, in that it both nucleates bubble formation in foaming and nucleates crystal formation in foamed and unfoamed applications. Crystal nucleation restores the strength and modulus properties that can be lost due to foaming, claims DeArmitt. While these results were obtained by adding separate masterbatches of Dragonite and the formulated foaming agent, Applied Minerals is now working on loading its hollow Dragonite tubes with a CFA to create foam nucleation, crystal nucleation, and reinforcement from one additive. Since the tubes have a 15-nm sized hole, bubbles released from the tubes would be small, which should further improve mechanical and insulative properties. Nucleating agents are also used with physical blowing agents. Interfacial Solutions, an independent R&D service provider, presented a study at the AMI Polymer Foams 2012 event that compared supercritical carbon-dioxide foaming with talc and several different nanoparticles as a nucleating agent. Researchers found that, as expected, cell size decreases and cell density increases with smaller nucleating agents. Researchers also found that a maleated polyethylene coupling agent with a nanoclay created a more stable foam, but an acrylate terpolymer coupling agent did not, possibly due to poor compatibility. Coupling agents can be used in foam formulations to The high surface area of Applied Minerals halloysite can bring benets to foamed plastics
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help disperse filler particulates and blowing agents, which helps improve cell size and structure. Coupled filler particulates reduce the tendency of particulates to act as a failure point in bubble formation.
Melt-enhancing additives
Good melt strength is necessary for producing and maintaining a foamed cellular structure. Melt strength can be improved with high molecular weight acrylic polymers that act as foam cell stabilizers, such as Dows SureCel and Arkemas Plastistrength. Arkema also offers Biostrength acrylic polymers for PLA. In polyester resins, processing causes chain scission and CFAs can cause further degradation, leading to reduced melt strength. Melt-enhancing additives counteract chain scission by knitting chains back together. For example, BASFs Joncryl functional additives contain reactive epoxy functional groups that create chain extension and branching. Clariant Masterbatches CESA-extend can be used in combination with its CFAs to repair broken polymer chains and improve melt strength. Titanate and zirconate coupling agents also catalyze chain building and branching, notes Salvatore Monte, president of Kenrich Petrochemicals. Material selection trends are driving increased use of melt-enhancing additives for improving foaming. First, the use of post-industrial and post-consumer recyclate is growing, and additive suppliers are seeing more projects looking at increased levels of regrind or recyclate. These reprocessed materials typically have experienced some degradation, causing melt strength loss that is detrimental to the foaming process. Second, in foamed film and sheet extrusion, improved melt strength may be needed to enable downgauging and prevent the thinner web from breaking during extrusion. Clariant Masterbatches CESA-extend, for example, is finding use in improving melt strength in thin-gauged, foamed PET sheet. Finally, poor melt strength is an inherent problem in some biobased materials, such as Click on the links for more information: PLA, and suppliers see increasing interest in meltenhancing additives for these resins as they grow in use. Interfacial Solutions carried out tests on nucleating agents using a Leistritz 27 mm twin-screw extruder
More information
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Foaming polyolens | technical paper
John Krist and Emanuel van der Ven of Sabic describe the optimisation of polyethylene foam formulations by design of experiments and validation with production results
Optimising foamed polyolen formulations using DOE and practical processes

The foaming of thermoplastic polymers is a process with a huge number of parameter settings and variables. For materials development and research programmes, many tests are needed to get an understanding of material properties and foaming behaviour. Executing all these tests is hard to do on production lines with outputs larger than 100 kg/hour. Therefore, there is the question whether tests executed using a small laboratory line at 10-20 kg/h can be representative for production on commercial lines. A Design Of Experiments (DOE) can be used to minimize the number of experiments and to obtain statistical information about accuracies. DOE is a mathematical approach to obtain as much possible quantitative information as possible out of a test matrix with the least number of possible tests. The results of these experiments at a laboratory scale are discussed in relation to practical experiences and production using commercial lines. The laboratory scale tests were used to study physical foaming processes with variation of parameters such as cell stabilizers, nucleating agents and blowing agents. Different foam resins were also compared during these tests, including Ultra Melt
Strength (UMS) grades. The processing and performance of the relatively new UMS resins was validated in practice and related to the properties of the end product. These properties were compared with the properties of products produced with regular foam grades. The work addressed the following main questions: (1) What are the most important parameters for the production of foam with UMS grades? (2) Does DOE supply useful information to build a model and what are the most inuential parameters for the foaming process? (3) How can these parameters be applied in practice? (4) What are the advantages for the market of these UMS grades?
Setting up the design

