Waxes for applications in PVC

Luwax

Luwax

Waxes for applications in PVC

1.

BASF products
1.1 1.2 Survey of the different product grades Survey of BASF products for applications in plastics

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2.

General information on PVC

2.1 Ingredients and their functions

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3.

Waxes and their applications in PVC

3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 Window profiles PVC pipes PVC fittings Rigid PVC film PVC bottles PVC cables Plasticized PVC products Compounds

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4.

Torque measurements with different Luwax types

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= registered trademark of BASF Aktiengesellschaft

Contents

BASF products

1.1 Survey of the product grades

Eth y lene homo poly mer waxes The high-pres sure pro duc tion pro cess employed by BASF makes it pos sible to man u fac ture a very diverse range of LD and HD eth y lene homo poly mer waxes with molar masses of 3500 and 7000 g/mol respec ti velly. The eth y lene homo poly mer waxes sup plied by BASF the Luwax A types are pre pared from pure eth y lene, which means that they do not con tain any func tional groups. The chem i cal struc ture of eth y lene homo poly mer waxes deter mines their phys i cal prop er ties and their suit abil ity for spe cific appli ca tions. Oxidized polyethylene waxes Oxi dized homo poly mer poly eth y lene waxes differ in terms of their molar mass, hard ness and acid num ber. It is char ac ter is tic of the Luwax OA types that they con tain different pro por tions of acid groups in the poly mer mole cule. These acid groups make the Luwax OA types easy to emul sify. Montan waxes Montan waxes can be divided up into montanic acid waxes Luwax S and Luwax LS and montanic ester waxes Luwax E; Luwax LG and Luwax OP. Both types of wax contain functional groups in the form of long-chain, unbranched carboxylic acids and short-chain alcohols. Montan waxes are highly polar.

BASF products

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Density (23C) DIN 53479 [g/cm 3] 0.910 0.930 0.930 0.950 0.910 0.925 approx. 0.96 approx. 0.99 approx. 0.95 approx. 0.99 0.98 1.00 0.97 1.00 0.98 1.00

1.2 Survey of BASF products for applications in plastics

BASF Waxes
Waxes Physical form Special features Melting point (DSC) DIN 51007 [C] 101 109 108 116 102 108 103 112 contains up to 10% residual water 126 133 102 110 contains up to 10% residual water 126 133 75 85 partially saponified on request 75 85 Acid number DIN EN 53402 [mgKOH/g] 0 0 0 19 20 15 25 24 19

Luwax A Luwax AH 6 Luwax AL 3 Luwax OA 2 Luwax OA 3 Luwax OA 5 Luwax ES 9696 Luwax E Luwax OP Luwax S

Powder Granules Powder Granules Powder Pastilles Powder Powder Pastilles Powder Powder Flakes Powder Flakes Powder Flakes

17.5 19 15 7 20 14

135 160

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* These products are included in the following formulations (1) Solvin is a joint venture between Solvay and BASF (2) Supplied by Henkel

Other Products*

Product Solvin 258 RF 1) Solvin 460 SL 1) Solvin 260 RF 1) Solvin 264 GB 1) Solvin 267 RC 1) Solvin 271 PC 1) Solvin 178 GE 1) Loxiol G 60 2)

Chemical nature/function PVC in powder form PVC in powder form PVC in powder form PVC in powder form PVC in powder form PVC in powder form PVC in powder form Dicarboxylic ester of a saturated fatty alcohol/ Internal lubricant

General information on PVC

2.1 Composition
Pure PVC is very diffi cult to pro cess, and var i ous addi tives need to be employed in order to man u fac ture viable prod ucts from it. Var i ous different addi tives can be used to make the plas tic hard and rigid or soft and flex ible as demanded by the appli ca tion in ques tion. The ver sa til ity of PVC enables it to be used in a very wide range of appli ca tions. Ingredients of PVC blends: Polyvinyl chloride Heat stabilizers Lubricants Plasticizers Pigments Miscellaneous additives

2.1.1 Polyvinyl chloride

Various different types of PVC are available, such as suspension-polymerized, emulsion-polymerized and mass-polymerized PVC with different K values, etc. The choice of PVC resin depends on the application in question.

