CW August 2012

August 2012
SOFT OPTIONS: NEW PVC PLASTICIZERS CARRIER MATERIALS FOR MASTERBATCH DEVELOPMENTS IN REACTIVE EXTRUSION fOAMED PLASTICS FOR LIGHTER CARS
Introducing
on the iPad, iPhone and Android-based devices
App sponsored by
Having led the way with high-quality digital-only magazines for the global plastics industry, AMI is now also making its titles available free-ofcharge on the iPad, iPhone and a wide range of Android-based smartphones and tablet computers. The dedicated apps for Compounding World magazine are now ready to download from Apples App Store and iTunes or from the Google Play Store. Just search for AMI Plastics. Current and past copies are available free-of-charge and new issues will be added to the apps as soon as theyre published. If you are using Apples latest iOS 5 operating system, then the magazines will appear in your Newsstand and new editions will be added automatically if you sign up for our free subscription. The Compounding World app is sponsored by Leistritz, a leading supplier of twin-screw extruders.
ANDROID VERSIONS NOW AVAILABLE

CHECK OUT OUR OTHER FREE APPS: AMI has also launched free apps for its three other digital magazines Injection World, Pipe and Profile Extrusion and Film and Sheet Extrusion. Plus theres an additional AMI Conferences app featuring brochures for our forthcoming events. Simply search for AMI Plastics in iTunes, Apples App Store or the Google Play Store.
contents
05 Industry news
page 17
The latest compounding industry news including international acquisitions and alliances, plus new investments and plant openings.
17 Developments in masterbatch carriers

page 27
The search for the perfect carrier material continues. Jennifer Markarian looks at new developments for masterbatches, plus porous carriers for liquids.
27 PVC plasticizers: the search for soft options

Pressure on phthalates is driving interest in alternative plasticizer options, with bio-based products joining a growing range of options. Chris Smith reports.
page 41
41 Chain reaction
The polymer modification potential of reactive extrusion is being used in a variety of applications including the production of novel bio-based blends.
page 45
45 Expanding interest in lightweight parts

Chris Smith examines how the need to reduce part weight and cost is driving interest in foamed injection moulding technologies.
53 New products: polymers and additives

page 53
58 Compounder of the month: Polycompound 60 Dates for your diary
coming next issue

Pigments and colorants Masterbatch trends Mineral fillers
Click here to make sure you get your copy
contact us
Applied Market Information Ltd AMI House, 45-47 Stokes Croft, Bristol, BS1 3QP, United Kingdom Tel:+44 (0)117 924 9442 Fax:+44 (0)117 989 2128 www.amiplastics.com Head of business publishing: Senior editor: Contributing editor: Designer: Advertisement manager: Andy Beevers Chris Smith Jennifer Markarian Nicola Crane Claire Bishop E-mail: abe@amiplastics.com E-mail: cs@amiplastics.com E-mail: editorial@compoundingworld.com E-mail: claire@amimagazines.com Direct tel: +44 (0)20 8686 8139
Copyright Applied Market Information. No part may be reproduced without the prior written permission of the publisher.
www.compoundingworld.com August 2012 | compounding world 3
quan tec 96 EV-10C
BUSS KNEADER TECHNOLOGY
Cutting-Edge Compounding Technology MX and quan tec BUSS Kneader Series

BUSS innovative 4-flight screw technology sets new benchmarks in the economical processing of temperature and shear sensitive plastics such as PVC and high grade cable compounds:
> > >
2.5 times higher throughputs Enhanced mixing quality and dispersion Energy savings up to 25%
Buss AG Hohenrainstrasse 10 4133 Pratteln Switzerland
Phone +41 61 825 66 00 Fax +41 61 825 68 58 info@busscorp.com www.busscorp.com
news
Manufacturers defend flame retardants in the US Senate

Representatives of the leading producers of brominated flame retardants responded to questioning by US senators in Washington DC on 24 July. The hearing before the Committee on Environment and Public Works followed allegations published by the Chicago Tribune that the flame retardants industry has misled the public and legislators about fire safety and health and safety issues. Marshall Moore, director of technology, advocacy and marketing at Chemtura, said: Flame retardants have received a significant amount of attention in recent months some of which has been inaccurate and misleading. He added Chemtura stands by its products. We have acted proactively with the Environmental Protection Agency (EPA) and other agencies not only to fully comply with chemical management (ACC) asking it to expel Chemtura, Albemarle and ICL from its membership. The legislators claim that the companies have acted unethically and do not confirm to the ACCs Responsible Care programme. They highlight the companies formation of a front group, called the Citizens for Fire Safety (www.cffsi.org), to counter the opposition to flame The debate about fire retardants has reached Capitol Hill regulations, but also to lead the industry in the introduction of greener alternatives. William Rawson of legal firm Lathan & Watkins represented the two other leading producers of brominated flame retardants, Albermarle and ICL. His testimony covered the Toxic Substances Control Act (TSCA), acknowledging the need for amendments, but warning against steps that could create enormous regulatory burdens. Moores written statement can be read in full at http://bit.ly/FRstatement1, while Rawsons testimony is at http://bit.ly/FRstatement2. You can view a video of the full hearing before the committee at http://bit.ly/FRvideo1. l Following the Chicago retardants. The three flame retardant manufacturers have told the Chicago Tribune that they are now reviewing their involvement in the organisation. The ACC responded by saying Albemarle, Chemtura and ICL Industrial Products have great confidence in their chemistries, supported by substantial testing and studies on safety and efficacy. You can read the legislators letter at http://bit.ly/ACCrequest, while the ACCs response is at http://bit.ly/ACCreply.
Tribune reports, 21 state legislators have written to the American Chemistry Council
Evonik invests in its crosslinking additives

Evoniks new capacity will meet growing demand from the photovoltaics industry Evonik is increasing capacity for its TAC and Taicros crosslinking additives for plastics and rubber at its Wesseling site in Germany. Production is scheduled to start in the fourth quarter of next year. The company says that the increased capacity will help it meet growing demands from the photovoltaics market and the increasingly stringent quality requirements of
www.compoundingworld.com
manufacturers in this sector. Crosslinking additives are used to improve the quality of the encapsulation films that protect photovoltaic cells, particularly in regard to ageing and colour stability, while increasing the transparency of the films. The boosters also reduce the cure time of the EVA films, thus increasing the efficiency of the production process.
www.evonik.com
August 2012 | compounding world 5
news
Europe adds new biocide regulation

The European Commissions new Biocidal Products regulation came into effect on 17 July and the regulatory requirements for the industry will apply from 1 September 2013. The new regulation sets rules for placing biocidal products on the market. It aims to simplify and harmonise the procedures for authorisation and at the same time ensure a high level of protection of human health and the environment. As with its predecessor, the Biocidal Products Directive, only biocidal products with approved active substances may be authorised to be placed on the market. A new element in the regulation is the Union Authorisation, allowing companies to get an authorisation for their biocidal products applicable across the whole EU. The European Chemicals Agency (ECHA) is preparing to start the new regulatory processes, recruiting additional staff and developing new IT tools that take advantage of synergies with REACH. The organisations task will be to coordinate the approval processes of biocidal substances and the authorisation of biocidal products at the Union level. The ECHAs guides to the new biocide regulation can be found online at:
Sabic plans to increase Stamax LGFPP capacity