A classical approach of experiments would be based upon one variable at a time (OVAT). For polymer foaming, a vast range of parameters can be applied. Therefore, parameters such as output, die pressure and temperature settings are kept constant. Only basic things are changed, for example: nucleating agent at 0.25, 0.5, 1.0 and 2.0%; blowing agent at 6, 10
technical paper | Foaming polyolens
Figure 1: Example of OVAT experimental set up with 36 experiments
Figure 2: DOE of two materials and three factors. Sabic LDPE 2202UMS and 2102TX00 grades (left and right respectively) are analysed using a total of 32 experiments
and 13 %; and cell stabilizer at 1, 2 and 3 %. With this example, 36 experiments are needed for each material with OVAT (Figure 1). Using DOE instead of OVAT provides several signicant advantages: G OVAT provides no statistical information (accuracy/ deviations); G OVAT does not work in the presence of interactions; G DOE provides more information from the same amount of experiments (deeper insight). When the DOE set-up is used, the total amount of tests for two materials is 32 experiments, or 16 per material (Figure 2).
As already mentioned, a set of 32 experiments was set up for the two foaming materials (Table 1). By changing the full the range of parameters for blowing agent, nucleating agent and cell stabilizer, the resulting densities and cell sizes were observed, as well as a wide range of corrugation levels. Several models were calculated using the data generated by the experiments to analyse density, corrugation and cell-size. Some statistical details of the obtained models are shown in Table 2 with the overall t statistics R2 and Q2 being the most important. In general, the properties R2, Q2 and R2Adj should be as high as possible and close to each other. The key gure R2 increases when more terms are added, R2Adj has an optimum and is used to signal a sufcient model whereas Q2 is cross-validation based and signals the robustness of the model. Figures 4 and 5 show the relative contribution of each factor and interaction for density of foams. Besides this, the t performance is illustrated by a graphical representation (the observed vs predicted plot). In the observed vs predicted plot. a straight line is shown together with all measured points clustered around that line. A good model will have all the points
Laboratory experiments and results

A laboratory single-screw foam extrusion line with an annular die and a maximum capacity of 20 kg/h was used to produce foamed LDPE sheets with 3 mm thickness (Figure 3). Two foaming grades were compared: Sabic LDPE 2102TX00 and 2202UMS. The sheets were produced with 10 kg/h output and with optimised (lowest) temperature settings for each combination of factors and or materials. Figure 3: A lab extrusion line with an annular die was used to produce the foamed LDPE sheets
46
Foaming polyolens | technical paper
Table 1: The DOE set-up

Name Material Cell-Stabilizer Stabilisation level Nucleating agent Isobutane Abbreviation Mat Stab stlev Nuc Iso % % % Unit Type Qualitative Qualitative Quantitative Quantitative Quantitative Use Controlled Constant Controlled Controlled Controlled Settings 2102TX00; 2202UMS Stearamide 1 to 3 0,5 to 4 6 to 13
grouped closely around the line and spread equally over the whole range. Contour plots give a graphical overview of the studied response as a function of the variables. Figures 6, 7 and 8 are contour plots visualizing the behaviour of density, corrugation and cell-size of the experimental foam-sheets. Densities achievable with LDPE 2202UMS can be lower than the densities obtained using a more typical PE grade, however the grade is more sensitive to parameter settings. Model inaccuracy and less perfect laboratory settings give values differing from practical achievements. Figure 4: Observed vs predicted plot and coefcient plot of the property density showing the relative contributions of each factor including interactions
Table 2: Statistical key gures for density, number of waves and cell size
R2 Log (density t0) waves cell size 0.94 0.80 0.83 R2 Adj. 0.92 0.78 0.80 Q2 0.89 0.71 0.76 RSD 0.049 4.02 0.35 N 32 32 32 DF 24 27 27
This model shows the UMS grade to be better performing in terms of corrugation with fewer waves. The total area where wave-less sheets can be produced is larger. Also here model inaccuracy needs to be taken into account, as with the normal grade a few spots
without waves could also be produced.
Figure 5: Coefcient plot for cell size and waves showing the relative contributions of each factor including interactions
January 2013 | COMPOUNDING WORLD
47
Do the UMS grades really lower product densities? Do they really give fewer waves and what about the cell structure? The UMS grades have been commercially available for two years and are mainly used for the physical foaming process with blowing agents such as CO2 and isobutane. In order to monitor and evaluate the results in practice, samples were extracted from commercial Figure 6: Contour plot of density at t0 as a function of the two relevant variables and material. Left Sabic LDPE 2102TX00 and right Sabic LDPE 2202UMS foam extruders and analysed. The results for the 2202UMS grade were compared with a regular PE grade or Sabic foam grade 2102TX00. The following properties of the samples were analysed: 1. Foam density 2. Average cell size (stereo microscope) 3. Cell structure (SEM analysis) 4. Compression stress (ISO 7214) 5. Resilience (ISO 3386-1)
Processing with UMS resin