2.1.2 Heat stabilizers

Heat stabilizers are generally added during the processing of PVC to protect it from thermal damage (e.g. lead (Pb), tin (Sn) and calcium/zinc (Ca/Zn) stabilizers). Metal-based stabilizers are increasingly the subject of debate about their toxicology and ecological behavior. The trend, partly determined by law and partly the result of voluntary commitments, is therefore to move away from lead and tin toward calcium/zinc. Calcium/zinc stabilizers require the use of substantially more wax than lead or tin. However, there are no clear guidelines as to how much the amount of wax needs to be increased. Rather, this must be determined empirically.

General information on PVC

2.1.3 Lubricants
A distinction needs to be made between internal and exter nal lubri cants, because they have a different mode of action. Inter nal lubri cants such as Luwax S improve the rhe ol ogy of the melt and shorten plas tifi ca tion time. They are highly com pat ible with PVC, which is polar, and they form a homoge ne ous blend. Exter nal lubri cants such as Luwax A, Luwax AH 6 and Luwax AL 3 have a low affin ity for PVC, and so they are not homog e nized in the melt. They pre vent the melt from stick ing to machin ery. The melt takes longer to be plas ti cized than if it con tains inter nal lubri cants. Some waxes, such as Luwax E, Luwax OP, Luwax OA 2, Luwax OA 3, Luwax OA 5 and Luwax ES 9696 have a hybrid action. They act as inter nal and exter nal lubri cants. The plas tifi ca tion time is shorter than with exter nal lubri cants, and they have a rel a tively good anti-stick effect.

2.1.4 Plasticizers
Plasticizers are used to increase the flexibility of plastics. Rigid PVC does not contain any plasticizers, and it is used for pipes, window frames and bottles, etc. Plasticized PVC contains between 10 % and 80 % plasticizer, and it is used for cable sheathing, hoses and film, etc.

2.1.5 Pigments
PVC products can be coloured with various different pigments. Pigments are only used to modify the visual appearance of the plastic.

2.1.6 Other additives

Various other additives can be added to PVC, such as the following. UV absorbers, Impact modifiers, Antioxidants, Antistatics.

Waxes and their applications in PVC

Application

Function

Waxes

Window profiles

External lubricant Internal external lubricant

Luwax A Luwax Luwax Luwax Luwax OA 2 OA 3 OA 5 ES 9696

Panels

External lubricant Internal external lubricant

Luwax A Luwax AL 3 Luwax Luwax Luwax Luwax OA 2 OA 3 OA 5 ES 9696

PVC pipes

External lubricant

Luwax A Luwax AL 3 Luwax AH 6 Luwax OA 2 Luwax OA 3 Luwax ES 9696 Luwax A Luwax OA 2 Luwax OA 3 Luwax ES 9696 Luwax A Luwax E Luwax OP Luwax E Luwax OP Luwax OA 5 Luwax AL 3 Luwax OP Luwax AL 3 Luwax OA 2

Internal external lubricant

PVC fittings

External lubricant Internal external lubricant

PVC film

External lubricant Internal external lubricant

PVC bottles

Internal external lubricant

PVC cables

External lubricant Internal external lubricant

Plasticized PVC products

External lubricant Internal external lubricant

Waxes and their applications in PVC

3.1 Window frames

Formulations for extruded profiles for window frames contain a range of additives that are used to improve the mechanical stability of the plastic. Homopolymer polyethylene waxes prevent PVC from sticking to hot machine components. Oxidized polyethylene waxes shorten the plastification time of the PVC melt. They increase the friction and the shear in the extruder. This makes it pos sible to homog e nize the melt more quickly, and also makes the extruded pro files more mechan i cally stable. The effi ciency of the pro cess ing machin ery is enhanced, and the out put of extruded pro files can be increased. Recommended waxes: Luwax A Luwax OA 2 Luwax OA 3 Luwax OA 5 Luwax ES 9696 Typical formulation: 100.0 parts Solvin 258 RF 3.2 parts Lead stabilizer (Pb sulphate or stearate) 7.0 parts Titanium dioxide or chalk 0.4 parts Loxiol G 60 0.7 parts Calcium stearate or hydroxystearic acid 0.1 parts Luwax A 0.2 parts Luwax OA 2

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Waxes and their applications in PVC