Sabic Innovative Plastics is increasing capacity for its Stamax long-glass-fibre-filled polypropylene (LGFPP) composites at its Genk plant in Belgium. Work has started on a new production line that is scheduled to start operation in the second half of 2013. The Genk PP compounding facility was opened in 2010 with a 30,000 tonnes/year Stamax LGFPP line alongside two lines for other PP compounds with a combined capacity of 100,000 tonnes/year. These made it the largest greenfield compounding plant ever built in Europe. Leon Jacobs, Sabic Innovative Plastics automotive leader in Europe explained that the plant was designed to be expanded when required. It took only two years before we needed to scale up with this new, state-of-the-art production line because our Stamax composite resins have become a material of choice for a growing number of automotive applications. Stamax composites are produced using a proprietary wire coating process that allows higher line speeds than pultrusion. The LGFPP composites produced at Genk go to Europe and Asia, while the American market is served by Sabics Bay St. Louis site in Mississippi. The company reports that Stamax is being used in a growing variety of automotive applications. In addition to front-end modules, door modules and seating structures, it is now also being applied in tailgate structures and under-the-hood applications where heat is non-critical. Sabic is expanding Stamax capacity at its huge Genk compounding plant in Belgium
www.sabic-ip.com
Styrolution extends PW agreement

Styrolution has signed a trademark license agreement with Plastic World (China) for the production of acrylonitrile styrene acrylate (ASA), acrylonitrile butadiene styrene (ABS) and high-heat acrylonitrile butadiene styrene (HH ABS) for the Chinese market. Plastic World (PW) has been colour compounding Styrolutions styrenic polymers, ABS and high-impact polystyrene (HIPS) for the Chinese market at its Shenzhen plant since 2002. Under this new agreement, the facility will produce ASA, ABS and HH ABS according to the specifications and conditions set out by Styrolution. The additional capacity of 4,500 tonnes/year at this facility will complement Styrolutions existing production in the region at Ulsan, South Korea, and Map Ta Phut, Thailand. The BASF and Ineos joint venture markets ASA under the Luran S brand, while ABS and HH ABS are sold as Terluran, Terluran HH, Novodur and Lustran. Hyung Tae Chang, Styrolutions Asia-Pacific president said: This agreement allows us to deepen our relationship with PW and is a positive step forward for us as we look to further strengthen our global market leadership, expand our product offerings and be closer to our customers in China.
http://bit.ly/Biocide
6
www.styrolution.com www.plasticworld.com.hk
compounding world | August 2012
solar reection with color

Huntsman introduces ALTIRIS infrared reflecting pigment
ALTIRIS pigment reflects infrared energy which can help reduce heat build-up in exterior polymer products, especially in dark and vibrant colors. ALTIRIS can give infrared reflectance from a single additive, making it easy to formulate into a wide range of colorful polymer products.
To learn more please visit the ALTIRIS pigments website or email us at altiris@huntsman.com
Follow @HuntsmanAltiris on Twitter For further info click here
This advertisement contains general information about the properties of the products described in it. Information is updated regularly. To check whether this is the most recent information, or if you would like more information, you can find contact details on www.huntsman.com/pigments. Huntsman does not recommend any of its titanium dioxide pigments for use in leadstabilized, rigid PVC formulations. Information is given in good faith but we do not guarantee the accuracy or completeness of the information. NOTHING IN THIS ADVERTISEMENT IS TO BE CONSTRUED AS A WARRANTY, EXPRESS OR OTHERWISE. IN ALL CASES IT IS THE RESPONSIBILITY OF THE USER TO DETERMINE THE APPLICABILITY OF THE INFORMATION AND RECOMMENDATIONS AND THE SUITABILITY OF THE PRODUCTS DESCRIBED FOR ITS OWN PARTICULAR PURPOSE. Unless otherwise agreed in writing, all sales of products referred to in this publication are subject to the general terms and conditions of sale of Huntsman International LLC or its affiliated companies. ALTIRIS is a registered trade mark of Huntsman Corporation or an affiliate thereof in one or more, but not all, countries. 2012 Huntsman Corporation.
news
Arkema sells stabilizers to PMC

Arkema plans to sell its tin stabilizer business to the PMC Group. The deal, which is expected to be completed this autumn, includes Arkemas Thermolite heat stabilizers for PVC compounds plus Fascat catalysts and fine chemicals. PMC will take over Thermolite PVC stabilizers The tin stabilizer business has a turnover of approximately E180 million, employs 234 people and runs four industrial sites around the world. The plants in Beijing, China, and in Carrollton, Kentucky, USA will be transferred to PMC along with certain assets of Arkemas facility at Mobile, Alabama, USA. In addition, part of the Vlissingen site in the Netherlands will be run by Arkema on behalf of PMC. Arkema says that the tin stabilizers sale is part of it strategy to refocus its activities on fast growing core specialty businesses. It sold its vinyl division to the investment company Klesch in November 2011. Headquartered in Mount Laurel, New Jersey, USA, the PMC Group manufactures performance chemicals including a wide range of plastics additives and masterbatches.
www.arkema.com www.pmc-group.com
Itochu signs CNT deal with SWeNT

SouthWest NanoTechnologies (SWeNT) has appointed Itochu Plastics to distribute its carbon nanotube (CNT) products throughout Asia. The agreement covers commercially-produced specialty multi-wall and single-wall CNTs. SWeNTs CEO Dave Arthur said:Sales opportunities in several key target markets are increasingly to be found in Asia, and the need for a strong distribution partner there has become evident. Itochu is the ideal partner to help us maximize our penetration of display, semiconductor, energy storage and advanced composites markets. The research market in Asia will continue to be served by Sigma-Aldridge.
Vinyl Compounds adds new line

Vinyl Compounds of the UK has ordered another Battenfeld-Cincinnati extrusion line for the production of rigid and flexible PVC granules. It brings the total number of compounding lines at the companys plant to eight, all based on Battenfeld-Cincinnati extruders. The new line features a BEX 2-130-22V twin-screw extruder with an energy-efficient AC drive, a nitrided steel barrel and an electrically adjustable shear gap. Its screws are optimized for the application and nitrided and coated for wear resistance, with a double venting zone and internal screw temperature control. The lines hot-cut pelletizer includes a swing-mounted head and die. Outputs between 1,200 and 2,000 kg/h can be achieved for flexible PVC compounds and between 850 and 1,500 kg/h for rigid PVC formulations, depeneding on the application. Richard Loynes, commercial director at Vinyl Compounds, said: We have been buying Battenfeld-Cincinnati machinery since 1976 and have always been really happy with their performance; this has been proven time after time by us coming back to buy new machines. Battenfeld-Cincinnati has updated its EMS extruders for pelletizing/compounding applications. It says that it has recently achieved the highest number of orders for compounding machines in its history, with a total of 15 orders in one year. Finalising the deal at the NPE 2012 exhibition in Florida: Battenfeld-Cincinnatis regional sales manager Hartmut Hachmeister together with Vinyl Compounds managing director Chris Makin and commercial director Richard Loynes
www.swentnano.com www.itc-ps.co.jp/e
8
www.battenfeld-cincinnati.com www.vinylcompounds.co.uk
news
Sun Chemical acquires metallic effects supplier Benda-Lutz

