CW November 2012

November 2012
SELECTING THE RIGHT CARBON BLACK

STIR IT UP WITH THE LATEST MIXERS
PUTTING COMPOUNDS TO THE TEST
KEEP IT CLEAN FOR MEDICAL MARKETS
Having led the way with high-quality digital-only magazines for the global
plastics industry, AMI is now also making its titles available free-of-
charge on the iPad, iPhone and a wide range of Android-based
smartphones and tablet computers.
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Current and past copies are available free-of-charge and new issues
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The Compounding World app is sponsored by Leistritz, a leading
supplier of twin-screw extruders.
IntroducIng
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App sponsored by
CHECK OUT OUR OTHER FREE APPS: AMI has also launched free
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AndroId VErSIonS noW AVAILABLE
Copyright Applied Market Information. No part may be reproduced without the prior written permission of the publisher.
www.compoundingworld.com November 2012 | COMPOUNDING WORLD 3
04 Industry news
The latest compounding industry news including international acquisitions and
alliances, plus new investments and plant openings.
15 Keep it clean
Clean compounding lines are being commissioned to meet the stringent demands
of medical and other markets. Jennifer Markarian reports.
25 Stir it up with the latest mixers
Mikell Knights reviews recent developments in batch and continuous mixers for
use in the production of compounds and masterbatches.
41 Building new benets for carbon black
Carbon black suppliers are tuning morphologies to improve processability and
performance. Pat Toensmeier reports.
49 Comparing conductive carbon blacks in HDPE
Dr Daniele Bonacchi and Ing Christine Van Bellingen of Timcal compare the
performance of conductive and extra-conductive carbon blacks.
59 New materials testing and analysis equipment
We review the latest materials testing equipment designed to check that your
new formulations meet performance and quality requirements.
64 Compounder of the month: Phon Tech
66 Dates for your diary
coming next issue
S Lab compounders S Compounding high-performance plastics S Flame retardants
Click here to make sure you get your copy
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compounding world | november 2012 www.compoundingworld.com 4
news
PolyOne has entered a
defnitive agreement to acquire
Spartech, a leading producer
of plastic products, including
compounds, concentrates,
custom extruded sheet, and
packaging solutions. The deal,
which is expected to be
completed in the frst quarter
of 2013, represents a total
transaction value of approxi-
mately US$393 million,
including the assumption of
Spartechs net debt of US$142
million.
Stephen Newlin, PolyOnes
chairman, president and chief
executive offcer, said:
Spartech expands PolyOnes
specialty portfolio with
adjacent technologies in
attractive end markets where
we already participate, as well
as new ones like aerospace
and security. By combining
Spartechs leading market
positions in sheet, rigid barrier
packaging and specialty cast
acrylics with PolyOnes
capabilities, we can accelerate
growth for both companies.
Victoria Holt, Spartechs
president and chief executive
PolyOne to buy Spartech
Spartechs sales, and Newlin
describes the opportunity to
expand the business globally
as huge.
The transaction, which was
unanimously approved by the
boards of directors of both
companies, remains subject to
approval by Spartechs
shareholders and receipt of
required regulatory approvals
as well as other customary
closing conditions.
To download PolyOnes 22
page presentation on the
Spartech acquisition, including
detailed business analyses
and strategic plans, go to
http://bit.ly/PolyOneSpartech.
www.polyone.com
www.spartech.com
offcer, added: PolyOne and
Spartech have complementary
growth strategies, and by
combining our resources we
expect to accelerate our shift
to specialty applications with a
more competitive cost
structure, enhanced customer
relationships, improved
market access and increas-
ingly innovative technologies.
Spartech operates 30
facilities in the United States,
Mexico, Canada and France.
The company achieved sales
and adjusted EBITDA of
approximately US$1.2 billion
and US$53.1 million, respec-
tively in the 12 months to 4
August 2012. North America
currently accounts for 94% of
Songwon of Korea, Pan Gulf
Holdings of Saudi Arabia
and Polysys of Abu Dhabi
have formally established
their new joint venture,
Songwon Additives
Technology, for the
manufacture of Songnox
One Pack Systems (OPS).
The three companies
frst announced their
intention to form the JV late
last year (Compounding
World, December 2011). It
includes Songwon ATG, the
former Greiz business in
Germany, which operates
one of Europes largest OPS
plants. Songwon Additives
Technology says that it is at
an advanced stage in
establishing further
manufacturing companies
in the Middle East and in
the US.
The JV is forming a new
subsidiary to manage Middle
East sales; Songwon will
handle the rest of world.
www.songwonind.com
Songwon
launches
OPS JV
TPEI has installed a new fve-axis CNC machining centre at its
factory in Lehighton, Pennsylvania, USA. It is being used specif-
cally for the production of rotors for continuous mixers.
The new machining centre has been installed to meet growing
demand and is able to produce rotor diameters from 1 to 12
inches (2.5 to 30.5 cm). The addition of this new large-capacity
equipment gives us the ability to increase productivity and
accuracy as well as develop and manufacture new rotor geom-
etries, said Harold Schafer, CEO at TPEI.
For more information on recent developments in TPEIs
product range, see the special feature on batch and continuous
mixers which starts on page 25 of this issue.
www.tpei.com
PolyOnes Stephen Newlin and Spartechs Victoria Holt plan to
grow specialty applications
TPEI invests in CNC centre for mixer production
www.compoundingworld.com November 2012 | compouNdiNg world 5
news
Chemtura is to acquire the
bromine assets of Solaris
ChemTech Industries,
Indias leading manufac-
turer of bromine and
bromine derivatives.
The acquisition, which is
expected to be completed
by the end of 2012, includes
two manufacturing facilities
and an R&D centre in the
State of Gujarat. The new
subsidiary will be head-
quartered in New Delhi and
will become part of
Chemturas Great Lakes
Solutions fame retardants
business.
The acquisition of
Solaris ChemTechs
bromine assets will further
strengthen our bromine
position and provide our
customers with increased
security of supply through
further diversifcation of our
bromine supply sources,
said Craig Rogerson,
Chemturas chairman,
president and CEO.
www.chemtura.com
Chemtura
acquires
in India
Hillenbrand is to acquire
Coperion from the German
private equity company
Deutsche Beteiligungs for an
estimated E408 million. The
transaction is expected to
close by the end of December
2012, depending on regulatory
approvals.
Hillenbrand is publicly
listed on the New York Stock
Exchange and is a leading
supplier of funeral products,
such as burial caskets, which
it sells under the Batesville
brand in North America. It has
recently been diversifying into
the industrial sector with the
acquisition of materials
handling systems supplier
K-Tron in 2010 along with the
purchase of TerraSource
Global, a manufacturer of size
reduction, conveying and
screening machinery. Last
year it added the separation
equipment specialist Rotex.
Coperion, which includes
the former Werner & Pfeider-
er and Waeschle businesses, is
a global leader in compound-
ing, extrusion and bulk
material handling equipment.
In the 12 months to the end of
September 2012, the business
had a revenue of E520 million
and EBITDA of E38.7 million.
Gnter Bachmann,
Coperions current CEO, will
continue as president of
Coperion reporting to Joe
Raver, president of Hillen-
brands Process Equipment
Group. Coperions headquar-
ters will remain in Stuttgart,
Germany.
The acquisition of
Private equity frm to sell
Coperion to Hillenbrand
Coperion represents a very
signifcant move forward for
our company, said Hillen-
brand CEO Kenneth Camp.
Post closing, the Process
Equipment Group will generate
revenue of more than US$1
billion and will represent about
two thirds of Hillenbrands
total revenue.
Coperions Bachmann
added: We are very familiar
with Hillenbrands Process
Equipment Group operating
companies, particularly
K-Tron. We are excited about
the growth opportunities that
now will be available to our
combined company.
The estimated purchase
price of E408 million includes
the assumption of an estimat-
ed E76 million of net debt and
E100 million pension liabil-
ity. Deutsche Beteiligungs and
Coperions management
acquired Coperion for E300
million in 2007 from Lyceum, a
UK private equity frm.
www.coperion.com
www.hillenbrandinc.com
AMI has announced the
programme for its 16th
Thermoplastics Concentrates
conference, which takes place
in Coral Springs, Florida, USA,
on 29-31 January 2013. The
line-up of speakers includes
experts from key players from
throughout the masterbatch
supply chain.
In addition to major
suppliers of pigments,
Coperions Gnter Bachmann:
excited by the growth
opportunities for the com-
bined company
Concentrates event attracts leading players
additives and processing
machinery, the programme
includes speakers from
leading concentrates produc-
ers such as Clariant, Plastics
Color Corporation and Accel
Color. End users are also
represented with speakers
from Graham Packaging and
MWB Toy Company.
In addition to covering the
latest technology develop-
ments, the conference has a
strong business focus. AMIs
research director, Andrew
Reynolds will cover overall
trends and the outlook for the
NAFTA thermoplastics market
as well as analysing the
regions concentrates market
in detail.
The annual event attracts
an infuential audience of
senior executives from
throughout the global supply
chain. In 2012, more than
US$2.5 billion in concentrates
sales was represented at the
conference.
For more information on
the full conference programme
plus booking details, visit
http://bit.ly/TC2013. Book
your place by 14 December
and save US$200.
www.amiconferences.com
news
Epic expands LFT capacity
tion with leading machine
builders and polymer suppli-
ers, set new standards for the
quality and possibilities of
LFTs. The classic LFT prob-
lems of bad feeding and
insuffcient impregnation are
now a thing of the past.
The LFT compounds
produced on the new line will
be marketed under the Strator,
Tribocomp and Star-Therm
tradenames, depending on the
formulation of the product.
www.epicpolymers.com
Epic Polymers is increasing
production capacity for
long-fbre thermoplastics
(LFTs) at its plant in Kaisers-
lautern, Germany. A new 4,000
tonnes/year production line is
being commissioned at the site
in the fourth quarter of 2012.
The company says that the
new capacity will allow it to
meet the growing demand for
LFTs that it is seeing across all
industry segments. The new
line will use its innovative
impregnation technology to
reinforce high-performance
plastics including polyamide
and PPA with long glass,
carbon and aramid fbres. It
will also produce tribologically
modifed grades as well as
electrically and thermally
conductive compounds.
Epics director of marketing
and technology, Fred Panhui-
zen said: The set up of the
new production line is unique
in this market. Through the
newly developed Epic Technol-
ogy, we have, in close coopera-
Washington Penn Plastic
(WPP) has offcially opened
its frst polyolefns com-
pounding plant in Europe.
Audia Plastics is located in
Voderady, Slovakia, and is
producing mineral- and
glass-flled polypropylene
grades as well as TPO
compounds.
In March 2011, Com-
pounding World reported
that WPP was investing
roughly E8 million in the
Slovakian facility with a
planned capacity of 66,000
tonnes/year of PP com-
pounds and 2,270 tonnes/
year of masterbatch.
The expansion into
Europe is intended to build
on the companys success
in North America, matching
manufacturing footprints
with its global customers.
The fve main target
markets are automotive,
appliances, building/
construction, consumer
products and packaging.
In addition to compound
manufacturing, the facility
houses both a development
line and a full-scale
laboratory to test and certify
materials. It is WPPs
second new plant opening in
the past four years.
The privately-owned
company also operates four
plants in the US and one in
Monterey, Mexico.
It says that the total
annual capacity for its
plants is more than 750
million lbs (340,000 tonnes).
www.washingtonpennplastic.com
Washington
Penn opens
in Slovakia
Group promotes PVC in healthcare
A new industry organisation
has been formed to promote
the benefts of PVC in health-
care applications. Based in
Brussels, Belgium, the
PVCMed Alliance is backed by
PVC resin and plasticizer
manufacturers as well as PVC
converters.
The Alliance aims to provide
a focal point for communica-
tion with healthcare profes-
sionals and regulators about
PVC-based healthcare
applications. In particular, it
wants to highlight the role that
PVC can play in the quality,
safety and cost-effciency of
healthcare, while also being
Epics new line will produce
high-performance LFTs including
Strator grades based on PPA
environmentally responsible.
PVC is widely used in
medical devices for screening,
diagnosis, treatment and care,
as well as in the building of
safe healthcare environments.
Nearly 30% of all plastic-based
medical devices are made of
PVC the two main application
areas for medically approved
PVC compounds are fexible
containers and tubing.
Current members of the
PVCMed Alliance include
BASF, Colorite Europe,
Eastman, the European
Council of Vinyl Manufactur-
ers, Oxea, Renolit, and Tarkett.
www.pvcmed.org
The PVCMed Alliance will
highlight the benefts of PVC
in medical devices
news
Baerlocher commissions
Chinese stabilizers plant
of solid PVC stabilizers in the
region. It also manufactures
liquid mixed metal stabilizers
in Jiangsu Province, China
through its production joint
venture Jiangsu U&B, which it
formed with Uniwel in 2010.
www.baerlocher.com
Baerlocher Plastic Additives
offcially opened its new PVC
stabilizers plant in Changzhou,
Jiangsu Province, China, on
19 October.
The facility, which is wholly
owned by Baerlocher, has a
capacity of 40,000 tonnes/year
and will produce Ca-based and
Pb-based stabilizer systems.
The plant is supported by a
state-of-the-art application
laboratory.
Arne Schulle, CEO of the
German-headquartered
Baerlocher Group, said: This
operation, which already
employs more than 50 people,
will help us to further meet the
needs of a dynamic market
utilising local talents. This will
be actively supported by our
global team and will enhance
our position as the global
leader in Ca-based stabilizer
systems.
Baerlocher established a
local sales company in China
in 2007 and claims to have
become the leading importer
DSM has begun construc-
tion of its new materials
sciences research building
on the Chemelot Campus in
Sittard-Geleen, the
Netherlands. Scheduled to
open in 2014, the facility is
part of DSMs E100 million
investment in three new
research facilities in the
country.
It will be the most
important R&D centre for
DSM Engineering Plastics
worldwide and it will also
support other DSM
materials divisions, such as
Dyneema, as well as
research activities in
bio-based and biomedical
materials.
www.dsm.com
DSM starts
work on
R&D site
RTP installs new mixer at German plant
RTP has completed the frst
phase of the previously
announced expansion at its
compoundng plant in Laden-
burg, Germany.
Maag Automatik expands presence in China
Maag Automatik has opened a new 11,000 m
2
facility near
Shanghai, China, along with its parent company Dover. It
more than doubles the size of its previous regional
headquarters in the country and includes a product
showroom and training facility.
The German supplier of pelletizing systems will use the
new building to provide its Asia-Pacifc customers with
technical expertise, after-sales service, plus faster delivery
of machines and spare parts.
www.maag.com
The new Maag and Dover building in
China will help to speed up deliveries
Baerlochers new plant
in Changzhou produces
Ca-based and
Pb-based stabilizers
The frst of two internal
batch mixers has been
installed at the facility. It will
produce a line of conductive
compounds that RTP acquired
from Clariant in March 2012.
The second line will be
installed in the frst half of
next year.
In addition, RTP is doubling
its capacity to produce
very-long-fbre composites at
Ladenburg with the installation
of extra pultrusion lines.
www.rtpcompany.com
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news
BYK starts
American
expansion
BYK Additives & Instru-
ments has begun construc-
tion of a new three-storey
production building on
newly acquired grounds at
its site in Wallingford,
Connecticut, USA. It is
investing E36 million in the
facility which is due to be
completed in 2014.
This investment in
Wallingford underlines once
again our aspiration to grow
on the North American
market and to produce as
many products as possible
locally, said Dr Roland
Peter, president of BYK
Additives & Instruments.
BYK produces a range of
additives including wetting
and dispersing agents for
masterbatches, plus
modifers for plastics.
www.byk.com
IPC meets ISO medical standard
Innovative Polymer Com-
pounds (IPC) of Kilbeggan in
County Westmeath, Ireland,
has achieved the ISO 13485
quality standard for medical
manufacturing.
IPC focuses on producing
compounds for medical device
manufacturers at its plant
which was established in 2008.
It says that achieving ISO
13485 will help it to grow its
European customer base.
Compounding is carried out
using a Leistritz ZSE 27 Maxx
twin-screw extruder in a Class
100,000 clean room (pictured).
pounded at the plant include
polyamides, TPEs, TPUs and
fuoropolymers.
The ISO 13485 standard is
primarily aimed at medical
device manufacturers, but a
growing number of compound-
ers and masterbatch makers
that supply such companies
are implementing the standard
themselves. Other examples
include Clariant, PolyOne,
Teknor Apex and Elasto. For
more information, see the
article on clean compounding
which starts on page 15.
www.ipcpolymers.ie
TPEs compounder Star
Thermoplastic Alloys &
Rubbers has opened its a new
process development labora-
tory at its headquarters in
Broadview, Illinois, USA. The
new purpose-built 8,000 ft
2