3.2 PVC pipes

There are two different types of PVC pipes: Pressure pipes (for water supply, etc.) Pressureless pipes (for waste water, etc.) Pipes are produced by extrusion. Homopolymer polyethylene waxes are used as external lubricants, and oxidized polyethylene waxes as internal/external lubricants. The ingredients are blended in a high-speed mixer before they are extruded. The dry blend is hot owing to the high friction in the mixer, and this enables it be plasticized easily and processed directly in the extruder. Recommended waxes: Luwax A Luwax AL 3 Luwax AH 6 Luwax OA 2 Luwax OA 3 Luwax ES 9696 Typical formulation: 100.0 parts Solvin 267 RC 0.6 parts Basic lead sulphate 0.6 parts Lead stearate 0.4 parts Calcium stearate 0.4 parts Luwax A 0.2 parts Luwax OA 2

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Waxes and their applications in PVC

3.3 PVC fittings

Fittings, such as the connectors and adapters used in piping systems, are manufactured by injection moulding. Homopolymer polyethylene waxes are used as external lubricants, and oxidized polyethylene waxes as internal/external lubricants. The ingredients are blended in a high-speed mixer before they are extruded. The dry blend is hot owing to the high friction in the mixer, and this enables it, to be plasticized easily and processed directly in the extruder. Recommended waxes: Luwax A Luwax OA 2 Luwax OA 3 Luwax ES 9696 Typical formulation: 100.0 parts Solvin 258 RF

2.0 3.0 parts Basic lead sulphate 0.2 0.6 parts Lead stearate 0.3 0.6 parts Calcium stearate parts Distearyl phthalate 0.2 parts Luwax 0A2

0.2 0.4 parts Luwax A

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Waxes and their applications in PVC

3.4 Rigid PVC film

The waxes that are used as lubricants in the production of calendered film from rigid PVC are expected to have the following properties. Good compatibility with the PVC resin External lubricating action No migration from the plastic High transparency These features are especially important in the production of thin, highly transparent film. Because of the high transparency, only montan waxes are used here. PVC is preplasticized with all additives, including wax, in an extruder and then sent hot to the calender. Recommended waxes: Luwax E Luwax OP Typical formulation: 100.0 parts Solvin 460 SL

1.0 1.5 parts Organic tin stabilizer 1.0 2.0 parts Processing aids 0.6 0.8 parts Internal lubricant 0.2 0.4 parts Luwax E

Luvitherm film The Luvitherm process employs emulsion-polymerized PVC and, unlike normal extrusion processes for manufacturing film, it requires the use of an external lubricant. Recommended waxes: Luwax E Luwax A Typical formulation: 100.0 0.35 parts Solvin 178 GE parts Organic tin stabilizer

3.2 3.5 parts Luwax E 0.3 0.5 parts Luwax A

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Waxes and their applications in PVC

3.5 PVC bottles

Two different types of sta bi lizers, tin sta bi liz ers and cal cium/zinc sta bi liz ers, are used in the pro duc tion of PVC bot tles. Tin-sta bi lized bot tles are used in the food stuffs indus try for pack ag ing oil and vin e gar, and they are also used for cos met ics. Cal cium/zinc-sta bi lized bot tles are used by the soft drinks indus try. The waxes/lubri cants used in this appli ca tion have to ful fil the fol low ing cri te ria. High transparency Pronounced external lubricating effect Conformity with food-contact legislation Neutral taste and odour Tin-stabilized bottles Recommended waxes: Luwax OP Luwax OA 5 Typical formulation: 100.0 parts Solvin 258 RF

8.0 10.0 parts Impact modifier 1.5 2.0 parts Organic tin stabilizer 0.2 0.4 parts Luwax OP 0.2 0.4 parts Luwax OA 5

Calcium/Zinc-stabilized bottles Recommended waxes: Luwax OP Luwax OA 5 Typical formulation: 100.0 parts Solvin 258 RF

8.0 10.0 parts Impact modifier 0.5 0.8 parts Calcium/zinc stabilizer 5.0 0.2 parts Epoxidized soya bean oil parts UV-Stabilisator

0.8 1.2 parts Hydrated castor oil (internal lubricant) 0.2 0.4 parts Luwax OP 0.2 0.4 parts Luwax OA 5

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Waxes and their applications in PVC

3.6 PVC cables

Plasticized PVC is used to sheath and insulate electrical cables. The PVC is processed in an extruder. Waxes/lubricants have to meet the following requirements. A high dielectric constant and specific resistance A pronounced external lubricating action owing to the presence of plasticizers. Lubricants with a pronounced external action have to be used here, because the plasticizer is reducing the external action of the lubricant. Recommended waxes: Luwax OP Luwax AL 3 Typical formulation: 100.0 parts Solvin 271 PC