Sun Chemical and its parent company, DIC, have completed the purchase of Benda-Lutz Werke, a leading manufacturer of metallic effect products based in Austria. The acquisition means that Sun Chemical will gain production facilities in Austria, Poland, Russia and the US to accompany its existing aluminium pigment manufacturing site in China. They will be combined to create a new global Metallics Business Unit This acquisition of Benda-Lutz will enable Sun Chemical to further expand our metallic effects offerings to our core coatings, plastics and graphic arts markets, while accelerating growth in future strategic areas such as specialties, cosmetics and electronics, said Myron Petruch, president of Sun Chemical Performance Pigments and Electronic Materials. As a 102-year-old family business, Benda-Lutz has rapidly grown over the last 25 years from a European to a global provider, and we look forward to leveraging Sun Chemical and DICs capabilities to grow Benda-Lutzs unique products and technologies in the marketplace, added Martin Lutz, managing director of Benda-Lutz Werke. Sun Chemicals acquisition of Benda-Lutz will expand its metallic effects range for plastics
www.sunchemical.com www.benda-lutz.com
Georgia Gulf plans PPG deal

PPG plans to separate its commodity chemicals business and merge it with Georgia Gulf. Schulmans new corporate headquarters will include its Product Technology Center The US$2.1 billion transaction, which will double the size of Georgia Gulf, is expected to be completed in late 2012 or early 2013. Georgia Gulf is a major North American producer of chlorovinyls and aromatics, as well as a leading PVC compounder. PPGs commodity chemicals business includes chlorine production, which will provide Georgia Gulf with additional feedstocks for its PVC production.
Schulman begins construction of new headquarters building

A Schulman has broken ground for its new corporate headquarters in Fairlawn, a suburb of Akron, Ohio, USA. The new building, which is due to be completed in 2013, is just two miles from the companys current HQ. The 34,000 ft (3,200 m )
2 2
Akron area staff are going to be consolidated into the one location and the companys Product Technology Center will also be relocated as part of the move. We are excited to move to a new building that will more efficiently accommodate all of our corporate staff and will serve as our US headquar-
ters, said Joseph Gingo, Schulmans chairman, president and CEO. We are thrilled that we will be able to remain in Fairlawn. Our new headquarters will serve as our global base to support the strategic expansion of our business in markets around the world.
facility will accommodate approximately 130 employees.

10
www.aschulman.com
www.ggc.com
news
US could face tougher chemical regulations

The US Senates Committee on Environment and Public Works has moved forward legislation that proposes major changes to the Toxic Substances Control Act (TSCA). If the proposal is passed by the full legislature, then it would make it much more difficult to achieve federal approval of chemicals. In effect, the onus would be on the chemicals industry to prove that chemicals are safe before they are used, rather than requiring that federal environmental officials prove that a chemical is harmful before it is banned. This proposed change is similar to the REACH legislation currently being implemented in Europe. The American Chemistry Council (ACC), which had been working on a bipartisan negotiating process for TSCA reform, reacted with dismay at the decision, saying: We are very disappointed that Senators Boxer and Lautenberg moved forward with a partisan mark-up of a bill that is inconsistent with the bipartisan negotiations that had just gotten underway in mid-June. We are also troubled that less than 24 hours before the mark-up Senator Lautenberg released a 174-page revised version of Frank Lautenberg, US Senator for New Jersey, has been pushing for TSCA reform the Safe Chemicals Act. After a cursory review, we believe the bill is still fundamentally flawed in many critical areas. Specifically, the bill would establish an unworkable safety standard, and would require an enormous amount of additional government resources to implement. The bill would also dramatically increase the time it would take for the Environmental Protection Agency (EPA) to review new chemicals. The future of the bill is uncertain as the committees vote was divided along party lines, with Republicans opposing the decision. It is therefore likely that its full progress would depend upon a negotiated compromise between the two political parties. The ACCs guide to TSCA modernisation can be found at:
Solvay starts up Chinese compounding

Solvay has started production at its new specialty polymer compounding plant at Changshu in Chinas Jiangsu province. The E21 million facility is producing grades of Amodel polyphthalamide (PPA), Ixef polyarylamide (PARA) and Kalix modified PARA. It is mainly serving China-based customers in the electronics, automotive, consumer and industrial markets. The start-up of our compounding plant in Changshu is an important step in the development plan of Solvays growing industrial base in China where the Group is committed to increase its customer base, said Augusto di Donfrancesco, general manager of Solvays Global Business Unit Specialty Polymers.
http://bit.ly/ACCTSCA
www.solvay.com
PlastiComp develops translucent LFT

PlastiComp has developed a translucent, long-fibre reinforced compound that it describes as a compounding breakthrough. The patent-pending TPU based product contains 20-40% long glass fibres by weight. When moulded it is smooth and translucent, while still maintaining the mechanical properties of a standard long glass reinforced thermoplastic compound. Moulded structural parts
12
with translucent qualities lead to unique applications that require strength and optical transparency, said Dr. Raj Mathur, vice president and director for technology and business development at PlastiComp. Target applications include medical devices, pumps, filters, power tools, sporting equipment, or anything requiring a see-through PlastiComp has produced an LFT compound that is translucent as well as being strong part-section.
www.plasticomp.com
news
EPA checks decaBDE alternatives

The US Environmental Protection Agency (EPA) has published a draft report assessing potential substitutes for decabromodiphenyl ether (decaBDE) flame retardants that are being phased out in the US by December 2013. Produced under the EPAs Design for the Environment (DfE) programme, the 800+ page report profiles the environmental and human health hazards of 30 alternative additives that are already on the market. The EPA is now seeking stakeholder and public input on the draft publication. Comments need to be submitted to Emma Lavoie (Lavoie.Emma@epa.gov) by 30 September 2012. The full draft report can be read at: http://bit.ly/DecaBDE. The organisation stresses that the health and environmental profiles are largely based on computermodel generated estimates, and that the models are limited in their ability to predict concern. It adds that laboratory testing and ongoing environmental monitoring are necessary to fully understand the potential for concern associated with these chemicals. DecaBDE is a common flame retardant that has been widely used in electronics, vehicles and building materials.
Suzuki seeks to patent talc-free PP compound

Suzuki Motor Corporation has developed a talc-free polypropylene (PP) compound that it says is 10% lighter and easier to colour while maintaining mechanical properties. Called Suzuki Super Polypropylene (SSPP), the new grade is used on the lower trim on the front bumper of the companys new Escudo model (picutred right) which was launched last month. Suzuki says that the addition of talc to PP compounds increases their weight and dulls their colour due to a reduction in transparency. It adds that its SSPP material achieves the required rigidity and impact resistance by adding only a thermoplastic elastomer to a high rigidity base PP resin. The flexural rigidity of the resulting talc-free compound is claimed to be comparable to existing PP compounds while weight is reduced by approximately 10%. The company has applied for a patent for the technology and plans to extend its use into interior parts and exterior components such as bumpers in the future. The first application of SSPP in the Escudo bumper trim takes advantage of the high colourability of the resin. The part has a bright metallic silver colour that is achieved without painting, increasing its resistance to scratches and stone chips.
www.globalsuzuki.com
New EU audit scheme sets the standard for recycled plastics