(740 m
2
) facility is equipped
with four extruders with
outputs ranging from 60 to 500
lbs/hr (27 to 230 kg/hr).
It is the ffth laboratory at
Star adds new extrusion lab
the site the others are used
for wet chemistry, polymer
research and characterisation,
physical testing and sample
production.
Stars R&D manager, Dr
Prakash Sanjeevaiah said: The
addition of this new lab gives
us and those customers we
serve a greater capability for
providing more samples and in
larger quantities. We are now
offering as many as 200
extrusion grade samples, argu-
ably the most in the industry.
Star reports that it has
achieved a 50% year-on-year
increase in sales. In addition to
the new lab, it has expanded
its sales and service offce
space and increased its
number of employees in
production, sales and service.
www.starthermoplastics.com
The line is fed by K-Tron
gravimetric dosing units, while
pelletizing is carried out at the
plant using a Gala underwater
system or an Automatik strand
pelletizer. Materials com-
ICL Industrial Products is
ending the sale of Tris(1,3-
dichloro-2-propyl)phosphate
(TDCP or Tris) fame
retardants for home furnishing
applications, including chairs,
sofas and nursery products,
with effect from 1 January
2013. At the same time, it is
expanding production of its
Fyrol HF-5 polymeric fame
retardant for fexible polyure-
thane foam applications at its
ICL advances with TDCP replacement
Gallipolis Ferry plant in West
Virginia, USA.
By expanding the produc-
tion of Fyrol HF-5, ICL-IP is
positioned to serve the
changing needs of the uphol-
stered furniture industry, said
Greg Symes, ICL-IPs global
business manager for polyure-
thane products.
The company is also
developing a new fame
retardant to replace TDCP in
automotive and other trans-
portation industry applications.
It plans to have this available
in 2013, which will allow
customers in transport-related
segments adequate time to
qualify the replacement
through the Production Part
Approval Process system.
ICL-IP says that it will cease
all production of TDCP by the
end of 2015.
www.icl-group.com
www.compoundingworld.com
news
Toray is to establish a new PA
and PBT compounding plant at
its Indonesia Toray Synthetics
(ITS) subsidiary, located at
Tangerang, Banten Province,
Indonesia. It is investing
approximately 600 million
(E6 million) in the 6,000
tonnes/year facility which is
expected to start production in
November 2013.
ITS already polymerizes
nylon and polyester at the
Tangerang site, as well as
producing flament yarns using
these materials. Toray claims
that its new resin compound-
ing plant will be the frst to be
established by an engineering
plastics manufacturer in
Indonesia.
The Japanese-headquar-
tered company says that
Indonesias annual demand for
engineering plastics is
expected to grow at around 9%
per annum from 21,000 tonnes
in 2011 to 45,000 tonnes in
2020. This growth is being
driven by the expansion of
Indonesia economy and in
particular increased produc-
tion of vehicles and electrical
and electronic products in the
country.
Indonesias automobile
production is estimated to
grow from 840,000 units in
2011 to more than 2 million
units in 2020, making it a
major automobile production
base in the region alongside
Thailand. In addition, the grow-
ing wealth of the countrys
huge population of 240 million
people is encouraging
increased local manufacture of
electrical and electronic
products.
www.toray.com
Toray invests in
Indonesian plant
RePin Masterbatches of India
has formed a joint venture with
Al Ahli Holding Group (AAHG)
to manufacture masterbatches
in the United Arab Emirates
(UAE) for the Middle East and
African markets. Called
AlwanRePin, the JV is 51%
owned by AAHG and 49%
owned by RePin.
AAHG is a large group with
interests in a broad range of
markets including real estate,
construction, engineering and
retail malls. Its existing
plastics activities are focused
on fexible packaging and bags
which are produced by its Al
Ahli Plastic Industries
subsidiary. Its plant at
Fujairah, UAE, includes a
fve-layer blown flm line for
making barrier flms.
RePin is part of RP
Industries and produces a
range of black, white, colour
and additive masterbatches at
its two plants in northern
India. It has also recently
opened an offce in Colombia
to grow sales in Latin America.
www.alwanrepin.com
Indian and UAE groups
form masterbatch JV
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combines high-end perfor-
mance and a low environmen-
tal footprint, thats a winning
proposition for players and
planet.
Merquinsa, a Spanish
subsidiary of Lubrizol, supplies
Pearlthane ECO grades of TPU
with a bio-based content of 32
to 46% and with 82 to 95 Shore
A hardness. The materials has
been developed for the sports
and recreation market and is
claimed to deliver excellent
abrasion resistance and cold
exibility combined with
improved hydrolysis resistance
and good adhesion to other
non-TPU shoe components.
S www.merquinsa.com
Nike saves
weight with
bio-based TPU
Nike has selected a bio-based
thermoplastic polyurethane
from Merquinsa for the sole
plate of its new light-weight GS
football boot. The Pearlthane
ECO TPU grade has a lower
density then its petroleum-
based counterparts, helping to
deliver a 15% overall weight
saving compared to traditional
sole plate designs.
The Nike GS is the lightest
and fastest football boot weve
ever made and really denes a
new era in how we create,
design and produce elite
football boots, said Andy
Caine, global design director
for Nike Football. When you
can deliver a boot that
Nike is using bio-based TPU
from Merquinsa in its new
GS football boot
Evonik has commissioned a
new compounding line at its
plant in Caojing, Shanghai,
China. This second line triples
the German companys existing
production capacity for
polyamide compounds in China.
The turn-key compounding
line was supplied from
Germany and will support the
rapid growth in demand that
Evonik is experiencing in Asia
and particularly China from
markets such as automotive,
sports and electronics.
S www.evonik.com
Evonik commissions
compounding line
Clean compounding lines and plants
are being commissioned to meet the
increasingly stringent demands
of the medical, pharmaceutical,
electronics and food sectors.
Jennifer Markarian reports
Clean compounding | processing feature
Compounding plants are generally busy and efcient
facilities, but they are not well known for being
particularly clean. However, an emerging trend in the
compounding industry is changing this stereotype, and
a growing number of companies are now operating
clean compounding facilities.
Although the processes used in clean compounding
have been used for at least 15 years in applications like
optical-quality compounds and medical compounds, the
last ve years have seen an increase in demand for
clean compounding and the emergence of new and
more exacting customer stipulations in a broader range
of applications.
One driver for the clean-compounding trend is the
growing industry focus on medical compounding, which
has stringent requirements for eliminating contamina-
tion. Another driver is the need for compounding
high-purity materials that will be used in a cleanroom
or used to produce cleanroom devices or equipment.
The electronics market, for example, has cleanliness
requirements that include specications for outgassing,
non-volatiles, and ionics content, comments Lai Chang
Fong, technical director for Engineered Materials Asia
at PolyOne.
In addition, the trend to smaller, thinner parts makes
aws more apparent and creates a need for reduced
contamination. Electronics and medical devices are
good examples of this requirement, but it is also seen in
automotive and lighting as innovation produces smaller,
thinner part designs, notes Susan Brate, general
manager for manufacturing and supply chain at Sabic
Innovative Plastics.
Yet another aspect is the increase in restrictions on
the types of additives going into certain products and the
accompanying requirement to avoid cross-contamination
with the restricted additives, for example heavy-metal
containing colours or phthalate-based plasticizers.
Customer and OEM demands for more stringent
and formalized manufacturing methods, process
control, and dedicated facilities have denitely in-
creased over time, notes Will Taber, business manager
for emerging technologies at RTP Company.
Medical, food, and electronics applications are key
markets, but others can benet as well. If you carry the
Keep it clean
processing feature | Clean compounding
PolyOne sees
growing
demand for
high-purity
materials used
in cleanrooms
in the electron-
ics sector
RTPs Ultra
Clean Com-
pounding
Center is
designed to
minimize
environmental
pollutants
clean-compounding model into other applications, youll
be way ahead on compliance, points out Doug Borgs-
dorf, president of Plastics Color Corporation (PCC).
From dedicated lines to complete plants
Some compounders have chosen to dedicate specifc
lines or sections of their plant to clean compounding,
which helps efforts to more tightly control incoming raw
materials and reduce contamination. PCC, for example,
runs a 7,000 ft
2
(650 m
2
) plant within a plant at its North
Carolina facility, in which the dedicated clean compound-
ing lines produce only FDA-approved materials.
Teknor Apexs Vinyl Division also runs dedicated,
high-purity facilities for the production of medical
compounds in. In 2008, the company further separated
production of medical-grade PVC compounds contain-
ing phthalate plasticizers from that of medical com-
pounds plasticized with non-phthalate alternatives at
two of its plants in the United States.
RTP established an Ultra Clean Compounding Center
(UCC) in 2009 at its headquarters site in Winona,
Minnesota, USA. It is a 3,300 ft
2
(300 m
2
), self-contained,
controlled manufacturing environment that is designed
to minimize and control the presence of environmental
pollutants such as dust, aerosol particles, and chemical
vapours.
Particles can come in the form of airborne dust from
outside a plant or from materials used within the plant.
It is important to control not only the contaminants in
the air, but also those on material processing and
handling equipment, says Taber.
To control contaminants, the UCC has dedicated
extruders and auxiliary equipment, positive pressure
ventilation, high-speed interlocking doors to control
access, and deionised, fltered cooling water. The UCC
also physically separates the feeding and compounding
lines, which is critical in reducing the potential for
cross-contamination due to airborne particles that can
be generated in weighing, mixing, metering, and
feeding. Compounding, cooling, pelletizing, classifying,
and packaging all take place within the contained
environment.
Operators, who have been specifcally trained to
work in the UCC, follow good manufacturing practices
for operating and maintaining the equipment, such as a
complete extruder tear-down and clean-out between
every run. The UCC is used to produce compounds to
meet strict cleanliness specifcations that cannot be
met in standard facilities.
For example, compounds produced in the facility can
meet requirements such as those for outgassing,
particle generation, and ionic purity (i.e., no anions or
cations that can contaminate a cleanroom) that are
demanded by applications such as some electronics
packaging. RTP also produces compounds in the UCC
for applications in food handling, medical products, and
some industrial applications where customers are
concerned with visible contaminants affecting the
perceived quality of their goods.
Clean compounding can also encompass an entire
plant. In 2010, PCC built a clean compounding facility in
California that is dedicated to medical compounds and
runs under the FDAs current good manufacturing
processes (cGMP) quality system guidelines. For
example, in this facility, air and water are fltered, and
water baths are drained and UV-sterilized between
runs. All PCCs facilities have ISO-9001 certifcation.
Teknor Apex has a clean-compounding plant at St.
Albans in Vermont that runs its Medalist range of
thermoplastic elastomers (TPEs) used in medical
devices. The plant is certifed under the ISO-13485
standard for quality management in medical manufac-
TWIN SCREW EXTRUSION - TECHNOLOGY
AND PRINCIPLES
POLYMERS FOR ELECTRICITY AND ELECTRONICS:
MATERIALS, PROPERTIES AND APPLICATIONS
STARCH-BASED POLYMERIC MATERIALS
AND NANOCOMPOSITES
ANTIMICROBIAL POLYMERS
COMPATIBILITY OF PHARMACEUTICAL
SOLUTIONS AND CONTACT MATERIALS
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PVC FORMULATION 2012 - CONFERENCE
PROCEEDINGS
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Clean compounding | processing feature
Leistritz says
compounders
can learn about
best practises
from pharma-
ceutical
manufacturers
turing, while companys Oldbury plant in the UK is in the
process of being certifed to the same standard. The
companys TPE plant in Singapore runs with the same
processes and quality management as the other two
plants and has ISO-9000 certifcation.
ISO-13485 is a requirement for medical-device
manufacturers, not compounders, but Teknor sought
the certifcation to provide its medical-device customers
with an extra dimension of quality assurance. The
comprehensive implementation program required for
ISO-13485 certifcation has focused our entire St.
Albans operation on processes and procedures that
maximize the safety and reliability of the compounds we
supply to medical device manufacturers, said Paul
Burke, now vice-president of manufacturing at Teknor
Apex, in a press statement last year.
In a recent interview with Compounding World,
Burke noted that, from the perspective of the com-
pounders customers, one of the most important
aspects of ISO-13485 is the management of change,
which gives assurance that a change in the process or
materials will not affect the end product. Testing of
incoming materials, as well as the more standard
testing of the fnished compound, is important in
maintaining tight process control. In addition, quality-
control checks during the production run of properties
like viscosity and durometer allow increased control
over the process and product quality, adds Burke.
Clariant has also implemented ISO 13485 standards
at selected plants in Asia, Europe and America. These
include its facilities in Malm, Sweden, as well as in
Lewiston, Maine, USA, and in Singapore. These three
locations have dedicated lines for medical materials
and can produce harmonised products in all three
regions, according to Steve Duckworth, Clariants head
of Global Segment Medical & Pharmaceutical.
The three plants produce Clariants Mevopur lines of
colour masterbatches and performance compounds for
the medical and pharmaceutical markets. All Mevopur
grades are manufactured using raw materials that
comply with USP parts 87 and 88 (Class VI devices) and/
or ISO 10993 and are produced on segregated com-
pounding lines to reduce the risk of cross contamination
The IS0 13485 standard includes evaluation of risk
potential within the manufacturing process and
maag is the innovative solution provider for pump,
pelletizing and filtration systems. We deliver high-
quality components and complete systems, from
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establishing controls to address this. For Clariant, this
covers the formulation of a masterbatch, incoming raw
materials, production processes and the fnished
product. Duckworth says that implementing ISO 13485
has taught the company lessons that are also useful in
other markets such as packaging and toys. It is much
more rigorous that ISO 9001, he adds.
Equipment design
In addition to dedicating and segregating extrusion lines,
equipment designed to minimize contamination risks
and allow easy cleaning and maintenance is critical in
clean compounding. When we moved to clean com-
pounding, not one piece of equipment didnt get modifed
in some way, notes Borgsdorf. While some technology
is available today, further advances in equipment and
process designs are needed, say compounders.
One aspect to consider is the design of the extruder
and the materials of construction used. It is important
to avoid materials that degrade over time and might add
contaminants, notes Sabics Brate. In addition, melt
fltration is a common method of reducing contaminants
in the material.
A key to clean compounding is that there is nothing
left behind when you change from one product to
another, which can involve designing equipment to
avoid hang-up points. Newer designs of both dosing
equipment and extruders that allow easier cleaning for
faster changeovers in general compounding applica-
tions also help to achieve the thorough cleaning needed
for clean compounding.
Cleaning and maintenance procedures also need to
be modifed to take into account all possible contamina-
tion risks. Cleaning a pelletizer, for example, usually
involves blowing out the pellets with air. This procedure
doesnt work in clean compounding, because it
introduces the risk of blowing a pellet somewhere it
shouldnt be, notes Borgsdorf.
When following cGMP guidelines in compounding,
equipment must be cleaned at appropriate intervals and
detailed, written procedures must be followed, noted
Charlie Martin, president of the US operations of
Leistritz, in a presentation explaining the use of
twin-screw extruders in the pharmaceutical industry at
the recent SPE Color and Additives Division conference
(CAD RETEC). cGMP guidelines also require inspections
Cleanroom compounding
Some clean compounding operations that
cater for the most demanding applica-
tions are carried out in cleanrooms.
Examples include the production of
compounds for medical applications,
including polymers containing an active
pharmaceutical ingredient for human
use, implants for the human body, and
some drug-eluting devices (For more
details, see the medical compounding
article in Compounding World, June 2012
http://bit.ly/MedCompounds).
Cleanrooms can be classifed by the
ISO system, which ranges from the most
stringent, ISO 1, to the least stringent, ISO
9, or by a similar FDA cGMP classifcation.
Biomedical compounds typically must be
compounded in at least an ISO 8 clean-
room, which is equivalent to a class
100,000 cGMP cleanroom.
Foster, for example, produces
compounds for implantable and highly-
regulated polymers in its class 10,000
cleanroom facility in Connecticut, USA.
The room features quartz epoxy seamless
foors, a dedicated fume and dust
collection system, interlock pass through,
gowning room, and temperature and
humidity controls.
Compounding of polymer blends with
active pharmaceutical ingredients must
be performed under cGMP standards and
must follow 21CFR Parts 210 and 211,
explains Tony Listro, managing director
at Foster Delivery Science.
For example, any part in contact with
the drug materials, including screws and
barrels, must be either dedicated to that
drug or undergo a validated cleaning
protocol before use in other applications.
In addition, the equipment must use
FDA-approved lubricants, and the
product-contact parts must be non-reac-
tive and non-absorptive.
Foster develops and produces compounds
under clean conditions in Connecticut
ENTEK Extruders
A Division of ENTEK Manufacturing
PO Box 39, 200 Hansard Avenue
Lebanon, Oregon, USA, 97355
Tel: 541-259-1068 Fax: 541-259- 8018 www.entekextruders.com
ENTEK_LarryKeith_CW_A4_051812_x1a.indd 1 5/18/12 3:23 PM
for cleanliness and records of both cleaning and
inspection. Martin noted the compounding industry can
benet from auditing and selectively implementing
practices of pharmaceutical manufacturing companies.
Limiting human interaction with the product through
automation is another way to reduce contamination. At
PCCs clean compounding facilities, operators are
involved in blending, but extrusion through pelletizing and
packaging are all automatic, says Borgsdorf. Automation
can also be applied to process data acquisition. RTP, for
example, notes that its automated data acquisition
system allows detailed monitoring and traceability.
The human component
Automation, however, cannot replace the need for
operators that are highly trained and understand the
value of running a clean compounding plant. The
methods that you use to run processes and having
trained and disciplined managers and operators are
even more important than equipment modications,
comments Burke.
Operators need to understand the specications
and the impact of correctly following procedures on
product quality. With our operating teams, an in-depth
FMEA (failure modes/effect analysis) is a good tool. This
type of risk analysis increases understanding of the
procedures, the potential points of failure, and the risk
mitigation points, adds Brate.
It comes down to the people in the end, says
Borgsdorf. You need to value your employees and their
input. As our operators got to know the system in the new
clean compounding plant, they suggested modications
to make it even better. We couldnt have been successful
without management listening to the operators and giving
them the ability to operate as was needed. Listening to
customers is another critical aspect for success. The
industry needs to change its old mentality that would not
want customers to come into a manufacturing plant.
Several times a month, we now have customers coming
to perform audits, and we gladly listen to their sugges-
tions to help make our process better and even involve
them in long-range planning, says Borgsdorf.
More information
Doug Borgsdorf of PCC will be speaking about human
factors at the Thermoplastics Concentrates 2013
conference which takes place on 29-31 January at the
Fort Lauderdale Marriott Coral Springs Golf Resort in
Florida, USA, on 29-31 January. He will join an impres-
sive line-up of speakers featuring experts from
throughout the masterbatch supply chain. For full
details, visit http://bit.ly/TC2013.
Click on the links for more information:
S www.polyone.com
S www.sabic-ip.com
S www.rtpcompany.com
S www.plasticscolor.com
S www.teknorapex.com
S www.leistritz-extrusion.com
S www.fostercomp.com
Clean com-
pounding
depends on
highly trained
operators that
understand the
value of
product quality
Pi pes i n
I nf rast r uct ure