In practice, the 2202UMS grade typically replaces a Figure 7: Corrugation expressed as number of waves formed. Left Sabic LDPE 2102TX00 and right Sabic LDPE 2202UMS regular grade with a comparable MFR and density. The UMS material is currently running on a commercial basis using single, double and tandem extruders. The recipe is mainly based on PE, talc and glycol mono stearate (GMS). For example, after starting up the foam extruder with 2012TX00 and stabilizing the process settings and validating the product properties, the grade is replaced by 2202UMS. If the machine settings are left unchanged, then the production density typically remains the same and the dimensions of the product become smaller. This is because the cell size decreases. The machine settings need to be changed to make Figure 8: Realized cell-sizes in 3 mm foamed sheets. Left Sabic LDPE 2102TX00 and right Sabic LDPE 2202UMS For the response density, a model equation is given expressing the behaviour and its dependency on different parameters. This also gives the opportunity to predict or calculate values for regions not covered by the experiments. log(density) = C0 + C1{Mat} + C2[Nuc] + C3[Iso] + the most of 2202UMS, and there are two main options: increasing the production efciency to reduce cost of production, or improving the product quality to create a premium product.
Increasing product efciency

In practice, it is possible to cool down the cooling zones and the head zones of the foam extruder much more than the regular temperature prole without getting frozen PE particles in the head or die build-up. If this is combined with adding more blowing agent, it is possible to maintain the machine pressure in the extruder more or less steady. Both adjustments (cooling down and adding blowing agent) will give a lower density for the end product. Another parameter that needs to be adjusted is the dosage of nucleating agent. Because of the ner cell structure that is created by 2202UMS for a given recipe, it is necessary to lower the amount of nucleating agent.
C4[Iso]2 + C5{Mat} * [Nuc] + C6{Mat}*[Iso]

Waves and cell-size give similar equations:
property = C0 + C1{Mat} + C2[Nuc] + C3[Iso] + C4[Iso] * [Nuc]
What happens in practice?

After studying the design of experiments and its results, one can ask the questions: Whats in it for me in practice and Is the prediction of the model correct.
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Foaming polyolefins | technical paper
Table 3: Foam density for 0.8 mm packaging sheet

Grade Regular grade 2202UMS End density (kg/m )
3
Table 4: Foam density for 11 mm packaging sheet

Grade Regular grade 2202UMS End density (kg/m3) 22 20
20 18
Table 5: Average cell size

Grade Regular 2202UMS Average cell size (mu) 2370 2250 Min. (mu) 1300 1180 Max. (mu) 3425 3233 Foam density (kg/m3) 22 20
This is done to make the cells comparable with the starting product (Note: this finer cell structure differs
compared to the regular grade. So 22002UMS offers the following opportunities to improve production efficiency in practice: a density reduction of approximately 5-15%; an increase of the line speed of approximately 3-13%; and, a reduction in web breaks, especially for sheet foam products with relatively thin thickness between 0.5 and 3.0 mm
from lab-trials with stearamide, where slightly larger cells were seen). After adjusting the formulation, the settings need to be further optimized to create a stable production. Because of the lower product density, another important side effect was noticed, namely an increase of the line speed. While running for a longer period with 2202UMS, it also became evident that in most cases the number of web breaks on a sheet foam extrusion line was reduced
Improving product quality