Europes plastics converters, recyclers and collectors have agreed to launch a new certification and audit scheme named EuCertPlast which implements the existing CEN standard 15343 for post-consumer plastics recycling. Ton Emans, president of the European Plastics Recyclers association (EuPR), said: A suitable harmonized auditing scheme for Europe was needed due to the difficulty in gaining access to plastics waste from the different and often complex national systems. Now with EuCertPlast a level playing field has been created and plastics recyclers can work with all national collection schemes to get access to raw materials for further treatment in Europe. The European Association of Plastics Recycling and Recovery Organisations (EPRO) worked on the two-year project with the EuPR. Its co-chairman Francis Huysman said that the scheme would enable our members, which include some of the largest plastics recovery organisations in Europe, to have confidence that recyclers holding this certification will process their plastics to the highest possible operational and environmental standards. Alexandre Dangis, managing director of the European Plastics Converters association (EuPC), added: I am very happy with the outcome of this project in which we have been able to demonstrate that good practices on post-consumer plastics recycling should be rewarded with a European Certificate and this will boost the use of recyclates in Europe by plastics converters.
www.epa.gov/dfe
14
www.eucertplast.eu
new possibilities for compounding with Vistamaxx PBE

Reduced cost. Simplied manufacturing. Improved quality. Meeting end-user expectations.
Vistamaxx propylene-based elastomers (PBE) are a new generation of metallocene polymer resin carriers. They offer compounders new possibilities to reduce costs and simplify manufacturing processes, while maintaining or improving the quality of compounds to meet increasing quality expectations from plastics fabricators. Compatible with many polymers, Vistamaxx PBE can be utilized to develop the optimum compound for applications requiring excellent dispersion, high ller loading and compounding at lower temperature.
visit: vistamaxxelastomers.com
ExxonMobil, the ExxonMobil Logo, the Interlocking X Device and all product names herein are trademarks of Exxon Mobil Corporation.
PolyolefinAdditives2012
International conference on technical and market developments in polyolefin compounding
CLICK HERE FOR DETAILS
23-25 October 2012

Maritim Hotel, Cologne, Germany
MEVOPUR Photo Courtesy: Clariant
* + 19% German VAT
Special offer: Save 100* if you register before 21st September 2012
Organised by: Applied Market Information Ltd. Sponsored by: Media supporter:
Giulia Esposito, Conference Organiser ge@amiplastics.com Ph: +44 117 924 9442 Fax: +44(0)117 311 1534
Carrier materials | masterbatch feature
The long-running search for the perfect carrier material continues. Jennifer Markarian looks at the latest developments for colour and additive masterbatches, as well as innovative porous carriers for liquids
Developments in masterbatch and additive carrier materials

Carrier polymers, which play the humble role of carrying the colorants or additives in a concentrate or masterbatch, need to blend easily into the base polymer to help disperse the pigment or additive. In addition, they should have minimal effect on the end-products physical properties. Some universal carriers are compatible with several different base or matrix polymers, while other carriers target a specific base polymer. Universal carriers are desirable for minimizing inventory. Typical universal carrier resins include low molecular weight, high-flow, low-density polyethylene (LDPE), ethylene vinyl acetate copolymer (EVA), and low molecular weight PE or polypropylene (PP) waxes. While universal carriers can go into a range of PE types, the extent of their compatibility in other resins may depend on the application, notes Prakash Patel, senior technical director at masterbatch producer Ampacet. For example, universal carriers will work in a thick PP part that has 1-2% masterbatch, but may have a negative effect on the properties of a PP film, fibre, or thin part, in which the relative contribution of carrier resin is higher. Formulators are still searching for the elusive polymer that is truly compatible across multiple resin families, says Patel. Finding the optimal viscosity is a
Formulators are still searching for the elusive polymer that is truly compatible across multiple resin families
Prakash Patel, Ampacet
balancing act, he adds. Lower viscosities flow easily, but if the viscosity is too low it will not develop enough shear to disperse during masterbatch production, and may degrade properties of the end part. In addition to better universal carriers, an ongoing request from masterbatch producers is for carriers that can hold higher levels of pigment or additive. This is because high loadings, which use less carrier resin, are more cost-effective for the processor. Titanium dioxide, for example, can already be loaded at the highest possible level (just over 80% empirical limit based on surface area), but the loading levels of organic pigments are limited by dispersion issues, says Patel. Improved dispersion of nano-size fillers is another industry requirement, notes Lynell Maenza, Asia Pacific market manager for specialty elastomers at ExxonMoAugust 2012 | compounding world 17
masterbatch feature | Carrier materials
shown in Figure 1. It therefore also increases the impact resistance of filled polymers, as shown in Figure 2. Good dispersion also allows lower additive loadings to have the same level of effectiveness as higher loadings, which reduces formulation cost, according the company. Compared to other types of EMA resins, Elvaloy AC products have higher melting temperatures (around 90C), which leads to less sticking in the feed hopper, says DuPont. Elvaloy AC (EMA) also has higher thermal stability than EVA; its upper processing temperature is 320C, compared to 230C for EVA resins. Figure 1: Improved filler dispersion with Elvaloy 1820AC (right) compared to using a PE carrier (left) ExxonMobils Vistamaxx elastomers are semi-crystalline copolymers of propylene and ethylene produced using the companys Exxpol metallocene catalyst technology. Vistamaxx is used for a variety of applications, including as a carrier resin, in which it is compatible with a wide range of polyolefins. The resins high ethylene content makes it compatible with both PE and PP, explains Maenza. Due to its unique product morphology, Vistamaxx has a very narrow molecular weight distribution and high heat stability. In masterbatches, these properties allow a broader processing window in various types of compounding machines with higher filler acceptance and improved dispersion of pigments and fillers, says the company. High filler acceptance is particularly important, for example, in CaCO3-based filler masterbatches for the raffia and shopper bags industry and in sophisticated Figure 2: Elvaloy delivers increased impact strength for filled compounds (PA 6 with 5 wt% TiO2 masterbatch containing 60 wt% of DuPont R-104 TiO2) bil Chemical. High filler levels are being used in white masterbatch compounds, in which there is an increasing use of cheaper fillers such as CaCO3 blended with white TiO2 pigment to reduce overall cost, adds Maenza. Suppliers continue their quest for appropriate universal and low-flow carriers that have good dispersion for higher loading levels, and they have introduced many new developments. For example, DuPonts Elvaloy AC products are ethylene acrylate copolymers, including ethylene methyl acrylate (EMA) and ethylene butyl acrylate (EBA). Elvaloy AC products have good compatibility with both non-polar and polar polymers such as PE, PP, PA, PET, PBT,PC, ABS, and PVC. They also have broad compatibility with polar and non-polar fillers and additives, such as those used to improve toughness and stress crack resistance. Using Elvaloy AC products as carrier resins permits higher filler loadings and improves filler dispersion, as
18 compounding world | August 2012
functional and colour masterbatches for foaming, flame retardant and spun-bond non-woven applications. Vistamaxx can accept up to 85% calcium carbonate loading. For monofilaments used in woven bags, Vistamaxx provides better anti-fibrillation performance, less yarn breakage and fewer dusting problems, says Maenza. In pipe applications, Vistamaxx can allow high filler loadings while maintaining flexibility. At higher masterbatch ratios, Vistamaxx can also yield improved tear and impact properties for films and enhanced weld line and impact strength for blow moulded containers. Vistamaxxs low melt temperature compared to LLDPE and PP allows it to be compounded at lower temperatures, which saves energy and reduces the potential for thermal degradation. It also allows it to serve as a carrier for heat-sensitive additives such as blowing agents or flame retardants, the company reported at AMIs Masterbatch conference in Singapore earlier this year. Clariant is also taking advantage of the ability of metallocene catalysts to control the molecular weight distribution and optimize the flow properties of
compatible with both polyolefins and polystyrenes. Arbor Plastics Technologies (APT) offers its MFP (multi-functional pellet) additive delivery system, in which multiple additives can be incorporated with APTs Qwik Shot process enhancer as the carrier. The advantage of this, says APT, is that Qwik Shot acts as a flow enhancer to reduce cycle times, lower barrel temperatures, and widen the processing window.
Porous carriers for liquids