2013
Market trends, new products and technical developments
in plastic pipes for infrastructure applications
Click here
for details on
attending, sponsoring
or speaking at
the conference.
Contact: Giulia Esposito
ge@amiplastics.com
9-11 April 2013, Hotel Nikko,
Dsseldorf, Germany
Organised by Applied Market Information Ltd. (AMI)
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Continuous and batch mixers | processing feature
Mikell Knights reviews recent developments in batch and continuous
mixers for use in the production of compounds and masterbatches
The suppliers of batch and continuous mixers are
developing new and enhanced models to meet the
changing demands created by the latest material
formulations. These include the production of
compounds and masterbatches with higher additive
loadings, as well as those containing sensitive
bio-based ingredients or nano-scale llers and
reinforcements.
New mixer developments are also addressing
the growing demand for processing smaller
batches that use more expensive ingredients. Other
drivers for change include demands for greater
processing versatility, machine modularity, higher
throughputs, simplied cleaning, quicker changeo-
vers, faster heating, enhanced cooling and energy
savings.
Over the following pages we review recent mixer
developments from Ross, Marion, Mixaco, Plas Mec,
Henschel, HF Mixing Group and TPEI. These include:
multiple agitators in a single planetary mixer for
enhanced processing; the use of microwave heating
elements for faster ingredient heating without shear;
pressurized water cooling circuits for unprecedented cool
down; mixer chamber bag liners that cut cleaning
requirements; new mixing tool designs that improve
productivity; and, more powerful motors that
raise output.
Better batches
Ross Mixers has expanded its line
of hybrid planetary mixers that
process high-viscosity and
high-solids formulations. Its
Planetary Dual Dispenser Mixers
(PDDM) feature two planetary
stirrers and two high-speed
dispersers that rotate on their own
axes while revolving around the mix
vessel. The stirrers continually turnover
the batch of material, feeding product to the high-speed
dispersers, and promoting heat transfer throughout the
different areas of the mixing zone. Stirrers can either
be rectangular-shaped paddles or helical high-viscosity
blades.
Each disperser shaft is equipped with saw-tooth
blades that provide an intensive shearing action which
is ideal for rapid solids dispersion and particle size
reduction. Sidewall and bottom scrapers eliminate
material build-up and ensure formulation and tempera-
ture uniformity.
This unit, our newest offering, has the high-speed
mixing power of a stand-alone disperser, but the
planetary design allows it to process highly viscous
formulations and not only materials that are owable,
says Christine Banaszek, application engineer at Ross.
In addition, the PDDM offers precise control over shear
Stir it up with the
latest mixers
processing feature | Continuous and batch mixers
levels and fow patterns because the agitators are
independently driven and controlled.
Shear-sensitive materials such as syntactic foams
and other microsphere-flled composites, as well as
abrasive and extremely viscous compounds would
typically be run on a more traditional planetary mixer
which does not feature the dispersers. These applica-
tions can be run on the PDDM since the disperser
shafts are easily removable, allowing the unit to
function as a classic Double Planetary Mixer, says
Banaszek. The PDDM line comes in a wide range of
sizes from 2 to 750 gallons (8 to 2,800 litres).
Ross also offers a new ultra-high-shear inline mixer,
called the MegaShear, which is designed for very
aggressive particle size reduction, homogenization and
emulsifcation. Typical applications of the MegaShear
include specialty coatings, polymers, lubricants, inks and
adhesives. In plastics production, the MegaShear is very
effective for soft polymer disintegration, wherein you
reduce the particle size of a solid polymer suspended in
liquid or dissolve the polymer entirely, says Banaszek.
The MegaShear rotor turns at tip speeds over 11,000
ft/min (3,400 m/min), within a close-tolerance stator, and
subjects the material to thousands of intense mechanical
and hydraulic shearing events in a single pass.
The stainless steel mixing chamber is designed for
150 psig (11 bar) internal pressure at 250
o
F (120
o
C).
Being an inline device, the MegaShear can be operated
continuously in a true single-pass confguration or
piped to a batch tank for recirculation.
Ross has also introduced a new unit ideal for
laboratory and pilot-scale requirements. With a
maximum working capacity of one cubic foot (28,000
cm
3
), the new 42NSD-1S model is a multi-purpose
blender equipped with interchangeable double ribbon
and paddle agitators.
The unit is commonly used for blending dry powders,
granules, pellets and other solid forms, but it can also
handle wet materials such as pastes and slurries. The
standard agitator features inner and outer helical
ribbons that are pitched to move material axially, in
opposing directions, as well as radially. The double
ribbon agitator is used in most applications for fast and
thorough blending while a paddle agitator is utilized for
lower impact mixing of friable and shear-sensitive
materials. Either agitator design is suitable for coating
a liquid or very fne solid component throughout the
surfaces of larger particle ingredients.
The 42NSD-1S vacuum-rated blender comes with a
discharge extruder assembly (auger) installed along the
bottom of the trough to enhance mixing, eliminate dead
zones, and ensure complete discharge of material.
www.mixers.com
Marion Mixers is a supplier of custom-designed mixing
and drying equipment. For more than 75 years it has
been designing and manufacturing equipment for
plastic processors involving many different applications.
There is growing interest in designs that feature paddle,
ribbon and hybrid style agitators, says Scott Jones,
marketing manager.
The companys paddle style agitators, which are
offered in either sanitary-welded or easily removable
bolted-blade styles, provide a great deal of versatility,
says Jones. The paddle agitators mix materials of
dissimilar size, shape or density in a gentle lift-scoop-
tumble fgure-of-eight pattern inside the vessel. This
design can be used with batch sizes that fll the
chamber from 20% to the full mixing capacity of the
unit. A 0.20 inch (5.1 mm) blade clearance to the inner
trough wall is said to deliver excellent clean-out
between batches regardless of batch volume.
This design pulls material to the middle of the
agitator for more intensive mixing, which is ideal for
blending fragile, friable or oversized ingredients, or for
mixing solids of various particle sizes, densities and
Above left:
Ross designed
this double
agitator mixer
for lab-scale
processing of
dry powders,
granules and
pellets
Above right:
The PDDM
mixer from
Ross features
newly designed
stirrers,
dispersers and
sidewall
scrapers
viscosities. This design can be used in Marions batch or
continuous mixers, says Jones.
The company also offers ribbon style mixers for use
with low-density free-fowing plastics materials. It is a
double-ribbon style design, which includes two sets of
fights on both the inner and outer mixing tool spirals.
The inner ribbons push product towards the end plates,
while the outer ribbons move material towards the
centre. The company also offers a hybrid mixer
featuring paddle- and ribbon-style mixing elements,
suitable for coating ingredients and for free-fowing
particles with similar particle, density and shape. The
additional fights are said to provide twice the mixing
action of a single ribbon mixer.
Marion is also bringing a novel microwave heating
approach as an option for its plastics and pigments mix-
ing unit. The microwave technology, which the company
offers through a licensing agreement with the Univer-
sity of Northern Iowa, can deliver faster and more
uniform heating and drying to ingredients.
This approach, initially developed as a solution to turn
oil into grease, may allow plastics processors to trim
batch processing times, saving money and also attaining
better heat control versus conventional thermal
temperature approaches. Jones says several tests with
plastics ingredients are ongoing in its lab and the
company would welcome additional industry suggestions
for application testing.
The microwave mixer features a transmitter, mixing
vessel, waveguide system and controls. Transmitters
typically range from 30-100 kW in power operating at
915 MHz. The stainless steel microwave mixing vessel is
ideal for compounds and powders.
www.marionmixers.com
Mixaco Maschinenbau developed its Speedy SD line of
sack/drum mixers for small batch mixing between
15-55 lb (7-25 kg) of dry solids and additives, and now
they can also be used for liquids. Material formulations
are secured in a double-walled sack that is placed in
the mixing container which serves as the transport-,
mixer- and storage-container for the material. The
mixer and mixing sack do not have to be cleaned since
the mixed material is not transferred, saving cleaning
time. A standard mixing barrel can also be used in place
of the mixing sack, although cleaning will be required.
Round containers eliminate dead space, allowing for
full low- and high-intensive mixing in the mixing sack,
says Markus Frantzen, general manager at Mixacos US
subsidiary in Greer, SC.
A multiple winged-blade mixing tool is lowered
pneumatically into the drum for intensive mixing and is
retracted after mixing. Speedy SD 50 (50 litre) and SD
100 (100 litre) models have been added to a line-up that
includes the Speedy S50 and S100 sack models plus the
Speedy D60 drum version. The main advantage is the
quick change-over time for different formulations.
Mixaco has also improved the effciency of its
Multi-Tool (MT) container mixer, which is designed for
the processing of temperature- or shear-sensitive
materials with little to no heating. The Container Mixer
MT uses a modular mixing tool arrangement that creates
two material fow currents in the mixer. The primary
current continually transports material in a conveying
action from the outer section of the chamber into the
active secondary current that contains a chopper-style
drive. The combination of both mixing currents ensures
fast mixing and excellent dispersion, says Frantzen.
The Container Mixer MT only increases the product
temperature at a rate of 0.5 to 1
C per minute, which is