The finer cell structure obtained with 2202UMS also gives opportunities in building and construction applications where cell structure influences the thermal
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Foam Density: Tables 3 and 4 show the results of the foam density for packaging sheet materials with a thickness of 0.8 and 11 mm respectively. A comparison is made between production with a regular grade and with 2202UMS. Both products had comparable cell size and cell structure. The recipe contained PE, isobutane and talc. The product was cured to stabilize the growing process and degassed. In this situation it was possible to reduce the density of the regular product by approximately 9-10%. These results are in line with results achieved at different locations. Average cell size: The average cell size was measured with a stereo microscope. A typical picture is shown in Figure 9, while statistical data is published in Table 5. The product produced with the regular grade had a density of 22 kg/m3, while the product produced with the UMS grade had a density of 20 kg/m3. In this Figure 9: Assessing cell size via stereo microscope conductivity of the material. Another potential opportunity for this grade is to help full certain re classications. In Europe, new re classications (Single Burning Item) are currently generating interest in the foam industry. By reducing the material density while maintaining the other properties, it is possible to improve the results in this new European re test. The ability of 2202UMS to reduce the waves or corrugation in physically foamed sheet material has been proven in practice. For certain application and product densities, it is even possible to reduce the number of waves to zero. However, because of the other foaming behaviour of 2202UMS, it is also possible to maintain the number of waves at a ner cell structure. The various product properties obtained using 2202UMS are covered below, including foam density, cell size and structure, compression stress, and resilience. situation, the number of waves in the end product was comparable, while the average cell size was reduced by 5% even with the density reduction of 9.8%. It is likely that an increase of the density of the foam produced with 2202UMS would make the cell size even ner. This is because reducing the blowing agent will lead to an increase of pressure, resulting in ner cells. Cell structure: The cell structure was measured via SEM microscopy. Figure 10 shows a typical cell fragment of regular foam, while Figure 11 shows a typical cell-fragment of foam produced with 2202UMS. Not only is the average cell size smaller for the foam produced with 2202UMS, but also the cell walls are more homogeneous and thinner. Compression stress: The compression stress was measured according to ISO 7217 and the results are compared in Table 6. The foams had a thickness of approximately 11 mm, and the foam density of the product produced with grade 2102TX00 was 21.1 kg/m3
Figure 10: cell fragment of regular foam
Figure 11: cell fragment of foam produced with 2202UMS
52
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Foaming polyolefins | technical paper
compared to 20.3 kg/m3 with 2202UMS. Although it has a lower density, the foam produced with 2202UMS shows higher compression stress. This compression stress is 5-20% higher, depending on the compression. Resilience: The resilience has been measured according to ISO 7217 / ISO 3386-1. The product is compressed at 10, 25 and 70% of its original thickness. This test is repeated four times, and the difference between the original compression stress and the last compression stress is calculated. The lower the difference, the better the resilience of the material. In Table 7, a regular foam with a density of 22 kg/m is compared to
3
Table 6: Compression stress

Grade 2102TX00 2202UMS Stress@10% Stress@20% Stress@50% (N) (N) (N) 80 95 150 170 525 550
Table 7: Resilience
Grade Regular Regular after 4x compression 2202UMS 2202UMS after 4x compression Stress@10% Stress@20% Stress@50% (Index) (Index) (Index) 100 32 100 38 100 63 100 78 100 96 100 97
foam produced with grade 2202UMS with a density of 20 kg/m3. In this situation, the average resilience for the product based on 2202UMS shows improved values after four compressions.
conductivity or fire behaviour of the foam. Improving product properties with lower product densities is a desirable goal for the foam industry. This DOE work is going to be expanded with research into the influential factors of production with UMS grades and GMS. This will give a more complete model and will have a better fit with practice. Further developments of UMS grades are a logical continuation of the achievements so far achieved.
Evaluation, discussion and continuation

Laboratory tests, with small output ranges of around 10kg/h, can be used to evaluate different materials with regard to the foaming process. Models can be established for density, number of waves and cell size. The analysis of the density shows that it depends mainly on the nucleating agent and isobutene concentration. The choice of resin shows a lesser, but still significant influence. Low density values are achievable using 2202UMS. After some years of development and commercial use, it has been show that Sabics LDPE UMS grades provide the PE foam industry with good opportunities to improve processes and products. The theoretical benefits of 2202UMS are demonstrated in the design of experiments. These benefits correlate well with the results shown in practice. The grade can be used to increase production efficiency or improve product qualities. In some situations, it is possible to achieve both. Some of the advantages of the UMS grades that have been demonstrated at different production sites in Europe are listed below. These are compared to the use of regular PE grades: l Lower product density l Increased line speed l Less web-breaks in case of physical foamed sheet l Better processing window l Lower average cell size (even with lower density) l More homogeneous cell structure l Better compression stress l Better resilience Currently, the PE foam industry is mainly using the UMS grades to increase production efficiency. However, the grade can also be used to optimize product properties, for instance through controlling the thermal
Company and author notes