While some processors are set up to handle and dose liquid additives, others prefer to dose these additives by first embedding them in free-flowing solids. Additives are typically mixed with and absorbed into the porous carrier at room temperature, which prevents degradation of thermally-sensitive additives. Clariants latest Licocene grades are used as universal dispersing and carrier agents in pre-mixes polymers. Its Licocene PP 1302, 1502, 2602 and 6102 highly crystalline waxes act as combined dispersing and carrier agents for pre-mix formulations. The high-performance metallocene-catalysed products can be used universally, displaying high compatibility with a broad range of plastics. According to the company, the four grades can deliver better control and dispersion of colorants, additives and fillers without any negative impact on the physical and mechanical properties of the formulation. The waxes allow the pre-mix ingredients to be shaped into a granular form for convenient handling. The new Licocene grades are supplied as amorphous and semi-crystalline granules. They have low melting points (80 to 165 C), low viscosities at 170 C (60

LyondellBasells Hifax CA7153 S is a PP copolymer in a highly-porous granule form that can serve as a carrier for liquid additives such as peroxides, polyisobutylene and pigment pastes. The additives are absorbed into the polymer by dry-blending to create free-flowing granules that are easy to handle, dose, mix and disperse. The company says that this can help users comply with health, safety and environmental standards. Membranas Accurel MP microporous polymers can be filled with liquid additives to produce free-flowing powder or pellet concentrates. Accurel MP can be made using a range of resins, including PP, PE, and polyamides (PA). The carriers can hold a variety of liquid additives, including antimicrobials, antioxidants, coupling agents, fragrances, peroxides, and silanes. Maximum loading capacity is 75% by weight, says the company. It also offers a line of standard super-concentrates as well as custom manufacturing services. Frilvam, a masterbatch producer based in Italy, has developed a method of foaming polyolefins to create a porous structure that absorbs liquid additives at up to 50% concentration by stirring a dry-blend. Avoiding heat is helpful for additives such as antifog, in which
to 7,000 MPas) and a narrow molecular weight distribution (<2). LyondellBasell is targeting masterbatch carrier applications with its Lupolen 1800U high-flow LDPE. This grade is produced using the companys Lupotech T high-pressure tubular process technology and has the highest melt flow rate (60 g/10 min) of any of its LDPE grades. ExxonMobils Vistamaxx reduces yarn breakage and dusting problems in monofilaments for woven bags The company says that the resin provides very good dispersion and homogenization of pigments and additives, and can also be used as a viscosity modifier in compounds. It adds that the new LDPE has better processing characteristics than LLDPE. In addition to masterbatch and compounding markets, the resin is also targeted at injection moulding applications, such as flexible thin-wall lids. Nova Chemicals is also promoting its UPES resin as an effective carrier material for universal masterbatches. Produced using the companys Qinnex suspension polymerisation technology, the resin is a very intimate blend of polystyrene and polyethylene. This means that it can be used to produce masterbatches that are
Exilicas micron-sized porous particles can absorb and then slowly release a range of chemicals
degradation can decrease organoleptic properties, notes the company. The method is also useful for achieving very high concentrations of liquid flame retardants. Frilvam is using the Prisma Absorber in its own masterbatch production, but will also supply the carrier to other masterbatch producers. The product line currently includes LDPE, EVA and PP versions. Exilica is a UK company that produces porous, micron-sized, spherical particles composed of poly(1methylpyrrol-2-ylsquarine) (PMPS). These can absorb and then slowly release a wide range of chemical species, including polymer additives such as fragrances, lubricants, antibacterials and insect-repellents. PMPS particles can be compounded into polymers at levels up to 4% without affecting polymer properties, and typical loading levels are 0.6-1.5%, says the company. Exilica has focused on using the particles to make fine-fragrance masterbatches, because in this market it offers the key benefit of protecting the fragrance through processing temperatures of up to 280oC (Compounding World, September 2011, page 57). The particles are compatible with many polymers, including polyolefins as well as PVC, nylons and PET. New application areas include floor coverings, wall panelling, textile fibres, and consumer product packaging like bottles and caps, says Daniel Lynch, technical director at Exilica. Applied Minerals Dragonite halloysite is a natural, aluminosilicate clay with a hollow, tubular morphology that can be used, among many things, as an adsorbent and carrier of polymer additives. The particles are 1-2 halloysite loaded with antioxidant to the formulation allows it to release slowly and protect the polymer from degradation at much lower use levels. While the possibility of slow-release of antioxidant has been known for some time, it is now beginning to be scaledup and proven in polymer systems. A carrier application that is now being used commercially is loading chemical blowing agents into halloysite tubes. Because the blowing agent is being released from the very small tubes, it creates small bubbles. In addition, while foaming generally reduces strength and modulus, Dragonite in the formulation increases the strength and modulus of the end part. Masterbatch supplier KibbeChem found that masterbatches with Dragonite resulted in 30% higher extruder throughput, better physical properties, and smaller bubbles for an improved surface finish. Another commercial application is loading the tubes, which themselves act as both a mineral flame retardant and a reinforcing agent, with a liquid flame retardant. For example, a customer needed to add flame retardancy to a high-end, glass-reinforced PET pallet application, but existing phosphorous-based systems plasticized the formulation and decreased the modulus to an unacceptable level, DeArmitt explained in a presentation at the recent AMI Fire Retardants in Plastics conference. A solution was found by loading Dragonite with a non-halogenated, oligomeric phosphate ester flame retardant, resorcinol bis-diphenylphosphate (RDP). Absorbing RDP in the halloysite tubes created a slow release that prevented premature blooming. The combination of flame retardancy of the halloysite and that of 2% RDP is expected to meet the UL 2335 requirement. In addition, the high aspect ratio halloysite acted as a reinforcing agent to replace a portion of the glass fibre
The tubular structure of Applied Minerals Dragonite allows it to carry additives
microns long and 50 nm across, with a 15-nm diameter hole in the centre of the tube and a very high surface area of 65-120 m /g.
2
One potential application is as a carrier for antioxidants. Much of the antioxidant that should go into protecting a polymer is lost to migration, explains Chris DeArmitt, CTO of Applied Minerals. Adding
22
ExxonMobils Vistamaxx can be used in highly filled masterbatches for shopper bags
and still retain strength and modulus. Dragonite is unique as an absorbent because it delivers active ingredients while at the same time enhancing mechanical properties and improving productivity by nucleating crystallization, claims DeArmitt.
More information
AMIs conferences on masterbatch markets and technology will be held on three continents next year. First up will be Thermoplastic Concentrates 2013 in Coral Springs, Florida, USA, on 29-31 January, followed by Masterbatch Asia 2013 in Singapore on 18-20 March. Last but not least, Masterbatch 2013 will take place in in Frankfurt, Germany, on 3-5 June. For more details, visit: www.amiconferences.com Click on the links for more information:
www.ampacet.com www.appliedminerals.com www.arborplastic.com www.additives.clariant.com www.dupont.com www.exilica.co.uk www.exxonmobilchemical.com www.frilvam.com www.kibbechem.com www.lyondellbasell.com www.membrana.com www.upesresin.com
CONFERENCES ON THE MOVE