far less than conventional mixing tools. The mixer is
suitable for powder coating premixes with low melt
temperatures, producing masterbatch and PTFE
premixes, and for mixing additives in powder and
granulate form. The main advantages are said to be
higher machine availability, better dispersion, quicker
changeovers, and very low energy consumption
compared to conventional mixing systems. In addition,
the MT tool system allows customers to produce a
wider range of batch sizes in the same mixer model.
Container Mixer models range from 15 to 4,000 litre.
Mixaco has also renamed its Heating-Cooling Mixer as
the Heating Mixer Cooling Mixer EC-Revolution (HM-KM-
EC Rev) unit to refect the improved energy savings gained
Marion Mixers
offers a wide
range of
agitators
including
easy-to-clean
welded blades
COMPOUNDING WORLD | November 2012 www.compoundingworld.com 30
The TRR series is designed to cold mix polymers in
powder or granule form with pigments or additives. It
can process ingredients for colour masterbatches,
powder coatings and pre-mix powder formulations. It is
said to be an ideal alternative to conventional turbomix-
ers, when production conditions require a wide range of
different products to be mixed with the same machine,
according to Plas Mec CEO Marco Marinello.
The TRR models now features a simplied, more
user-friendly interface, while mixer cleaning has been
rethought to be more effective. The machines design
divides the mixer and storage container into two
separate units, which helps to reduce contamination
and improve cleaning time. Stainless steel is used in the
mixing head chamber, mixing hopper, and the tooling.
Plas Mec offers seven models in the line ranging from
150 to 2,000 litres of capacity, and able to handle 60 to
1,000 kg of material.
Plas Mecs TRM line of high-speed mixers for PVC
dry-blending (either rigid or plasticized) features new
mixing tools, a special hard stainless steel, and the use
of the latest variable frequency drive technology. The
new mixing tool type provides optimum mixing with a
large variety of clear, non-clear, soft, semi-soft and
rigid materials. Plas Mec says the vessel lid can be
supplied in different congurations for horizontal or
vertical opening.
The models can also be used for densication or heat
agglomeration of other thermoplastics, such as ABS, PE
and PP. In addition, they can be used for the drying or
Batch mixing of
dry solids,
additives or
liquids from
15-55 lbs with
fast change
over between
formulations
are benets of
Mixacos
Speedy Sack/
Drum (SD)
mixer
The TRR mixer
series from
Plas Mec is a
more versatile
alternative to
conventional
turbo mixers
from a tool-less type cooing mixer. Designed primarily for
PVC compounding, the unit incorporates Mixacos EC
Revolution Cooling mixer technology that cools without
any tooling in the mixing chamber.
The mixing bodies are in the shell of the chamber
and rotate around their own axis, therefore increasing
the available cooling surface for quicker cooling, says
Frantzen. A conventional cooling mixer typically
features a horizontal shaft with plough tools on them. In
this approach, water-cooled modular cooling elements
cool without introducing mechanical energy into the
product, which adds no additional heat. The tool-less
cooling mixer has a cooling jacket, large internal
cooling elements, and optimized water supply that
creates an enlarged cooling surface while reducing
design size and drive power requirements.
The mixer is said to be maintenance friendly and
reduces energy consumption signicantly, as the design
requires no tooling, no mixing drive, and no mixing
shaft seals. The novel discharging feature of the mixer
ensures complete material discharge. Frantzen says
customers experience shorter cooling times compared
to traditional cooling mixers. The HM-KM-EC-Rev
design features a high-intensity hot mixer with
improved high-intensity wear-coated tooling as well as
several vessel lid and discharge valve options.
S www.mixaco.com
Plas Mec expects that recent upgrades to its TRR and
TRM series of batch mixers will deliver 20% higher
productivity, 15% lower energy consumption, and 50%
more exibility. The company has designed a new type
of mixing tool for both models, and has also introduced
other upgrades to improve performance.
>>
The advance into a new performance dimension of compounding technology. The new
ZSK Mc
18
twin screw extruder of Coperion, formerly Werner & Peiderer, is the most pro-
ductive high performance ZSK of all time. With a specic torque of 18 Nm/cm
3
it stands for
considerable throughput increases with improved product quality and the widest processing
window on the market to provide you with a unique technology advantage. Thats what
we mean when we say condence through partnership.
>>
www.coperion.com
>compounding & extrusion >materials handling >service
1242_CE_ZSK_Mc18_en_210x148.indd 1 29.04.2011 11:47:00
Thi s Mul t i f unct i onal Addi t i ve i s a
POWERFUL LITTLE PELLET
STRUKTOL TR 063A
Increased Productivity
Longer Flow Lengths
Our newest Intelligent Additive Solution is specifically designed to improve the processability of filled or reinforced
nylon compounds. Added during compounding or at the molding machine, processors will see:
Superior Mold Release
Expanded Possibilities
To find out more about our additives or to request a sample,
call 330.928.5188 or email plastics@struktol.com or visit www.4struktol.com
the hot or cold distribution of pigments. The TRM is
offered in 12 models ranging in size from 200 to 2,500
litres, and formulation weights from 85 to 1,050 kg.
www.plasmec.it
Henschel, a division of Zeppelin Reimelt, has launched
a new cooler mixer for rigid PVC compounding. It is
claimed to deliver very short cooling times together
with fast feeding and discharging times. The Horizontal
Cooler Effciency (HCE) series relies on newly developed
mixing container geometry, redesigned mixing tools,
and a reconfgured discharge unit that makes it possible
to increase the throughput by 30-40% for the same
machine size or to shorten mixing times when process-
ing similar volumes. A throughput of 11 batches per
hour can be achieved.
The extremely effective cooling of the HCE line is
achieved through the use of a newly designed water
jacket installed in the body of the cooling mixer. Cooling
water chambers and pipes in the mixer body achieve a
higher degree of turbulent fow because the cooling
medium is delivered under high pressure, says
Christian Tittensor, Henschels sales and marketing
manager, North and South America, rubber and plastic.
The system can handle operating pressures up to
7 bar, which allows for very large fows of cooling water
and a higher heat exchange rate. Conventional systems
using cooling channels deliver the water under
0.5-1.0 bar typically, says Tittensor. In addition, the
mixing bowl and other components of the HCE line are
made entirely out of non-corrosive stainless steel, and
product contact surfaces are highly polished to prevent
material build-up. Integration of the mixer to the water
supply system is easy and not expensive.
The mixing tools used in the HCE are of a new design
to provide excellent mixing, and the tools themselves
also feature a cooling circuit running through them. The
helical structure of the new tools allows for extremely
close contact of the mixture to the cooled mixing bowl.
Cooling water is supplied to the tools through the
mixers drive shaft.
The charge/discharge opening has been completely
redesigned as a large lid that is easier to open and close.
The overall height of the mixer has also been reduced
due to the lower height of the discharge housing.
The HCE, shown at this years NPE show in Orlando,
is currently offered in fve sizes that handle from 1,700
to 6,000 litres. Zeppelin Reimelts Henschel division
also offers the HC line featuring the same develop-
ments shown on the HCE, but without a water cooling
circuit in the helical tools.
A new small batch mixer offering superior mixing in
a short time, along with rapid product changeover and
short clean up times is also new from the company.
The Container Mixer Inliner (CMI) features a thick
plastic liner placed inside the vessel that contains the
formulation during mixing and becomes the transporta-
tion device for the mixed material after processing. The
mixing container is designed with a basket structure
that keeps the liner in place by fxing the liner in the
square openings (golf-ball effect). Users can tie the bag
up and store the mixture for future use or bring it to a
compounding extruder or downstream unit for further
processing.
CMI is designed for the production of pre-mixed
powder coatings, mixing of colour concentrates and
masterbatches, and for the homogenizing of free-fow-
ing bulk materials. Mixing is achieved using a rotating
mixing tool that is supported by a counter-rotating
mixing drum.
When the mixing drum and liner are attached, the
drum swivels 120
o
on a horizontal axis, so the material
comes into contact with the mixing tool. Container
clamping and rotation are electronically monitored. The
Above left: The
Henschel HCE
Cooler mixer
from Zeppelin
Reimelt can
boost PVC
compounding
productivity
Above right:
The Container
Mixer Inliner
from Zeppelin
Reimelt is
suitable for
small batch
mixing
applications
Images courtesy of: Dow Chemical Company
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material is homogenized solely by the rotation of the
container.
Users can remove the liner with the mixed material
and install the next liner and formulation quickly. A
Tool-Click feature allows users to remove and replace the
mixer drum tool with a clean tool in minutes. Three sizes
from 75 to 450 litres are available with additional sizes
planned for introduction over the next several months.
www.zeppelin-systems.com
Continuous improvements
HF Mixing Group is implementing a range of enhance-
ments to its Compact Processor series including a new
icon-based control interface and higher rotational
speeds for increased throughput. The CP Series II is
comprised of an independently controlled FCM
non-intermeshing dual-rotor continuous mixer
integrated with a single-screw extruder. It will be
upgraded with an easier to use icon-based control
panel mounted on a swing-arm.
At the same time, the company is upgrading its
motors to extend the throughput of the line. Launched
last year, the CP 550 model produced 500 kg/h (227
lb/h), but thanks to more powerful motors is now
capable of up to 700 kg/h (318 lb/h), says Steve
Peterson, vice president and business unit director.
New, harder surface liners are also being developed to
improve the handling of highly abrasive materials, such
as PE formulations with 80% calcium carbonate.
The CP line is designed specifcally for the disper-
sion of polymer compounds with high levels of mineral
fllers, additives and pigments, polymer-elastomer
blends and for applications requiring high intensity
mixing at low processing temperatures. The mixing
chamber features a segmented construction for
processing fexibility, and zoned heating and water
cooling across its short 3.5:1 L/D for controlled heat
transfer. It also has a hinged clamshell design for easy
access to the mixing chamber and for straight-forward
cleaning and part replacement tasks. A replaceable
tool-steel liner is resistant to abrasive materials.
Harburg-Freudenberger (HF) Maschinenbau, a
German manufacturer of batch mixers for rubber
processing and continuous mixing technologies,
acquired Farrel as well as the batch mixer business of
Italy-based Pomini Rubber & Plastics, then renamed the
overall entity HF Mixing Group-Farrel/Pomini. The frm
recently reshuffed its assets into business units. All of
the continuous mixing activities are centred in Ansonia,
Connecticut, USA, with development and testing
laboratories in the USA and England, while the batch
mixing assets from Farrel and Pomini (including the
Banbury and tangential mixer) will be based in England.
Farrel says that it has added the latest rotor
technology to its Banbury mixer. The NST rotor
performs better than the proven ST design, utilising a
novel helical four-wing geometry that enhances
material circulation axially within the chamber and
results in higher material fow and shear intensity.
The new distributive rotor design is said to improve
product uniformity by up to 70% compared to two-wing
rotors, or 65% better than other four-wing rotors.
Productivity is said to be up by 14% compared to
two-wing rotors, and 6% higher than four-wing designs.
The physical properties of the product are also said to
be signifcantly improved when mixed using the NST
style rotors.
Farrel has also upgraded its F305 and F440 Banbury
mixers to provide 5% and 8% more free volume in the
same footprint compared to its F270 and F370 units
respectively. Combined with the NST rotors, the new
chambers can mix additional volume of a formulation
using less power.
www.farrel.com
Technical Process & Engineering (TPEI) has introduced
a new continuous mixer scaled down for laboratory
trials. We used to use our two inch [5 cm] rotor
diameter line as a scale-up model, but that requires a
minimum of 50 lb [23 kg] of material to run. Customers
looking to test very expensive engineering or medical
grades are looking to run a pound or two of material,
says CEO Harold Schafer.
The companys latest models, the 1FR and 1FRE, can
process 1-50 lb (0.45-23 kg) of material using two
non-intermeshing rotors with a diameter of 1 inch (2.5
cm). TPEIs continuous mixers employ a free rotor con-
cept, unlike more conventional designs where the rotors
are integral with the bearing housing. With a conven-
tional rotor, a user must open the bearing housing in
order to remove the rotor. With a free rotor, opening the
bearing housing is not required. The rotor is free from
HF Mixing
Group is
upgrading the
Farrel CP550
Compact
Processor to
deliver higher
throughputs
Germany
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Experience the speed and versatility of our new Continuous
Hybrid Screen Changer.
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the drive bearing block and is held with couplings.
The new lab line joins a product line-up ranging from
2 inch (5 cm) diameter rotors (2FR) through 9 inch (23
cm) rotors (9FR). Output ranges from several lb up to
15,000 lb/hr (68,000 kg/h) depending on model. Each
model in the line has a 5:1 L/D and features two heating
zones and three cooling zones for extremely tight
temperature control.
The new lab model features a brand new rotor
design, which will eventually be scaled up for larger
machines. They will join the two standard No. 7 or No.
15 rotor styles that TPEI offers for processing a wide
range of materials, especially formulations with
loadings up to 80%.
The rotor designs, temperature zones, and variable
rpm control allow processors to put a little or a large
amount of energy into the product without having to
change rotor elements, allowing the unit to process PE,
PP, PVC and other materials.
Protecting pigments
We ran trials using aluminium pigments where the
customer did not want the aluminium scuffed, says
Schafer. A continuous mixer like ours can process
without scuffng, because this mixer type works with a
fairly large clearance between the wall and rotor itself.
With an intermeshing twin-screw, the tolerance
between screw and chamber wall is tighter, he adds.
These rotor styles are offered for all rotor diameters in
its Free Rotor line.
The No. 7 and No. 15 rotors can run the same
materials, but the rotor selection depends on the model
size it is used with, and what you want to do with the
material. If you have a PE and you want to put a
foaming agent in that kicks off at a certain temperature,
youll want the material to stay as cool as possible when
processing. A No. 7 would lower the output, but yield a
better quality for that specifc product. If you were
running a green PE masterbatch or colour concentrate,
you would put in the No. 15 for maximum output. Trials
would determine the best rotor design, says Schafer.
TPEI also offers the Free Rotor models in an
extended version (FRE) where two additional fights
are added for conveying, and the feed-throat is opened
up to better facilitate the fow of materials into the
machine. The enhancements speed up the compound-
ing process in the mixer and raise throughput by 20%
while extending the unit to 9:1 L/D.
TPEI is considering lines with even larger diameter
rotors, and has a 15 inch (38 cm) line (15FR) in develop-
ment. Applications will vary depending on customer
demand, but the initial targets include large automotive
or recycling applications where there are really high
volumes of material using mineral fllers, glass fllers,
and even low-bulk density materials. TPEI is also
looking into new rotor geometries for bioplastics and
nano-compounds.
The company offers custom material feeding
solutions for its continuous mixer. Its special J-Block
unit transfers discharge from the mixer into an
extruder, and it offers its own extruder design. The
continuous mixer can be included as part of a turn-key
system designed for a wide range of thermoplastics.
www.tpei.com
TPEI can build
complete
turn-key
compounding
lines around its
continuous
mixers
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advertorial advertorial
Plastribution Limited.
All rights reserved. 2011
On the basis of the vast range
of classifcations currently used,
Plastribution has chosen to employ
simpler and clearer terminology for
greater transparency:
Prime
As it comes from the polymerisation
plant, and within a published
specifcation.
Off Grade
plant, but does not conform to a
published specifcation.
Compound
Material within which additives have
been incorporated by means of a
compounding process.
Pre-consumer Waste
Thermoplastic material that is a waste
by-product of an industrial process.
Post-consumer Waste
Thermoplastic material which has
been recovered from a consumer
item that has reached the end of its
intended use.
In the event that you require further
information, or need to comply with
specifc requirements in terms of
post-consumer waste concentration,
please do not hesitate to contact a
member of the Plastribution team for
further information on 0845 3454560 or
sales@plastribution.co.uk.
One of the core values of
Plastribution is its expertise
something that all of its
suppliers and customers
know they can rely on.
Industry know-how is a series
of articles from Plastribution,
exclusively available to the readers
of Injection World and on its website
www.plastribution.co.uk, that shares
this expertise to provide essential
background on some of the
common terminology and practices
used within the plastics industry.
Whether to cover gaps in
knowledge where high levels are
assumed, or to provide clarity
where terms of reference have
become confusing, Industry
know-how aims to provide
clear explanations and, where
appropriate, thought leadership
to support industry growth.
In this frst article, it addresses the
wide range of terminology relating
to the classifcation of thermoplastic
raw materials that has evolved
over time, and Plastributions
approach towards transparency.
By defnition, thermoplastics are
a group of materials that can be
repeatedly melted by the application
of heat (or thermal energy), shaped
into the required product, part or
component, and frozen to retain
that shape through suffcient cooling.
This process leads to a thermoplastic
having a thermal history.
Because thermoplastics can be
reshaped upon reheating a number
of times, they are considered to be
recylcable. Yet thermoplastics also
demonstrate varying degrees of
thermal instability.
Particularly at temperatures where
they begin to melt or soften, thermal
degradation of the polymer can start
to affect its properties, with this rate
of change increasing further if shear is
also applied.
For the moulder this means that great
care should be taken in selecting
the correct quality of material for
a specifc application, where, for
instance, a prime grade of material
may be preferred to ensure the
delivery of properties as specifed on
data sheets.
This particularly applies to plastic
components that are exposed
to hostile environments including
contact with chemicals and at
elevated temperatures.
Care should also be taken with
materials containing additives such as
fllers (see separate Industry know-how
fact sheet on Regrind Guidelines)
For various reasons a wide range of
terminology has evolved to describe
the quality of the original polymer and
materials that have been recovered
or recycled. As can be seen from the
table, this can lead to confusion.
Moreover, an increase in both
consumer pressure and government
legislation has promoted the use
of recycled plastics, and more
specifcally recycled post-consumer
waste, thereby adding to the list of
materials available to choose from.