Saudi Arabic Basic Industries Corporation (Sabic) is a global polyolefin producer with more than 40 years of LDPE foam experience. Its Global Foam Technology Centre is located in Geleen, the Netherlands. John Krist (above) is staff scientist for Sabic Technology & Innovation, responsible for the companys Global Foam Technology Centre. Emanuel van der Ven (below) is responsible for technical marketing for foam, masterbatches and geoliners at Sabic. The authors thank DSM Resolve for help in analysis of the models and critical evaluation of the paper, the Sabic Foam Technology Centre and IKV laboratories for the foam trials.
www.sabic.com
References
[1] New developments in high melt strength polyolefins for foaming; Blowing Agents and Foaming Processes 2008; Krist and Sengupta; 20-21 May 2008 [2] How to choose a Polyolefin grade for Physical Foaming, Important parameters for the Physical Foamability of Polyolefins; Blowing Agents and Foaming Processes 2005; Henk Ruinaard
55
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The Instant Expert: Plastics, Processing and Properties
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Polymers and additives | products
masterbatches
Ampacet provides black magic effect

Ampacet has launched Nuanced Blacks, a new range of effect masterbatches it says are based on black accentuated with subtle plays of colour. The new products include Apocalyptic Purple, Passion Crush, Machined Green, Hush Hush Gold, Shadowed Brown and Blued Mood. Linda Carroll, Ampacets Color Insight manager, says: Theres a new colour story on black that embraces changeability and mystery.
www.ampacet.com
minerals
Trinity offers talc alternatives

Trinity Resources of Canada has introduced two new mineral reinforcing fillers based on pyrophyllite (hydrous aluminium silicate). Altiplus and Altibright are being marketed as alternatives to talc and kaolin. The company says that the pyrophyllite fillers are macrocrystalline platelets with a high aspect ratio and the same monoclinic crystal structure as talc. They are produced from a large deposit located in Conception Bay South, Newfoundland, Canada. The minerals properties are said to include high dry and wet brightness thanks to their low levels of iron oxide and other mineral impurities. The excellent optical properties of Altiplus and Altibright makes them ideally biocides suited for natural and colour sensitive systems, says the company. In addition, the additives are said to provide high levels of stiffness, impact and dimensional stability together with chemical resistance, thermal stability and low electrical conductivity. Altiplus grades are supplied in sizes ranging from 2 to 10 micron median, while the Altibright grades with 95-96 Y brightness values come in 1 and 2 micron median sizes. Target applications include compounds based on polyolefins, TPOs, TPEs and nylons. Distributors have been appointed in Canada, the USA and northern Europe with additional agents being sought for other territories. Altiplus is a bright mineral with a high aspect ratio
anti-counterfeiting
Gabriel set to tackle forgers

Gabriel Chemie has launched a new additive masterbatch that is designed to combat the counterfeiting of thermoplastic products. Its Maxithen ProTec4 contains individual codes in the form of security pigments that can be verified using a special detector. It is possible to use different codes for different manufacturing runs. This can be used for quality control purposes or to protect manufacturers against false compensation claims. Gabriel Chemie describes the security pigments as inert, inorganic, and highly temperature resistant substances.
www.trinityresources.ca
www.gabriel-chemie.com
Fast acting, durable antimicrobial masterbatch

Safe-Touch is an antimicrobial masterbatch from US-based PolyFusion that is claimed to provide fast action and long active life-time. It is based on organo-functional silane technology. According to the company,
when evaluated in accordance with the ASTM E2149:10 dynamic contact protocol, it requires a one hour test timeline compared with 24 hours for ion exchange and phenol-based products. CFU reductions of 99.99% are said
to be typical when using the additive at 1-2% loading levels. PolyFusion says the Safe-Touch product is available as a pellet or powder and is compatible with most commodity and engineering polymers. No special handling
precautions or process changes are required. The company adds that it is targeting the additive at thermoplastic applications where control of environmental bio-burden is paramount.
www.polyfusionllc.com
57
This months free brochure downloads

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BKS: pelletizing technologies

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compounder of the month
Innovative Polymer Compounds (IPC)