30.0 50.0 parts Plasticizer 0.2 3.0 parts Basic lead sulphate 0.2 0.3 parts Luwax OP 0.2 0.4 parts Luwax AL 3

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Waxes and their applications in PVC

3.7 Plasticized PVC products

Plasticized PVC is used for the following applications. Film Hoses Shoe soles Imitation leather The waxes/lubricants have to fulfil the following criteria. A large reduction in tack A pronounced external lubricating action The lubri cants that are used in the pro cess ing of plas ti cized PVC are mainly inter nal lubri cants, and they are only used in extreme cases. Garden hoses are a typ i cal exam ple, because they con tain a high pro por tion of plas ti cizer and they have a very pro nounced ten dency to become tacky. Luwax OA 2 is used in for mu la tions of this type alone or in combination with Luwax AL 3 at a rate of 0.5 1.0%.

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Waxes and their applications in PVC

3.8 Compounds
The Luwax types are incor po rated in addi tive com pounds. These one-pack com pounds con sist of mix tures of sta bi liz ers and lubri cants, and they are for mu lated for PVC pro ces sors. The cus tomer merely needs to blend in the PVC resin. The great advan tage of these com pounds is that they are com pletely homo ge ne ous, their exact com po si tion is known and they do not dust. They are easy to pro cess, because there is no dan ger of that too much addi tive will be added or that the mix ture will be inho mo ge ne ous. These com pounds can con tain the fol low ing ingre dients: Pb, Ca/Zn or Sn sta bi liz ers Impact mod i fi ers Waxes and other lubri cants Com pounds for win dow frames usu ally con tain sta bi liz ers and lubri cants based on lead and cal cium/zinc. Com pounds for pipes usu ally con tain sta bi liz ers and lubri cants based on lead, cal cium/zinc, cal cium/tin and tin. Com pounds for bot tles usu ally con tain sta bi liz ers and lubri cants based on cal cium/zinc and tin, because of the required high trans pa rency. Com pounds for cables usu ally con tain sta bi liz ers and lubri cants based on lead and cal cium/zinc. Bar ium/zinc and cal cium/zinc sta bi liz ers are used for PVC hoses.

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Torque measurement with different Luwax types

The torque meas ure ments in the table below show the effects of different Luwax prod ucts on the plas tifi ca tion time of a Ca/Zn-sta bi lized PVC for mu lation. Conditions: Weight Temperature Rate of revolution Formulation (Ca/Zn-stab.PVC) 5 kp 160C 40 U/min/rpm

100.0 parts Solvin 258 RF 2.5 parts Ca/Zn stabilizer 0.3 parts Costabilizer 0.6 parts Loxiol G 50 2.0 parts Titanium dioxide 4.0 parts Chalk

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Torque measurement with different Luwax types

Wax concentration 0.3% without wax Luwax A Luwax AL 3 Luwax OA 2 Luwax OA 5

Plastification time [min] 2.4 6.9 6.3 4.8 6

Torque max. [Nm] 64.5 51 50 54.5 53

Final torque [Nm] 42.5 42 42 41.5 41.5

Measured temperature [C] 208 203 203 208 208

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Note The data contained in this publication are based on our current knowledge and experience. In view of the many factors that may affect processing and application of our product, these data do not relieve processors from carrying out their own investigations and tests; neither do these data imply any guarantee of certain properties, nor the suitability of the product for a specific purpose. Any descriptions, drawings, photographs, data, pro portions, weights etc. given herein may change without prior information and do not constitute the agreed contractual quality of the product. It is the responsibility of the recipient of our products to ensure that any proprietary rights and existing laws and legislation are observed. Safety We know of no ill effects that could have resulted from using our products for the purpose for which they are intended and from processing them in accordance with current practice. According to the experience we have gained up to now and other information at our disposal, our products do not exert any harmful effects on health, provided that they are used properly, due attention is given to the precautions necessary for handling chemicals, and the information and advice given in our safety data sheet are observed. Labelling Details about the classification and labelling of our products and further advice on safe handling are contained in the current safety data sheets.

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EVD 409 e 10. 2007 supersedes edition ESA/C 409 d, e dated July 2005

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