Plastribution is the UKs
leading distributor of plastics
raw materials, delivering
reliability, know-how and
true business partnership to
the worlds best polymer
suppliers and our
UK customers.
PLASTRIBUTION TERMINOLOGY INDUSTRY TERMINOLOGY
Prime Virgin, Prime
Prime Compound Compound
Off Grade
Wide-spec, Off Grade, Near to Prime,
Second Quality, Second Choice
Off Grade Compound Industrial
Post-consumer waste
Repro, Reprocesses, Recycled,
Reclaimed, Re-engineered
Pre-consumer waste
Industrial, Repro, Recycled,
Re-engineered
Prime + Post-consumer Waste
Repro, Blended, Industrial,
Recycled Content
Prime + Pre-consumer Waste
Repro, Industrial, Blended,
Recycled Content
Off-Grade + Post-consumer Waste
Recycled Content
Off-Grade + Pre-consumer Waste
Recycled Content
PLA0031_Industry know-how.indd 1-2 28/12/2011 14:37
industry
advertorial advertorial
Plastribution Limited.
All rights reserved. 2011
On the basis of the vast range
of classifcations currently used,
Plastribution has chosen to employ
simpler and clearer terminology for
greater transparency:
Prime
plant, and within a published
specifcation.
Off Grade
plant, but does not conform to a
published specifcation.
Compound
Material within which additives have
been incorporated by means of a
compounding process.
Pre-consumer Waste
Thermoplastic material that is a waste
by-product of an industrial process.
Post-consumer Waste
Thermoplastic material which has
been recovered from a consumer
item that has reached the end of its
intended use.
In the event that you require further
information, or need to comply with
specifc requirements in terms of
post-consumer waste concentration,
please do not hesitate to contact a
member of the Plastribution team for
further information on 0845 3454560 or
sales@plastribution.co.uk.
One of the core values of
Plastribution is its expertise
something that all of its
suppliers and customers
know they can rely on.
Industry know-how is a series
of articles from Plastribution,
exclusively available to the readers
of Injection World and on its website
www.plastribution.co.uk, that shares
this expertise to provide essential
background on some of the
common terminology and practices
used within the plastics industry.
Whether to cover gaps in
knowledge where high levels are
assumed, or to provide clarity
where terms of reference have
become confusing, Industry
know-how aims to provide
clear explanations and, where
appropriate, thought leadership
to support industry growth.
In this frst article, it addresses the
wide range of terminology relating
to the classifcation of thermoplastic
raw materials that has evolved
over time, and Plastributions
approach towards transparency.
By defnition, thermoplastics are
a group of materials that can be
repeatedly melted by the application
of heat (or thermal energy), shaped
into the required product, part or
component, and frozen to retain
that shape through suffcient cooling.
This process leads to a thermoplastic
having a thermal history.
Because thermoplastics can be
reshaped upon reheating a number
of times, they are considered to be
recylcable. Yet thermoplastics also
demonstrate varying degrees of
thermal instability.
Particularly at temperatures where
they begin to melt or soften, thermal
degradation of the polymer can start
to affect its properties, with this rate
of change increasing further if shear is
also applied.
For the moulder this means that great
care should be taken in selecting
the correct quality of material for
a specifc application, where, for
instance, a prime grade of material
may be preferred to ensure the
delivery of properties as specifed on
data sheets.
This particularly applies to plastic
components that are exposed
to hostile environments including
contact with chemicals and at
elevated temperatures.
Care should also be taken with
materials containing additives such as
fllers (see separate Industry know-how
fact sheet on Regrind Guidelines)
For various reasons a wide range of
terminology has evolved to describe
the quality of the original polymer and
materials that have been recovered
or recycled. As can be seen from the
table, this can lead to confusion.
Moreover, an increase in both
consumer pressure and government
legislation has promoted the use
of recycled plastics, and more
specifcally recycled post-consumer
waste, thereby adding to the list of
materials available to choose from.

Plastribution is the UKs
leading distributor of plastics
raw materials, delivering
reliability, know-how and
true business partnership to
the worlds best polymer
suppliers and our
UK customers.
PLASTRIBUTION TERMINOLOGY INDUSTRY TERMINOLOGY
Prime Virgin, Prime
Prime Compound Compound
Off Grade
Wide-spec, Off Grade, Near to Prime,
Second Quality, Second Choice
Off Grade Compound Industrial
Post-consumer waste
Repro, Reprocesses, Recycled,
Reclaimed, Re-engineered
Pre-consumer waste
Industrial, Repro, Recycled,
Re-engineered
Prime + Post-consumer Waste
Recycled Content
Prime + Pre-consumer Waste
Recycled Content
Off-Grade + Post-consumer Waste
Recycled Content
Off-Grade + Pre-consumer Waste
Recycled Content
PLA0031_Industry know-how.indd 1-2 28/12/2011 14:37
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Carbon black | additives feature
Carbon black suppliers are
tuning morphologies to improve
processability and performance.
Pat Toensmeier reports
Thermoplastics account for only 5% of the global
market for carbon black, but these applications are
powering innovations in formulations.
Despite the economic slowdown in many regions, the
use of carbon black in thermoplastics should increase
by 4.6% this year over 2011, and maintain average
annual growth of 4.5% through 2015, according to
gures from Notch Consulting Groups 2012 Workbook,
which were cited by Birla Carbon.
This means that in 2012, the carbon black market for
thermoplastics is expected to top out at 552,000 tonnes.
If growth continues as projected, demand could account
for 630,000 tonnes in three years.
The markets driving consumption in thermoplastics
are mostly conventional end-uses: pipe, wire and cable,
automotive applications, industrial parts with conduc-
tivity requirements, food packaging, agricultural lm
and electronics.
The real demand driver, however, is geography,
notably the build-up of industry and markets in Asia and
South America, as investments continue to grow in
infrastructure and manufacturing. Another growth area
is the Middle East where sales of plastic pipes to the oil
and gas industry remain strong and could be buoyed by
recent offshore oil and natural gas nds in the eastern
Mediterranean.
In Asia, China has become the worlds second-larg-
est plastics producer after the US, and is a major
consumer of carbon black as it develops its automotive
industry, invests in infrastructure (pipe, wire and cable)
and upgrades agriculture (lm and irrigation pipe).
Elsewhere in the region, Indias plastics industry is
growing at a rate of 15%/yr., according to reports,
creating signicant demand for similar reasons.
Add to this market growth in Eastern and Central
Europe, along with improving demand in North America,
and its little wonder that carbon black producers are
optimistic about the near-term outlook for business.
Some of this optimism is reected in capacity
expansions. Cabot, considered to be the worlds largest
supplier of carbon black and masterbatches, has been
building up operations in China for several years. The
company is already expanding a newly opened (2012)
research laboratory in Shanghai, and in 2011 added
45,000 tonnes of masterbatch manufacturing in Tianjin,
where an undisclosed amount of additional capacity is
planned.
Our recent focus has been supporting the develop-
ment of the plastics industry in China, says George
Haines, global segment product manager for plastics.
Much of the work that Cabot is undertaking in China is,
Building new benets for
carbon black
additives feature | Carbon black
from a technical standpoint, critical to the countrys
success as a global supplier of manufactured goods, he
adds. Providing the latest carbon black technologies
and capabilities is important, particularly since China is
adopting many international standards ISO among
them but also because many of the products it makes
end up in Europe or the US.
Timcal, which specializes in conductive carbon
blacks, is investing in its Willebroek, Belgium, plant to
signifcantly increase production capacity, according
to Christine Van Bellingen, product manager of carbon
black and graphite for polymers. Timcal isnt releasing
expansion numbers, but Van Bellingen says the move is
in response to growing demand from polymer and
battery markets.
Discussing the US market, Jan Kozma, vice president
of black masterbatch supplier Modern Dispersions,
says: We are seeing more demand as the economy
recovers from its recession. Automotive is coming back,
along with pipe, food packaging, geomembranes and
agricultural applications such as irrigation tubing.
Modern Dispersions is encouraged enough by growth
in the US and elsewhere that it recently completed an
expansion of production at its Fitzgerald plant in the
state of Georgia. Amit Dani, the companys technical
director, doesnt reveal numbers but says the increase
is in the range of 10-20%.
New product developments
Most of what is emerging from new and upgraded
formulations, or being covered by capacity expansions,
is not only for targeted markets, but increasingly
specifc product needs within those markets. Require-
ments here include regulations from Europe and North
America that cover product use in critical and hazard-
ous environments, better performance under dynamic
operating conditions, and greater shielding of sensitive
electronic components in a variety of applications.
The key driver [in our product development] is
providing customers solutions and a competitive
advantage in their applications, says Natalie Harris,
who is North American technical service manager for
Birla Carbon, a unit of Indias Aditya Birla Group.
Recent developments at Birla include products that
increase UV protection in pipe and cable jacketing, and
conductive grades that meet growing standards for
insulation, electrostatic discharge and antistatic
properties.
Harris says that features of these carbon blacks
include greater dispersibility through tailored morphol-
ogy, process enhancements, and improvements in
product cleanliness.
Most suppliers continue to focus on morphology and
other material development techniques to improve the
process effciency of their grades while maintaining or
increasing performance.
One way of doing this is by fne-tuning cleanliness and
dispersibility, which have, of course, always been key
properties of carbon black formulations, especially in
conductive compounds. They are particularly important
when it comes to meeting the performance, productivity
and cost needs of compounders and end-users.
Van Bellingen, for example, says that Timcals
process routinely produces the companys Ensaco
grades with low sulphur and ash content, thus enhanc-
ing cleanliness. The materials also achieve surface
smoothness and dispersibility, and retain mechanical
and fow properties through compounding.
This means that the materials can rival the perfor-
mance of more costly specialty grades such as extra-
conductive carbon blacks, including those made by
Timcal. The latter are engineered to meet conductivity
requirements at up to half of a usual loading, which is
important when additional properties such as weldabil-
ity or foaming are necessary. With a very high structure
and surface area, these specialty grades meet conduc-
Cabots new
carbon black
plant in Tianjin,
China, is
helping to meet
growing
demand in Asia
Infrastructure
investments
are driving
growth in pipe
applications for
carbon black
P
H
O
T
O
:

O
R
I
O
N
AMI is a global provider of market research, consulting and analytical services to the worlds plastics industry.
The company is also a leading publisher of commercial and technical information and an organiser of international
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Trends and technical developments in the international closures industry
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tivity requirements at lower loadings. Nevertheless, Van
Bellingen says that compounders can have process
effciency, performance and economy at higher loadings
without using extra-conductive grades.
One example she cites to back this up is Ensaco
250G, a conductive carbon black with an unusual
combination of high structure and low surface area,
which stems from Timcals production process. As a
result of its cleanliness, dispersibility and properties
retention, the grade can be compounded effciently and
at less cost than an extra-conductive material that is
more diffcult to disperse than a lower-surface-area
carbon black.
This clearly highlights the importance of having
good in-bulk dispersion, and the fact that working with
the lowest additive level is not necessarily giving the
best overall performance versus higher loadings of
easy-dispersible black, Van Bellingen says. Impor-
tantly, she notes, The in-bulk dispersion of an additive
will orient the fnal mechanical properties of a formula-
tion, whatever the loading of the additive.
The Ensaco 250G grade has other benefts as well.
One is low water content (maximum 0.3% in a saturated
atmosphere), owing to its low surface area. Van
Bellingen says this means it can be readily mixed with
water-sensitive polymers and doesnt require a drying
step before use.
The surface area also helps reduce the viscosity
increase that accompanies a high structure. At equal
volume resistivity, a compound flled with a lower-sur-
face-area carbon black will have a higher melt-fow
index (MFI) than a compound flled with a higher-sur-
face-area black, even though the percentages of carbon
blacks might be different, she notes.
Another supplier working to upgrade carbon black
through morphology and other process technologies is
Cabot. Citing an established trade-off concern with
additives, Haines remarks that a carbon black loading
necessary for conductivity can adversely affect a
compounds mechanical performance. We continue to
look at particle size, structure and surface treatments
to fnd the right balance to help customers achieve the
desired conductivity without sacrifcing mechanical
performance, he says. The key factors driving this are
the need to improve the cost-performance balance of
end-use product while meeting ever-expanding
performance requirements in existing and new
applications.
In the presentation, at AMIs Masterbatch 2011
conference held in Vienna, Austria, in June, Cabot
stressed the importance of expanding carbon-black
performance through morphology and improving
functionality with enhanced surface treatments to
reduce trade-offs. Advances in morphology are being
pursued to avoid trade-offs in loading and viscosity, and
to improve viscosity and dilutability with minor material
reformulation. Surface treatments, meanwhile, are
being pursued to increase carbon black wetting, its
selectivity in multiphase systems, hydrophobicity and
surface smoothness.
In the presentation the company disclosed fndings of
a polystyrene electronic packaging application that used
a new grade of conductive carbon black, which was
formulated to reduce the trade-off between conductivity
and mechanical performance. The new conductive black
had MFI (g/10 min) of 9.3 versus 5.6 for the old grade;
compound moisture absorption of 420 ppm compared to
3,044 ppm; fexural modulus of 2,015 MPa versus 2,361
MPa; and impact resistance of 11.7 kJ/m
2
compared with
5.7 kJ/m
2
. Signifcantly, resistivity was 6.4 X 10
3
in the
new grade and 6.0 X 10
5
in the old version.
Cabot argues that besides improvements in resistiv-
ity, mechanical performance and processing, the
enhanced morphology and surface treatments mean
that compounders can buy less material to meet
specifcations, ideally saving money up front, and
reducing deliveries, handling and packaging waste,
which adds to proftability on the back end.
Modern Dispersions, meanwhile, has developed
various conductive compounds and masterbatches for
polyolefns as well as engineering grades of thermo-
plastics using high-structure, high-surface-area carbon
black, says Dani, who adds, We see very good growth
for this market.
Pigment progress
As important as conductivity is, its not the only
application for which suppliers are upgrading formula-
tions. Another area of activity is colour. Modern
Modern
Dispersions is
meeting
demands for
deeper shades
of black for car
interiors
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Polymers
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For electronic packaging, fuel hoses,
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Graphite & Coke
thermal conductivity
electrical conductivity
lubrication
For seals, water-meters, heat sinks, geothermal
pipes, LED light sockets, primers for electrostatic
painting, gas barrier properties.
Dispersions is among the companies working to
improve the carbon black masterbatches it provides for
colour intensity.
Kozma says the company is fne-tuning its process-
ing technology to improve cleanliness, dispersion and
processability. We continue to optimize our production
lines as part of an ongoing evolution in this area, he
remarks.
Modern is getting requests from customers for
deeper shades of black colour. The deep black master-
batches are popular for interior and exterior automotive
applications, due to the gloss and aesthetics they
provide and their ability to match topcoats.
The deep (or high jetness) shades of carbon black
have problems in masterbatches that are common to
other specialty grades. These include high surface area,
dispersion diffculties and viscosity increases when
compounded in high loadings. As a result, the company
is using its expertise in machinery, processing and
materials knowledge to produce grades that effectively
meet required colour and dispersion needs.
Another application for carbon black as a colouring
aid is in the UV protection of agricultural water pipes,
hoses and flms. One company that specializes in
formulations for the growing market of drip irrigation
pipes is Orion Engineered Carbons. Among the
companys developments for this market are pigment
blacks. These are described as small, high-surface-
area particles that combine multiple properties in a
package that outperforms single additives.
The foremost property of these materials is UV
protection, of course, but the pigment blacks also
contain high-purity pigments and outstanding disper-
sion properties that reportedly minimize the potential of
microscopic defects that could cause pipes to crack or
degrade prematurely.
As might be expected, irrigation is a major market in
developing countries. India, for example, is a global
leader in micro-irrigation, and according to compound-
er Spartech, it produces 7-10 times the volume of black
masterbatch resin for this application as the US.
Orion and other carbon black producers supplying
the irrigation market clearly have applications that will
account for substantial volumes of material.
Sustainable feedstocks are also gaining use in
carbon black formulations. Orion, for one, produces
Printex Nature, a pigment for polymers that is derived
from renewable materials such as plant oils. Printex
Nature offers a good balance of coloristic properties,
dispersibility and UV protection, and can be used in a
range of applications, food packaging, agricultural
flms, electronics and automotive among them.
Click on the links for more information:
www.notchconsulting.com
www.birlacarbon.com
www.cabot-corp.com
www.timcal.com
www.moderndispersions.com
www.amiconferences.com
www.orioncarbons.com
www.spartech.com
Orion
Engineered
Carbons is
targeting the
growing
market for drip
irrigation pipes
with special
grades
Carbon black is
used in
UV-resistant
agricultural
flms
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Conductive compounds | technical paper
Daniele Bonacchi and Christine Van
Bellingen of Timcal compare the
overall performance of conductive
and extra-conductive carbon blacks
in HDPE compounds. They nd that
the more conductive additive is not
always the best choice
In the eld of permanent electrically conductive
additives, conductive carbon blacks remain the most
reliable and economical choice
[1]
.
Carbon blacks suddenly decrease the electrical
resistivity of polymer composites when added to a
certain loading, which corresponds to the percolation
threshold. In fact, the resulting decrease in electrical
volume resistivity of a polymer when increasing the
amount of added carbon black can be described by a
percolation mechanism.
At a certain carbon black loading, the critical volume
fraction (also referred to as the percolation threshold),
the electrical resistivity dramatically drops from a
domain of high electrical resistivity to one of low
electrical resistivity, reaching an ultimate level of
resistivity, the lower plateau of the percolation curve. In
that region, further increasing the amount of added
carbon black does not decrease to a signicant degree
the low level of electrical resistivity.
The carbon black loading at which the sudden
decrease in resistivity occurs is different from one
carbon black to the other and is primarily related to
what is called the carbon black structure
[2]
. Conduc-
tive carbon blacks all have a high structure which
means that they are able to transfer electrical conduc-
tivity to composites at lower loadings than less
structured carbon blacks. They are made of aggregated
primary particles in three dimensional highly branched
structures (Figure 1).
The highly branched structures are responsible not
only for the electrical conductivity at low loading, but
also for the low bulk density of conductive carbon
blacks. Primary particles are bound to one and other via
covalent bonding in such a way that carbon black
aggregates are very resistant and will not break apart
under normal compounding conditions
[3]
. The extent of
the aggregation of the primary particles and the
agglomeration of the aggregates is referred to as the
carbon black structure. The oil absorption number
(OAN), as described in ASTM D2414, is employed to
measure the average structure level
[4]
.
Conductive carbon blacks with different OAN values
decrease the electrical resistivity at different loadings
(percolation thresholds) and can be classied according
to this number. This classication is present in the
market with different names such as conductive,
extra-conductive and ultra-conductive carbon blacks,
indicating their increasing structure (decreasing
percolation threshold) and usually also their increasing
related cost.
Another important carbon black property is surface
Comparing conductive
carbon blacks in HDPE
Figure 1:
Carbon black
Ensaco 250G
aggregate,
primary
particles are
visible
Surface Area
Ensaco 250G Ensaco 350G
Structure
Conductive
65
BET
(m
2
/g)
190
OAN
(ml/100g)
770
320
Extra-Conductive
Table 1: Surface area and structure of Ensaco 250G and Ensaco 350G
technical paper | Conductive compounds
area an increase of structure usually is accompanied
by an increase of the carbon black surface area. This
certainly holds true for extra-conductive carbon
blacks, though it is not always the case with conductive
carbon blacks. In fact, the proprietary production
process of Timcal is able to deliver high purity, soft
ake conductive carbon blacks of both high structure
and low surface area. This combination is of high
importance to ensure ease of dispersion and mixing of
the carbon black in the polymer matrix, as well as an
excellent surface smoothness in the nal material.
There is a trend to search for the highest structured
carbon blacks (meaning the more conductive) as a
rst approach, based on the assumption that a lower
carbon black loading would necessarily result in better
properties (usually mechanical properties).
In this article, we compare the performance offered
by conductive and extra-conductive carbon blacks in a
semi-crystalline polymer high density polyethylene
(HDPE) at the same nal electrical resistivity, rather
than at the same carbon black loading. We are able to
demonstrate that an easily-dispersible conductive
carbon black of high structure and low surface area
such as Ensaco 250G (E250G) can perform at least as
well as extra-conductive blacks, which are inherently
more difcult to disperse, despite the higher loadings
needed to achieve equivalent conductivities.
Results
The physico-chemical characteristics of conductive
carbon black Ensaco 250G (E250G) and extra-conductive
carbon black Ensaco 350G (E350G) are presented in
Table 1. It can be seen that the two materials differ in
OAN values (190 vs 320 ml/100g, respectively) as well as
in specic BET nitrogen surface area (65 vs 770 m
2
/g,
respectively).
The lower surface area of E250G increases its
mobility and enables easier wetting with the polymer in
comparison to higher surface area carbon blacks
[5]
. The
easier wetting, together with adequate de-agglomera-
tion provided by the high structure, results in increased
dispersibility (easy mixing), which ultimately produces
excellent surface smoothness; this is a clear advantage
especially in sensitive applications like lms and thin
sheets for electronic packaging.
With very highly structured carbon blacks, not only is
the surface area much higher, but also the many chain
entanglements upset the de-agglomeration step,
making their dispersion in polymers more difcult.
In this study, we present the results obtained in
general purpose injection moulding HDPE with a melt
ow index (MFI) at 190C/5kg of 11 g/10min. HDPE was
chosen as it is the material used for many conductive
applications such as mining hoses, drums for explo-
sives, tools for ATEX equipment, as well as conductive
power cable jacketing.
Compounds were produced on a Thermo Fisher
Haake co-rotating twin-screw extruder (16 mm screw
diameter, L/D = 40) in which the carbon black was added
downstream via a gravimetric side feeder equipped with
twin-screw. Further processing involved compression
moulding or injection moulding (ISO:3167 mould).
Figure 2 shows the classical percolation curves,
describing the electrical volume resistivity with
increasing carbon black loading of compression
moulded HDPE compounds. As expected, with the
highly structured carbon black E350G, the percolation
threshold is achieved at a lower carbon black loading.
In most industrial plastics applications, injection
moulding is used as an efcient processing technology.
Unfortunately, with this kind of processing, a decrease in
Figure 2: Percolation curves showing the electrical volume resistivity as a
function of carbon black loading, for HDPE pressed plaques containing
Ensaco 250G and Ensaco 350G
Figure 3: Percolation curves showing the electrical volume resistivity with
increasing loadings of Ensaco 250G and Ensaco 350G for injection moulded
samples and pressed plaques
conductivity is observed, especially for compounds near
the compression moulded percolation threshold
[6]
.
This effect has been explained by S.C. Jana as shear-
induced migration
[7]
, but also as structure compres-
sion by Probst et al.
[8-9]
.
In our study, the high tendency of HDPE to crystallize
certainly also plays a role; most probably the typical
compression moulding cooling rates induce a higher