Location: Date founded: Chairman: Ownership: No. of employees: Current capacity: Prole: Kilbeggan, County Westmeath, Ireland September 2008 Alan Looney Privately owned Seven 350 tonnes Innovative Polymer Compounds is dedicated solely to materials for use in the medical device sector, working with designers, extruders and moulders from concept through to production. It carries out compounding in a purpose-built Class 100k clean room facility located at the heart of the world-class medical device cluster in Ireland. The company is certied to the ISO 13485 medical device quality standard as well as ISO 9001. The Kilbeggan plant features a Leistritz twin-screw extruder equipped with K-Tron loss-in-weight feeders, plus a choice of Automatik strand-cut or Gala underwater pelletizers. Innovative Polymer Compounds processes a wide range of polymers for medical applications including PEBA, PA, TPU, PEKK, PEEK, PP, PE, PC and PC/ABS. It carries out its own in-house colour matching using US-FDA approved pigments to Munsell, Pantone, and RAL colour standards. Innovative Polymer Compounds specialises in meeting rapid lead times and has the ability to produce small lots in support of medical R&D activities. The company also focuses on delivering the highest levels of material consistency and quality backed up with excellent customer support. www.i-p-c.ie
Product line:
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Forthcoming features
The next issues of Compounding World magazine will have special reports on the following subjects: February Thermally-conductive compounds Materials handling Additives for polyolens March Additives for PET Twin-screw extruders Natural bres and llers
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dates for your diary
Global exhibition guide

29 Jan - 1 Feb 22-25 February 6-7 March 6-8 March 12-15 March 12-15 March 3-5 April 3-6 April 10-11 April 10-12 April 7-10 May 14-16 May 20-23 May 20-24 May 6-8 June 16-23 October Interplastica, Moscow, Russia GAIL Plastasia, Bangalore, India Plastec South, Orlando, FL, USA Plast Bulgaria, Sofia, Bulgaria Plastimagen, Mexico City, Mexico Pro-Plas Expo, Johannesburg, South Africa Plastex Uzbekistan, Tashkent, Uzbekistan Tiprex, Bangkok, Thailand PlastTeknik, Malmo, Sweden Plastic Japan, Tokyo, Japan PlastPol, Kielce, Poland Plast-Ex, Toronto, Canada Chinaplas, Guangzhou, China Feiplastic, Sao Paolo, Brazil Plastics Printing Packaging Tanzania K 2013, Dsseldorf, Germany www.interplastica.de www.plastasia2013.com www.plastecsouth.com www.plast.bg www.plastimagen.com.mx www.proplasafrica.co.za www.plastex.ite-uzbekistan.uz www.tiprex.com www.easyfairs.com www.plas.jp/en www.plastpol.com www.plast-ex.org www.chinaplasonline.com www.feiplastic.com.br www.pppexpo.expogr.com www.k-online.de
AMI conferences
29-31 January 18-20 February 25-27 February 5-7 March 12-14 March 18-20 March 19-21 March 7-8 May 14-15 May 14-16 May 3-5 June 4-6 June 13-14 June Thermoplastic Concentrates, Coral Springs, FL, USA The Grass Yarn & Tufters Forum, Cologne, Germany Wood-Plastic Composites, Vienna, Austria Cables, Cologne, Germany PVC Formulation, Dsseldorf, Germany Masterbatch Asia, Singapore Green Polymer Chemistry, Cologne, Germany Bioplastics Compounding & Processing, Miami, FL, USA Polymers in Cables, Miami, FL, USA Polymer Sourcing, Vienna, Austria Masterbatch, Frankfurt, Germany End of Life Plastics, Cologne, Germany Fire Retardants in Plastics, Denver, CO, USA
For information on all these events and other conferences on film, sheet, pipe and packaging applications, see
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January 2013

ANDROID VERSIONS NOW AVAILABLE

13 Coupling agents make new connections

blends that are fullling emerging applications. Pat Toensmeier reports.

23 Pelletizing systems: cutting edge technology

37 Blowing up: advances in additives for foaming

45 Optimising foamed polyolen formulations

57 New products: additives

60 Compounder of the month: IPC 62 Dates for your diary

coming next issue

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Americhem acquires Infinity Compounding

PolyOne moves into composites

Wells Plastics plans expansion

E1.8 million follow-on

January 2013 | compounding world

Invista buys Dutch compounder

NFM picks Jan van Bakergem

Epsan increases compounding capacity with Coperion line

compounding world | January 2013

ECHA considers cadmium ban

Graphene growth could fall short

Clariant sells off divisions

compounding world | January 2013

UMass Lowell inaugurates new Technovel lab for compounding

Arsenal Capital invests in Dash Multi-Corp

compounding world | January 2013

PVC Formulation 2013

12-14 March 2013

Coupling agents | additives feature

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additives feature | Coupling agents

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additives feature | Coupling agents

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Pelletizing & Pulverizing Technology

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machinery feature | Pelletizers

compounding world | January 2013

compounding world | January 2013

compounding world | January 2013

compounding world | January 2013

compounding world | January 2013