Access brochures for AMIs forthcoming conferences on your smart-phone or tablet computer using our free apps for the iPad, iPhone and Android-based devices.
Fax back to +44 (0) 117 311 1534
WIND TURBINE
BLADE MANUFACTURE
2012
International industry conference on design, materials, production and performance of windmill blades
HEADLINE SPONSOR
27-29 November 2012

Image courtesy of: Siemens
Maritim Hotel, Dsseldorf, Germany

* + 19% German VAT
SPECIAL OFFER: Save 200* if you register before 12th October 2012
Organised by: Applied Market Information Ltd. Also sponsored by:
Simply search for AMI Plastics in iTunes, Apples App Store or Googles Play Store. Alternatively click on the relevant link below.
PLEASE PRINT
REGISTRATION FORM
Company:_____________________________________________________ Address:_______________________________________________________ ____________________________________________________________ __ ______________________________________________________________ Country: ______________________________________________________ Tel: ________________________ Fax: ______________________________ E-mail address: _________________________________________________ VAT No.:__________________________________________________
(Must be completed by all EU Companies)
POLYMERS IN PHOTOVOLTAICS 2012 CONFERENCE INFORMATION

Date and location 24-26 April 2012 Maritim Hotel Heumarkt 20 D-50667, Cologne, Germany Tel: +49 221 2027 0 Fax: +49 221 2027 826 Registration fee The registration fee includes attendance at all conference sessions, the welcome cocktail reception, lunch and refreshment breaks on both days, and a set of conference proceedings.
POLYMERS
in
Photovoltaics 2012
Early bird registration: Register before 16th March 2012 for only 850*.
Thereafter the cost is 990*.
International forum on markets, materials and manufacturing of photovoltaics
Company activity: ______________________________________________ Invoice address (if different from above): ____________________________
Group rates: For companies wishing to register two or more delegates, group discounts are available. Please contact Jenny Skinner for more details
Polymers in Photovoltaics 2012 table top exhibition A limited number of table top exhibition spaces are available in the registration area and coffee lounge directly outside the conference room. The table top exhibition fee is only 1750* and includes 1 free delegate place. Exhibitors may either use tables provided by the hotel (120 x 45 x 75 cm), or bring their own stand or display. Sponsor this event and promote your company A variety of sponsorship opportunities are available at this event that can help to promote and enhance your companys products and services to this highly targeted international audience. For further information, please contact the Conference Organiser on: +44 (0) 117 924 9442. Social events The social events organised for Polymers in Photovoltaics 2012 will provide an ideal setting for delegates and speakers to mix business with pleasure.
________________________________________________________ ________________________________________________________
DELEGATE DETAILS
(If more than one delegate please photocopy form)
Title:________ First name: ________________________________________ Surname: ______________________________________________________ Position:_______________________________________________________ Special dietary requirements: _________________________________
PAYMENT DETAILS
All payments to be made in Euros
The full delegate fee is 990 + 19%* = 1178.10 per delegate
Welcome cocktail reception

A welcoming cocktail reception will be held on the first evening. All delegates are invited to attend and it will offer an excellent opportunity to meet speakers and other colleagues. The welcome cocktail reception will run approximately from 18:00 to 19:30 and is included in the delegate fee.
FEES PAID - please tick box and write amount:

Early bird rate: 850 + 19%* = 1011.50
(Until 16th March 2012)
___________ ___________ ___________ ___________
Delegate fee thereafter: 990 + 19%* = 1178.10 Table top exhibition: 1750 + 19%* = 2082.50 (Includes one free delegate place) Conference dinner: 70 + 19%* = 83.30
* German VAT
Conference dinner
All delegates are warmly invited to attend the conference dinner, which will take place at a local restaurant on the evening of 25th April 2012. The additional cost is 70*. Hotel accommodation Delegates are responsible for booking their own accommodation. AMI has negotiated a room rate of 156.71 for a single room and 196.49 for a double room (breakfast and taxes included) at the Maritim Hotel in Cologne. To reserve a room please contact the hotel directly and state that you are attending AMIs Polymers in Photovoltaics 2012 conference. Tel: +49 221 2027 849 Fax: +49 221 2027 826 E-mail: reservierung.kol@maritim.de Cancellations Full refunds, less a cancellation charge of 200 will only be made on cancellations received prior to 23rd March 2012. Thereafter we regret that no refunds can be made. Delegates may be substituted at any time. Please note no refunds may be given on table top bookings or dinner places. * + 19% German VAT
Total:
___________
METHOD OF PAYMENT
On receipt of this registration form your credit card will be debited. You will be sent an invoice in 5-10 working days. Bank Transfer quoting: Applied Market Information Ltd. -Polymers in Photovoltaics 2012 to: Commerzbank, Filiale Dsseldorf, Breite Strae 25, 40213 Dsseldorf, Germany Account number: 1024710 Bank No. 300 400 00 IBAN: DE93 3004 0000 0102 4710 00 SWIFT: COBADEFFXXX Visa / Mastercard / Eurocard / JCB (Please note all card payments will be processed in Sterling)
24-26 April 2012

Image courtesy of: Yingli Green Energy
* + 19% German VAT
CONFERENCE HOTLINE
JENNY SKINNER, CONFERENCE ORGANISER Applied Market Information Ltd. 45-47 Stokes Croft, Bristol BS1 3QP, United Kingdom Tel: +44 (0) 117 924 9442 Fax: +44 (0) 117 311 1534 E-mail: js@amiplastics.com
The latest programme, including any new speakers or changes to the schedule can be viewed on our website: www.amiconferences.com
SPECIAL OFFER: Save 140* if you register before 16th March 2012
Organised by: Applied Market Information Ltd. Sponsored by: Media supporters:
Name of cardholder: ____________________________________________ Expiry date: _____________________ 3- digit security code: ____________ Cardholders signature:___________________________________________ Signature: _______________________ Date:_________________________ ____________________________________
Fax back to +44 (0) 117 311 1534
www.amiconferences.com
bookshelf
Brought to you by Plastics Information Direct Online Bookshop
RECOMMENDED READING
Our selection of the latest titles and essential reference works for the compounding industry
PVC Formulation 2012 - Conference Proceedings
2012, 22 papers and CD, E335.00 or 280.00 or $420.00 Brand New. Markets, flexible and rigid materials and nanocomposites. . More info/Buy here
d anw r b ne
Compatibility of Pharmaceutical Solutions and Contact Materials

2009, by Jenke, E90.00 or 75.00 or $120.00 Safety assessments of extractables and leachables for pharmaceutical products. More info/Buy here
Antimicrobial Polymers
2012, by Lagaron, Ocio & LopezRubio, E110.00 or 90.00 or $145.00 Brand New. Covers the science, applications and regulation of biocides. More info/Buy here
d anw r e B n
Starch-based Polymeric Materials and Nanocomposites