proportion of crystalline region, segregating the carbon
black in a reduced amorphous phase portion, and shifting
the percolation towards the lowest concentrations.
When comparing volume resistivity measurements
of injection moulded samples to those after compres-
sion moulding (Figure 3), we see a shift of the percola-
tion threshold towards higher carbon black loadings:
E350G percolation threshold increases from 4% to 8%
while E250G shifts from 12% to 16%. It is interesting to
note that the absolute increase in the percolation
threshold remains constant.
To get the most representative comparison, the
compound characteristics (uidity and mechanical
properties) were examined at equal electrical conduc-
tivities rather than at equal carbon black loadings.
Compound melt ow indexes as a function of
electrical resistivities are shown in Figure 4; despite the
higher content, E250G shows similar if not higher
uidity (especially at high loadings) when compared to
extra-conductive carbon black.
The similar behaviour of E250G and E350G carbon
blacks at the same electrical resistivity, despite having
different carbon black loading, can be understood by
similar relative proximity of the loading amount to the
respective percolation threshold. We remember that the
percolation threshold can be dened as the loading at
which a spanning cluster will come into existence and is
different for both compounds as it depends on the
structure of the carbon black (Table 1). In other words,
when separated aggregates contact each other at the
percolation threshold, a rise in viscosity is observed
(decrease in MFI) which is proportional to the number of
interactions present.
Figures 5 and 6 present the mechanical properties
(ISO:527 and ISO:178) of the injection moulded com-
pounds showing that we have again strong similarities
of the mechanical properties. Specically, a similar
increase of the yield strength and increase of stiffness
is observed at the same electrical conductivity, despite
the large difference in carbon black loadings.
According to both tensile and exural modulus, E250G
based compounds appear stiffer. An increase in yield
strength often corresponds to a good interaction between
the polymer and the ller, as expected for two hydropho-
bic surfaces (Ensaco carbon blacks and HDPE). A similar
trend to tensile results has been found for the notched
Charpy impact properties (ISO:179/1eA); the retained
impact energy of the E250G and E350G compounds are
similar at the same volume resistivity (Figure 7).
Considering the measured properties, it is clear that
easily dispersible carbon black, such as E250G, can be
Figure 4: Melt ow rates of HDPE/Ensaco compounds (190C/5kg) as a
function of volume resistivity
Figure 5: Tensile
moduli and yield
strengths of
HDPE/Ensaco
compounds
(ISO:527) as a
function of volume
resistivity
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References and notes
[1] Global electroactive polymers market trends, applications and forecasts, Electronics.ca
publications (May 2012)
[2] J Donnet, RC Bansal and M Wang, Carbon Black, second edition, pg 271-287
[3] G Wypych, Handbook of llers, Chemtec Publishing (Toronto 2010), pg 241-243
[4] Note: the void volume is a measure to compare the structure of carbon blacks. The void
volume depends on the size and shape of the aggregate, the agglomeration of aggregates
and the porosity on the primary particles. Therefore the carbon black structure can be
considered as the sum of a number of accessible voids by unit weight: the inter-aggregate
space, the interstices within the aggregates, and the porosity of the elementary particles.
The higher the structure level of the aggregate, the higher is the volume of the voids. The
oil absorption number (OAN), described in ASTM D2414, is employed to measure the void
volume and therefore the average structure level.
[5] C Van Bellingen, N Probst, E Grivei, Meeting application requirements with conductive
carbon blacks Annual Conference of the Society of Plastics Engineers (ANTEC 2005),
Curran Associates (April 2006)
[6] SC Jana, Polymer Engineering and Science (2003) Vol 43-3, pg 570-579
[7] SC Jana, C Hong and J Kim, Polymer Engineering and Science (2004) Vol 44(11), pg
2101-2109
[8] C Van Bellingen, E Grivei, N Probst, P von Hoffmann, Addcon World 2003 Conference
Proceedings, Rapra Technologies 2003
[9] N Probst, E Grivei, Carbon 40 (2002) pg 201-205
[10] C Van Bellingen, N Probst, E Grivei Polymers and Polymer Composite (2002) Vol 10, No 1
used instead of extra-conductive carbon black, since it
retains at least the same overall properties at the same
compound electrical resistivity. The same conclusion,
drawn here for semi-crystalline polymer (HDPE), had
been already reported from the comparative testing of
E250G and E350G in amorphous polymer (polycarbon-
ate)
[10]
.
It should be noted that our conclusions are only valid
for easily dispersible and high purity conductive carbon
black such as Ensaco 250G; the use of carbon blacks
which are less pure or more difcult to disperse would
dramatically increase the level of impurities (chemical
and physical) and increase the amount of domains of
undispersed carbon black inside the compound. An
increase in such domains worsens not only the surface
quality but also introduces weak points which would
decrease the overall quality of the product.
The high structure and low surface area of E250G
has been especially designed to guarantee outstanding
dispersibility in polymer matrices, which minimizes
defects in the conductive compound and helps to retain
other material properties.
Conclusion
For conductive applications which do not necessarily
require extreme weight saving or any other added
property (for example, easy welding or low sloughing),
using nearly twice the amount of easily dispersible
conductive carbon black E250G, instead of inherently
more difcult to disperse extra-conductive carbon
black, provides both full productivity benets and an
excellent price-to-performance ratio, without sacric-
ing mechanical or rheological properties.
About the authors
Dr Daniele Bonacchi is development scientist, R&D
polymer applications with Timcal in Switzerland
(d.bonacchi@ch.timcal.com). Ing Christine Van Bellingen
is product manager, carbon black & graphite for polymers
at Timcal, Belgium (c.vanbellingen@be.timcal.com).
S www.timcal.com
Figure 7: Notched Charpy impact energies of HDPE/
Ensaco compounds (ISO:179/1eA) as a function of
volume resistivity
Figure 6: Flexural
moduli and stress
at max of HDPE/
Ensaco
compounds
(ISO:178) as a
function of volume
resistivity
Images courtesy of: Albemarle Martinswerk and LyondellBasell
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the oxo people
OXSOFT
Phthalate-free, non-VOC plasticizers www.phthalate-free-plasticizers.com
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plastribution newsletter 2011
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materials, and looks in detail at a selection of new resins.
Shepherd Color: inorganic pigments
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inorganic colour pigments (CICPs) produced by The Shepherd Color Company, which has offces in the USA, Europe, Japan and Australia.
Steer: EPZ screw elements
This 20-page brochure from Steer Engineering has details of the companys EPZ screw elements, barrels and shafts, including innovative designs that deliver higher intake, enhanced mixing and effcient conveying.
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Timcal has produced this 24-page brochure to provide technical details of its Timrex graphite and Ensaco conductive carbon black additives for polymer
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www.compoundingworld.com November 2012 | compouNdiNg world 59
Materials testing | products
melt flow testing
Zwick streamlines melt index testing
control and force control, which
adjusts test loads up to 50 kg.
Automatic parameter
control is particularly useful
for polymers with an unknown
MFR, where operator infuence
in the determination of
parameters could lead to
reductions in measurement
accuracy. Another automated
feature is push-button
pre-compacting and cleaning,
which saves additional
operator time.
Zwick says that its Mfow
extrusion plastometer is
designed for typical quality
assurance applications in
Zwick recently introduced two
new extrusion plastometers for
melt index testing. The Afow
and Mfow are part of the
companys Xfow series and
they both have new automated
features that streamline the
test process and improve
laboratory effciency.
The Afow extrusion
plastometer for determining
the melt mass fow rate (MFR)
and melt volume fow rate
(MVR) has been designed for
high throughput environments.
Automated features that
improve speed and reliability
include automatic parameter
polymer analysis
netzsch speeds up characterization
Netzsch says that its latest TG
209 F1 Libra thermobalance
enables polymer analysis to
be carried out faster, more
accurately, and across an
extended temperature range.
Its special BeFlat function
automatically compensates
for any external factors
infuencing the measurement.
The calculated DTA signal,
c-DTA, yields valuable
information on a polymers
phase transitions. This
additional information allows
for an unknown sample to be
identifed and characterized
much more easily and
precisely.
Q-Lab has opened its new,
fully-equipped contract
testing laboratory in
Saarbrcken, Germany. The
facility includes multiple QUV
weathering, Q-Sun xenon arc
and Q-Fog corrosion test
chambers. Colour, gloss and
other expert visual evaluation
services are also available.
The lab provides European
customers with many of the
same contract testing
services that are offered by
Q-Labs Florida facility.
www.q-lab.com
Q-lab opens
contract lab
in germany
weather testing
The vacuum-tight design of
the TG 209 F1 Libra not only
allows for the creation of a
pure inert atmosphere via
evacuating and flling, but also
for the execution of measure-
ments under vacuum condi-
tions. The mass loss steps
from the evaporation of the
plasticizer and the decompo-
sition of the polymer can be
clearly separated. Therefore
it becomes possible to
characterize the plasticizer
content precisely.
www.netzsch.com
areas such as R&D, QA and
goods inward checks. It
incorporates program-con-
trolled weight positioning and
removal, which streamlines
the testing process by
eliminating the need for an
operator to manually position
the weights required for each
individual test.
The modular design of the
Mfow enables easy upgrading
and retroftting. For example, it
can be ftted with extrudate
cutters, a displacement
transducer for MVR measure-
ment and a weight-lifting unit.
www.zwick.com
netzschs tg 209 f1
libra thermobalance
accelerates
polymer
analysis
putting your formulations to the test
the afow has been
developed for high
throughput
applications
we look at some of the latest materi-
als testing equipment and software
developments designed to ensure that
your new formulations deliver the
required levels of processability,
mechanical performance, appearance
and longevity. Click on the web links
at the end of each story for more
information.
products | Materials testing
mechanical testing
Tinius Olsen has launched a
range of new hardness
testers that can rapidly and
accurately determine the
hardness value of a wide
variety of materials including
plastics, large parts and
small precision components.
Covering portable, bench,
and foor-mounted testers,
the range includes method-
specifc units as well as
universal models. The latter
can run any popular hardness
colour monitoring
X-rite adds new hand-held spectrocolorimeter
surface being measured from
three different directions while
simultaneously recording 27
colour-accurate images in 1.8
seconds. With eight different
visible illuminations and one
ultraviolet illumination, the
RM200QC is able tto accurately
defne the location of a colour
in the colour space.
The instrument can give
results as a simple pass/fail
message or CIE L*a*b* values
and delta E colour differences.
It also reports results in
standard colour difference
equations and tolerances, such
as CIELAB, CMC, CIE 94, or
CIE 2000.
Its memory holds 20
standards and up to 350
measurements automatically
stamped with time and date
and saved as PDF and CSV
fles. These can be downloaded
using a USB cable so the
information can be shared
throughout the supply chain.
X-Rite has launched a new
hand-held spectrocolorimeter
the RM200QC which it says
delivers an inexpensive yet
powerful way to record and
communicate colour differ-
ences, speeding up the
introduction of new products
and reducing scrap levels.
The instrument is designed
to simplify the comparison of
the colours of lab samples or
production parts with
reference standards, creating
reports for sharing with supply
chain partners. It boasts
advanced features that identify
colour differences
between samples and
standards, opacity,
and greyscale
assessment, as well
as highlighting how
colours may change in
appearance under D65
daylight and Illuminant A
household tungsten-flament
lighting,
tinius olsen expands its range
of material hardness testers
scale test, including Vickers,
Micro-Vickers, Brinell,
Rockwell, Superfcial Rockwell,
Knoop, HBT or HVT.
The testers feature the
latest designs, hardware and
frmware to deliver fast and
accurate results. According to
Tinius Olsen, they provide very
high gauge repeatability and
data reproducibility, along with
excellent accuracies and
resolutions.
The FH series of hardness
testers use load cell based
systems to ensure enhanced
test results. Most models
incorporate the latest
full-colour touch-screen
displays and controls for easy
operation. Connectivity is via
USB port and wi-f, providing
the ability to consolidate test
results data from other Tinius
Olsen testing machines using
the companys latest Horizon
test automation software.
www.tiniusolsen.com
Target users include
masterbatch formulators,
injection moulders and
extruders, according to
Matthew Adby, product/
market manager for X-Rite.
The RM200QC is already
being used by Poppin of New
York, USA, to set colour
standards and enhance
productivity for its desk sets,
pens and pencils, which are
designed in-house for
manufacture in China.
The companys manufac-
turing personnel use the
RM200QC as a quality control
device to monitor colour
deviation between items in
production and the Pantone
standard colour. Using
L*a*b* data generated by the
RM200QC, Poppin has been
able to reduce the difference
between what New York
designers stipulate and what
is manufactured in China.
www.xrite.com
X-Rite says that the
RM200QC is inexpensive
enough for companies to
purchase multiple units that
can be stationed at individual
machines or at critical steps in
a workfow to alert quality
control personnel if a
manufacturing process is out
of control. It adds that the
instrument is particularly
suited to helping companies
that currently manage colours
by comparing incoming raw
materials or fnished products
with colour swatches, fan
decks or sample products.
A proprietary camera
technology is used in
the RM200QC to
illuminate the
This months free
brochure downloads
If you would like your brochure to be included on this page, please contact
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@
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Plastribution: know-how
In the third edition of
Plastributions know-how
magazine you can nd out
more about the newest
additions to the companys
product portfolio , including
the latest resin options for
LED applications.
www.plastribution.co.uk
0845 34 54 560
Issue 03 October 2012
the magazine
In this issue