2012, by Ahmed, Tiwari, Imam & Rao, E130.00 or 108.00 or $170.00 Brand New. Covering chemistry, processing and applications. More info/Buy here
d anw r e B n
Polymers for Electricity and Electronics: Materials, Properties and Applications

2012, by Drobny, E100.00 or 85.00 or $130.00 Brand new. From fundamentals through specific materials and applications. More info/Buy here
d anw r b ne
Twin Screw Extrusion - technology and principles

2010, by White & Kyu, E130.00 or 108.00 or $160.00 Revised edition. Comprehensive but still practical and readable.
ed is ion v re dit e
More info/Buy here
Visit www.pidbooks.com for hundreds of recent titles, easy online ordering, special offers and clearance bargains!
Order online or by telephone, fax or email. Contact Matt Wherlock, Tel: +44 (0)117 924 9442 Fax: +44 (0)117 9892128 email: mjw@amiplastics.com All prices are correct at the time of publication but may be subject to change. Please check the Plastics Information Direct website for current prices and shipping charges.
PVC plasticizers | additives feature
Ongoing pressure on phthalates is driving interest in alternative plasticizer options, with bio-based products joining a growing range of phthalate-free options. Chris Smith reports
The search for soft options

There is no doubt that phthalate-based plasticizers are under intense pressure. Several of the commonly used lower molecular weight plasticizers, including DEHP, BBP, DBP and DIDP, have been included on the European Unions REACH authorisation list, which means they will be restricted to certain authorised uses beyond February 2015. And while higher molecular weight plasticizers, including DINP, DIDP and DPHP, are not considered to be substances of very high concern they were not placed on the REACH Candidate List precautionary restrictions on the use of DIDP and DINP in toys and childcare articles that can be placed in the mouth and some food contact applications do little to convince consumers of their safety. Around 6 million tonnes of plasticizers are produced globally each year, according to data from the industry trade association European Council for Plasticizers and Intermediates (ECPI), and the majority of this production is phthalates. ECPI also says phthalate plasticizers are among the most intensively tested and scrutinised of all chemicals in use today. While risk assessments have categorised low molecular weight phthalates as Category 1B Reproductive agents, one reason for their inclusion in the REACH Candidate List, the higher molecular weight types give little cause for concern among the scientists advising global regulators. Even so, media campaigns against phthalates continue and political decisions rarely favour their producers. Denmark, for instance, acted outside of the EU
www.compoundingworld.com August 2012 | compounding world 27
REACH process with its proposals last year to ban the use of DEHP, DBP, BBP and DIBP in consumer products intended for indoor use or that come into contact with skin. In July this year, the Committee for Risk Assessment within the European Chemicals Agency (ECHA) ended a six-month review by ruling that the proposals were not justified, sending the Danish decision into yet another period of consultation. Against such a background, it is little surprise that many end-users are looking for alternatives to phthalate-based plasticizers. The past few years have seen a number of new introductions and non-phthalate capacity expansions, with the most recent focusing on bio-based and renewably-sourced production feedstocks that The medical sector is a key application market for BASFs Hexamoll DINCH plasticizer
promise a more favourable environmental footprint.
additives feature | PVC plasticizers
Common phthalate plasticizers

Classification C atoms in backbone Total C atoms in chain Abbreviation Chemical name Very low C1 C1 DMP Dimethyl phthalate phthalate C2 C2 DEP Diethyl phthalate Low phthalate C3 C3 DPP Dipropyl phthalate C4 C3 DBP C4-6 C4/C6 BBP di-n-butyl phthalate Butylbenzene phthalate C3 C3 DIBP Diisobutyl phthalate C5-6 C6 DHP Diisohexyl phthalate C5-6 C7 DIHP Diisoheptyl phthalate C6 C8 DEHP/DOP Di(2-ethylhexyl) phthalate C6 C8 DIOP Diisooctyl phthalate High phthalate C7-8 C9 DINP Diisononyl phthalate C8-9 C10 DIDP Diisodecyl phthalate C7 C10 DPHP Dipropylheptyl phthalate C11 C11 DUP Diundecyl phthalate C10-12 C11 DIUP Diisoundecyl phthalate C12-14 C13 DTDP/DITP Ditridecyl phthalate
Source: ECPI
Non-phthalate plasticizer types

Family Typical example (abbreviated) Chemical name di-2-ethylhexyl adipate/di-octyl adipate di-2-ethylhexyl sebacate di-2-ethylhexyl azelate di-isodecyl sebacate di-propylene glycol dibenzoate Tributyl citrate Acetyl tributyl citrate Triethyl citrate Acetyl triethyl citrate Epoxidised linseed oil Epoxided soybean oil Tris(2-ethylhexyl) phosphate 2-ethylhexyl diphenyl phosphate 1,2-cyclohexane dicarboxylic acid diisononyl ester di-(2ethylhexyl) terephthalate di-octyl terephthalate Tri-octyl trimellitate Aliphatic dibasic acid esters DEHA/DOA DOS DOZ DIDS Benzoate esters DPGDB Citrates Epoxy esters Phosphate esters TBC ATBC TEC ATEC ELO ESBO TEHP EHDP
Cyclohexane diacid esters DINCH Terephthalates DEHTP DOTP Trimellitates