The Olympic torch Momentum 13
Joining the App revolution 14
Recycle with industry know-how 16
Nylon replaces metal in cars 32
More effcient LEDs
Dont be left in the dark, turn to page 24 and fnd out more.
Key Filters: KCH screen-changer
This brochure from
Parkinson Technologies
features the new Key Filters
KCH continuous hybrid
screen-changer which
delivers continuous
extrusion pressure, reacting
rapidly to disruptions
caused by varying
contaminant levels.
In plastics extrusion, having the right
screen changer for your materials fltration
requirements can make the difference
between proft and loss. Parkinson
Technologies line of Key Filters products
offers customengineered solutions and
turnkey services to meet melt fltration
needs for most thermoplastic materials.
The new KCH is a development product
that joins the best features of the proven
KC product with the time-tested reliability
of the KCN product line.
Like the KCN, the KCH delivers the same
uniformcontinuous extrusion pressure,
varying as little as 20psi. However, with
hydraulic puller action, the KCH can react
rapidly to disruptions caused by varying
contaminant levels.
No process interruption translates into
increased production and decreased
scrap, bringing maximumeffciency to your
extrusion operation.
Introduces its new
KCH Continuous Hybrid Screen Changer
Parkinson Technologies Inc. Dusenbery is a registered trademark of Parkinson Technologies.
A brand from Parkinson Technologies Inc.
Shepherd: pigments for plastics
This selection guide from
Shepherd Color Company
has details of 20 different
pigments with their
properties, regulatory
approvals and applications
listed in an easy-to-read
table.
Steer: SPL40 turn-key lines
This eight-page brochure
covers Steer Engineerings
new SPL40 compounding
pelletizing systems that
include feeders, extruders,
strand die heads, water
troughs, air knives,
pelletizers and classiers.
PlasMec TRM Turbomixers
This eight-page brochure
covers PlasMecs TRM
Turbomixer, which can be
used for mixing PVC
dry-blends, producing
wood-plastics composites
(WPCs) or the hot/cold
dispersion of
masterbatches/additives.
Steer: EPZ screw elements
This 20-page brochure from
Steer Engineering has
details of the companys EPZ
screw elements, barrels and
shafts, including innovative
designs that deliver higher
intake, enhanced mixing and
efcient conveying.
How to advertise in this magazine
Use Compounding World to
promote your products and
services. This updated
media pack has full details
of our global coverage,
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2013, simple copy
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specifc sectors of the global plastics
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Profle Extrusion, Filmand Sheet
Extrusion plus Pipeline Coating. If you
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fve magazines, then the series bookings
accumulate across all of your adverts.
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Compounding World offers:
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For more information about advertising in
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Compounding World is a monthly magazine written
specifcally for polymer compounders and masterbatch
producers around the globe. It is distributed electronically and
can be read free-of-charge online. In addition, it can be
accessed on tablet computers and smartphones using our
free apps for the iPad, iPhone or Android devices.
The magazine is published by Applied Market Information
(AMI), the leading provider of market intelligence and analysis
for the global compounding and masterbatch industries.
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Compounding World with comprehensive global access to the
key purchasers of polymer additives, compounding machinery
and ancillary equipment.
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trends, business news and legislative announcements. And
unlike other general plastics magazines, Compounding World
is 100% focused on the specifc information needs of
Visit www.compoundingworld.comto see the latest issue and take out a free subscription
MEDIAINFORMATION2013
The global magazine for
polymer compounders
compounders and masterbatch producers.
Adverts are very competitively priced and can include links
straight to your own website. If you are selling machinery,
ancillary equipment, materials, additives or services to
compounders or masterbatch producers, then Compounding
World provides an extremely effcient vehicle to promote your
business globally.
CW media pack October 2012.indd 5 25/09/2012 17:36
products | Materials testing
melt flow testing
Instron describes its new
Ceast MF20 and MF30
modular melt fow testers as
versatile, single-weight
measurement systems
suitable for use both in R&D
and in advanced quality
control. They provide users
with increased convenience
for easy and accurate
measurement of the fow
properties of plastics
according to ASTM D1238
and ISO 1133.
Both instruments are said
to conform to strict toler-
ances with regard to
temperature accuracy and
stability. In particular, they
comply with the stringent
requirements of the latest
ISO 1133-2 testing standard
weather testing
atlas updates entry-level instrument
viewing for the operator, while
a choice of eight languages are
now offered (English, German,
French, Spanish, Italian,
Chinese, Polish and Russian).
Two pre-programmed test
Atlas Material Testing
Technology has updated the
design of its Suntest CPS+, a
widely-used entry-level
instrument for accelerated
materials testing. It is
particularly suitable for the
ageing of smaller specimens,
including the light and weather
testing of plastics.
The new fourth generation
model provides improved
functionality and ease of
operation. Its new features
include improved quality of
light for better performance.
Control the UV output of the
xenon test chamber has been
enhanced to eliminate areas of
instron melt fow testers meet
new iso 1133-2 requirements
for materials sensitive to
time-temperature history and/
or moisture.
The Ceast MF30 includes a
weight magazine and weight
lifter, which is also available
as an option for MF20. The
weight magazine contains a
complete set of eight test
masses ranging from 0.325 kg
(piston mass) up to 21.6 kg for
testing a wide spectrum of
materials, from fast-fowing
masterbatches to highly
viscous elastomers or flled
thermoplastics.
The newly developed
Manual Mass Selector enables
pre-selection of the required
test mass, thus facilitating
preparation and execution of
the tests.
when testing low MFR
materials.
The MF20 is offered as a
basic instrument to be
confgured with a variety of
options, such as a manual or
motorized melt cutting device
and a high-resolution digital
encoder for MVR measure-
ments according to ASTM
D1238, methods B and C.
www.instron.com
methods are also included to
help those who are new to
the use of xenon equipment.
A range of accessories are
offered, including fve
interchangeable optical
flters that simulate all
relevant light conditions:
outdoor daylight, indoor
daylight, artifcial supermar-
ket light, ID65 (ICH) and solar
standard. Other add-ons
include an immersion unit for
the simulation of extremely
wet, marine or acidic
environments, plus a chiller
and water-cooled specimen
table for specimen cooling.
www.atlas-mts.com
UV fading, while repeatability
has been improved.
In addition, the instruments
ease-of-use has been
improved. Its larger four-line
display panel provides easier
atlas says its fourth
generation suntest CPs+
provides improved
functionality.
A further standard feature
of the MF30 model is a
high-resolution load cell for
controlled compacting of the
material prior to the start of
the test up to a maximum force
of 750 N. Also included in the
test system is a high-precision
encoder that permits the
controlled extrusion of the
melt to a defned height. In
addition, the supplied software
enables purging of the barrel
at the end of a test, specifcally
Download the programmes for
these forthcoming conferences
To see our full line-up of more than 25 plastics industry events
over the next 12 months, please visit www.amiconferences.com
Pipeline Coating
AMI is holding the fth
international Pipeline
Coating conference on 18-20
February in Vienna, Austria.
This event, which attracts a
large global audience,
covers the latest
developments in pipeline
protection and coating
technologies.
Click here to download Fax back to +44 (0) 117 311 1534
Pipeline Coating 2013
Organised by:
Applied Market
Information Ltd.
Sponsored by:
Media supporters:
sPECIAL OFFER: Save 110 if you register before 14th December 2012
18-20 February 2013
Austria Trend Hotel Savoyen,
Vienna, Austria
Images courtesy of: Bredero shawand shawCor, Canusa systems and Wasco Coatings Group
International conference on pipeline protection, coating technology, materials and markets
The hugely popular Wind
Turbine Blade Manufacture
conference returns for the
third time on 27-29
November in Dsseldorf,
Germany. Download the
programme that covers the
latest materials and
processing innovations.
speCial OFFer: Save 200* if you register before 12th October 2012
* + 19% German VAT
Organised by:
Applied Market
Information Ltd.
Also sponsored by:
Image courtesy of: siemens
WIND TURBINE
BLADE MANUFACTURE
2012
International conference and exhibition on wind blade composites design,
manufacturing and markets
27-29 November 2012
Maritim Hotel, Dsseldorf, Germany
heaDline spOnsOr
Media supporters:
TM
Companies attending the
previous Polyethylene Films
conference accounted for
more than 3 billion lbs of PE
resin usage. Dont miss this
essential industry event
when it returns to Floridas
Daytona Beach on 5-6
February 2013.
The international industry
conference on markets and
technical aspects of
waterproong for roong
and geomembranes is being
held in Dsseldorf, Ger-
many, on 11-13 December.
This brochure has all the
details.
Organized by:
Applied Market
Information LLC
Images courtesy of: Bold text
for company name
The international marketing, business and technical conference for
the polyethylene flm industry
Polyethylene
Films 2013
HEADLINE SPONSORS
SPECIAL OFFER: Save $200 if you register before December 14, 2012
February 5-6, 2013
The Shores Resort & Spa,
Daytona Beach, Florida, USA
Also sponsored by: Media supporter:
Bottle im
age courtesy of:
ExxonM
obil Chem
ical Com
pany
Im
ages courtesy of: Firestone Building Products
Fax back to +44 (0) 117 311 1534
International industry conference on markets and technical aspects of
waterproofng for roofng and geomembranes
waterproof
membranes
2012
Media Supporters: Organised by:
Applied Market
Information Ltd.
SPECIAL OFFER: Save 100* if you register before 9th November 2012
* + 19% German VAT
11-13 December 2012
Hotel Nikko, Dsseldorf, Germany
HEADLINE SPONSOR
AMIs seventh Thin Wall
Packaging conference has
attracted a great line-up of
speakers from companies
such as Nestl, RPC, Linpac,
General Mills and EDV
Packaging. This brochure
has the full programme.
Thin Wall
Packaging 2012
3-5 December 2012
Maritim Hotel, Cologne, Germany
speCial OFFer: Save 210* if you register before 2nd November 2012
Organised by:
Applied Market
Information Ltd.
Sponsored by: Media supporters:
International conference on market trends and developments in
plastics tubs, cups and tray packaging
Im
ages courtesy of: n
aturew
orks llC, n
estl,
printing Com
pany Verstraete n
V.,
rpC Containers ltd. and sem
plastik
* + 19% German VAT
Wind Turbine Blade Manufacture Thin Wall Packaging
Waterproof membranes Polyethylene Films 2013
Grass Yarn & Tufters Forum
The Grass Yarn & Tufters
Forum is the international
conference covering trends
and developments in the
articial grass market. The
seventh such event is being
held in Cologne, Germany
on 18-20 February and its
inuential programme
includes FIFA.
fax back to +44 (0) 117 311 1534
Images courtesy of: DowChemical Company * + 19% German VAT
Organised by:
Applied Market
Information Ltd.
speCIaL offer: Save 210* if you register before 18th January 2013
The Grass Yarn
& Tufters
Forum 2013
Trends and developments
18-20 February 2013
Germany
heaDLIne sponsor
Media supporter:
Head ofce location: Yunlin, Taiwan
Date founded: 2005
CEO: Antony Chang
No. of employees: 40
Sales 2011: US$3 million (estimated)
Plant locations: Yunlin, Taiwan
Production 2011: 1,500 tonnes
Prole: Phon Tech is one of the leading manufacturers and exporters of styrene-based
thermoplastic elastomers (TPEs) in Taiwan. The company was established
in 2005, bringing together a team with decades of industry knowledge and
experience. Phon Tech specialises in styrenic block copolymer compounds
(SEBS) that are marketed under the brand name Phoenix.
Product line: Phoenix TPE compounds are available in transparent, translucent, white, black,
colour and over-moulding grades. They are used in applications such as medical
appliances, food/beverage closures and containers, non-slip surfaces (power
tools, bike grips, knife grips), footwear, stationery, toys, electronics and so on.
Phoenix compounds are suited to standard plastic processing including injection
moulding, blow moulding and extrusion.
Product strengths: Phon Tech claims to produce materials with excellent anti-brittle properties,
rubber-like texture, excellent UV stability and high tensile/tear strength. In
addition, the materials are odourless, chemically resistant and recyclable.
Ongoing innovation ensures the products keep pace with ever changing
customer requirements.
Phon Tech Industrial Company
compounder of the month
Forthcoming features
The next issues of Compounding World magazine will have special reports on the following subjects:
December
Laboratory compounders
Flame retardants
Compounding high-performance plastics
January
Polymer foam technologies
Pelletizers
Dispersants and coupling agents
Editorial submissions should be sent to Andy Beevers: abe@amiplastics.com
For information on advertising in these issues, please contact
Claire Bishop: claire
@
amimagazines.com Tel: +44 (0)20 8686 8139
Take out your own FREE subscriptions to any of the magazines.
Click on the logos below to simply register on-line.
Catch up on our recent
issues for FREE
Simply click on the cover to see the full magazine,
or download the issue in the relevant iPad/iPhone app
Compounding World Sept
Compounding Worlds
September issue is packed with
articles on developments in
pigments and colorants, the
North American masterbatch
industry, adding value with
mineral llers, and how to
measure the weathering
resistance of plastics.
Click here to view
Injection World October
Injections Worlds October
issue is lled with features on
the latest trends in caps and
closures, advanced medical
device applications, moulding
multi-layer optical parts, plus
innovations in thin wall
packaging.
Click here to view
Compounding World Oct
The October edition of
Compounding World contains
special features on reinforcing
bres, titanium dioxide trends,
extruder alignment
techniques, melt ltration
systems plus Fakuma show
highlights.
Click here to view
Pipeline Coating November
This new edition of Pipeline
Coating magazine boasts
features on deep sea joint
testing, shale gas
opportunities, the lining of
subsea hydrocarbon pipes, and
delivering water in Botswana.
Click here to view
Pipe and Prole Sept/Oct
The September/October issue
of Pipe and Prole Extrusion
examines the latest ideas in
co-extrusion, downstream
equipment, and PE100 resins.
It also looks at how trenchless
technology is reducing the cost
of installing plastic pipes.
Click here to view
Film and Sheet November
The November edition of Film
and Sheet Extrusion magazine
contains special features on
BOPP trends, multilayer
packaging, bioplastics research,
extruder innovations and
additives for polyolens.
Click here to view
dates for your diary
Dont miss a single issue
Register now for your free subscription at:
And dont forget to tell your colleagues, customers and suppliers
about the magazine. You can use the e-mail button above
(the
@
symbol in the browser) to help spread the word.
14-15 November Expoplast,Montreal,Canada www.expoplast.org
29 Nov 2 Dec PlastEurasia,Istanbul,Turkey www.plasteurasia.com
7-10 January ArabPlast,Dubai,UAE www.arabplast.info
29 Jan - 1 Feb Interplastica,Moscow,Russia www.interplastica.de
6-7 March PlastecSouth,Orlando,FL,USA www.plastecsouth.com
12-15 March Plastimagen,MexicoCity,Mexico www.plastimagen.com.mx
12-15 March Pro-PlasExpo,Johannesburg,SouthAfrica www.proplasafrica.co.za
3-6 April Tiprex,Bangkok,Thailand www.tiprex.com
10-11 April PlastTeknik,Malmo,Sweden www.easyfairs.com
14-16 May Plast-Ex,Toronto,Canada www.plast-ex.org
20-23 May Chinaplas,Guangzhou,China www.chinaplasonline.com
20-24 May Feiplastic,SaoPaolo www.feiplastic.com.br
18-19 June PDM,Telford,UK www.pdmevent.com
18-20 June PlastecEast,Philadelphia,USA www.plasteceast.com
10-12 September PlastecMidwest,Chicago,USA www.plastecmidwest.com
16-23 October K2013,Dsseldorf,Germany www.k-online.de
Global exhibition guide
AMI conferences
27-28 November MineralsinCompounding,Atlanta,GA,USA
27-29 November FireResistanceinPlastics,Cologne,Germany
29-31 January ThermoplasticConcentrates,CoralSprings,FL,USA
18-20 February TheGrassYarn&TuftersForum,Cologne,Germany
25-27 February Wood-PlasticComposites,Vienna,Austria
5-7 March Cables,Cologne,Germany
12-14 March PVCFormulation,Dsseldorf,Germany
18-20 March MasterbatchAsia,Singapore
19-21 March GreenPolymerChemistry,Cologne,Germany
7-8 May BioplasticsCompounding&Processing,Miami,FL,USA
14-15 May PolymersinCables,Miami,FL,USA
14-16 May PolymerSourcing,Vienna,Austria
3-5 June Masterbatch,Frankfurt,Germany
For information on all
these events and other
conferences on flm,
sheet, pipe and
packaging applications, see
www.amiplastics.com

CW November 2012

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November 2012

SELECTING THE RIGHT CARBON BLACK

BUSS Kneader Series

Krntner Montanindustrie (KMI)

KMI uses unique processing

These minerals have a higher aspect

With KMIs Phlogopite in combination

C per minute, which is

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