Source: ECPI/Compounding World
TOTM
US-headquartered Eastman, for instance, has increased capacity for its Eastman 168 general purpose non-phthalate DOTP plasticizer by 60% following the retrofit of the former Sterling Chemicals plant in Texas, which the company acquired last year. This additional capacity will allow us to serve the growing demand for non-phthalate plasticizers such as Eastman 168 around the globe, says Heidi Barnes, business director of
Eastmans performance chemicals and intermediates segment oxo and plasticizers. Last year, Eastman also said it was to discontinue production of its DEP and DBP low phthalate plasticizers, both of which would have required REACH authorisation for the European market. While not linking the decision to the REACH authorisation requirement, the company said at the time it had alternative fast-fusing, high solvating
alternatives within its plasticizer range, including its non-phthalate Benzoflex dibenzoate products. BASF of Germany is currently expanding capacity for its Hexamoll DINCH plasticizer, adding a second 100,000 tonnes/year production line alongside its original 100,000 tonnes/year plant at Ludwigshafen. The new line is expected to begin production during next year. The company cites growing demand for phthalatefree plasticizers as the reason for its decision to expand Hexamoll DINCH capacity. It says initial demand from the toy industry has been supplemented by interest from producers of food packaging and medical items, where it has already shown itself suitable for production of sensitive products such as blood bags, nutrition tubes and breathing masks. The plasticizer, which BASF says offers an excellent toxicological profile, is also being used by a number of producers of vinyl coated wallpapers and flooring products. Germanys Oxea, which added a further two grades to its Oxsoft line of non-phthalate plasticizers at the beginning of the summer, is also increasing its non-phthalate plasticizer capabilities. The company is doubling the capacity for its Oxsoft plasticizers at its European production plant at Oberhausen, which will take maximum output to 60,000-70,000 tonnes when it comes on stream in October of this year. The company is also building a new derivatives unit at Nanjing in China, which will come on stream in the second half of next year and will be capable of making a wide range of Oxea products including Oxsoft plasticizers. Oxeas global marketing manager for speciality esters Jacco de Haas says when the Chinese facility is up and running the company will have a global Oxsoft capacity of 90-100,000 tonnes. The move is intended to position the company to exploit growing demand for products capable of replacing phthalate plasticizers. It is not that the total plasticizer market is growing but it is substituting, says de Haas. We estimate 80% of all plasticizers used in Europe now are phthalates but are predicting that in 2014 or 2015 the phthalates market will be only 50%. It is not only that people want phthalate-free but that they now have phthalate-free options [such as DOTP] that are the same price or even cheaper. According to de Haas, the North American market will also see a move away from phthalates in the coming years. Although the shift may not be as fast as in Europe, he says US industry groups are now distinguishing between lower and higher molecular weight phthalate products in their communications with consumers and regulators. Oxeas GPO (DOTP) plasticizer is a general purpose grade suitable for direct 1:1 substitution of phthalates
such as DOP or DINP. The company also offers a range of specialty products including TOTM - for more demanding applications such as medical devices, where low migration is a key customer requirement. However, de Haas says TOTM can be challenging to formulate and process, prompting its development of two new products: Oxsoft Duo 1 and Duo 2. These are low migration two-component ester blends designed to provide higher levels of performance than its general purpose GPO product without the processing complexities of TOTM. Both grades offer good elevated temperature flexibility and relative extraction resistance; the Duo 1 product offers better low-temperature flexibility while Duo 2 provides better reduced fogging. US-based Emerald Performance Chemicals is also investing in phthalate alternatives, with its Emerald Kalama subsidiary announcing earlier this year it is to build a new European plant to produce its K-Flex plasticizer products. It will be located on the Rotterdam site it acquired from DSM in 2010. Currently, the K-Flex dibenzoate ester products are only manufactured at the companys US facility in Washington state. Emerald Kalama president Edward Glotch describes the K-Flex product line as one of the companys key growth platforms and says it is being fuelled by demand for effective environmentally-friendly alternatives to phthalate plasticizers. The company describes its K-Flex plasticizers as high solvating and fast fusing products pitched at general purpose applications in areas such as flooring, coatings and sealants. Emerald Kamala says the products will be fully REACH registered before the European unit begins production later this year. The company outlined three new plasticizer products at AMIs PVC Formulation conference in Dsseldorf in Germany earlier this year. X-20 is a blend of three dibenzoate plasticizers optimised for PVC compounds Oxea is expanding Oxsoft nonphthalate plasticizer capacity at its Oberhausen site in Germany to 60-70,000 tonnes/year
August 2012 | compounding world
29
Construction applications can benefit from the sustainability message provided by bio-based plasticizers, says Teknor Apex
of natural plant sugars. Lanxess says the first commercial plasticizer products from this cooperation will be launched before the end of this year. Our investment in BioAmber shows our commitment to launching a new generation of plasticizers that satisfy regulatory requirements and can also score in terms of sustainability, says Jorge Nogueira, who is head of the Lanxess Functional Chemicals business unit and also sits on the BioAmber board. BioAmber currently operates a pilot scale bio-succinic acid plant at Pomacle in France with an annual production capacity of 3,000 tonnes. However, it is planning to build a 17,000 tonnes/year commercial and plastisols, X-100 is a new dibenzoate grade for plastisol applications, and X-250 is a dibenzoate diblend intended for melt compounding and plastisol processing. US-based ISP Corporation, which was acquired by Ashland last year, developed its Flexidone range of plasticizers to provide a cost effective replacement for phthalates in applications including footwear, flooring and wire and cable. Based on alkyl pyrrolidone chemistry, the product line includes two product families extending to eight grades covering a range of solvating efficiency and thermal stability requirements. Flexidone FE is the most recent addition to the ISP product line. The company says the FE products are more versatile than most traditional plasticizers, allowing them to be used both as primary and co-plasticizers. Like the longer established Flexidone line, formulations containing Flexidone FE products can be processed at lower temperatures than traditional alternatives, opening up potential to reduce energy consumption. Germanys Lanxess is a major player in the non-phthalate plasticizer market with products such as its flagship Mesamoll range of alkylsulphonic phenyl ester products. It estimates the global market for scale unit on the Lanxess site at Sarnia in Canada. US chemical group Dow is also active in bio-based plasticizers with its Ecolibrium range, which it markets for applications in industries such as electrical and electronic, wire and cable and transport. The company claims a near 100% renewable content for the Ecolibrium plasticizers, which it says reduce greenhouse gas emissions by 40% compared to conventional plasticizers. Characteristics include high temperature resistance and good solubility with general performance characteristics similar to formulations based on DIDP, it claims. Earlier this year, Dow signed an agreement with US compounder Teknor Apex assigning exclusive marketing rights in North America for PVC formulations containing the Ecolibrium plasticizers in a number of key market areas, including consumer and industrial products, some medical applications, automotive components, and wire and cable products. Teknor Apex already offers customers an extensive range of phthalate-free plasticizer options, including adipates, citrates, dibenzoates, and trimellitates. It launched its first vinyl compounds using the Ecolibrium additives at the NPE show in the US in April this year.
Consumer products are also being targeted by Teknor Apex with its vinyl compounds incorporarting bio-based plasticizers
non-phthalate plasticizers to be worth around E1.3 billion and says demand is growing at around 7% a year. Aside from the Mesamoll products, the Lanxess line of phthalate plasticizer alternatives includes Unimoll glycerine acetates, Ultramoll adipic polyesters, and Adimoll adipates. The company further strengthened its position in the non-phthalate sector with the acquisition of US-based Unitex last year, which manufactures a range of phthalate-free plasticizers at its site at Greensboro in North Carolina. Lanxess is also working to develop a range of bio-based phthalate-free plasticizers. The company has a development partnership with BioAmber, a US-based firm focused on manufacturing bio-based chemicals, including succinic acid, by fermentation and purification
30
Brands is using the material in its flip-flop sandals; Barbour Plastics is making shoe welts; and Flooring Adventures is producing a range of interlocking floor tiles. Earlier this year, US-headquartered PolyOne introduced its reFlex 100 bio-based plasticizer, which it has developed in collaboration with US agricultural products group Archer Daniels Midland (ADM) and which it says is the first in a new line of bio-based plasticizers. The company describes the plasticizer as a fast-acting high solvating grade with 94% bio-content and says it is one of the first bio-based plasticizers to be recognised by the US Department of Agricultures USDA BioPreferred programme.
Source: Teknor Apex
PolyOne says the reFlex 100 grade is not targeted directly at general purpose phthalates but at products Marketed under the BioVinyl name, the company is emphasising the renewable content of the products and the contribution the grades can make to meeting its customers environmental targets. The renewable message is not stronger than the phthalate-free, it is just addressing a different market need. For those concerned with developing bona fide sustainable solutions, using a fact-based approach, BioVinyl products have a very strong message, says Louis Cappucci, vice president responsible for the companys Vinyl Division. Teknor Apex says the combination of renewablysourced plasticizer and PVC, around 50% of which is derived from salt, makes the carbon footprint of BioVinyl compounds very attractive compared with alternative polymers. The company claims global warming potential of the BioVinyl compounds, measured in CO2 equivalents, is half that of polyolefins and is lower even than PLA bioplastic. Cumulative energy demand, including feedstock and processing, is also lower than many alternative polymers, the company says. What BioVinyl technology has accomplished is the ability to make a much stronger argument for PVC, one which is hard to dispute, even from some of vinyls staunchest opponents, says Cappucci. BioVinyl compounds are cost competitive against non-phthalate options, and very cost competitive against alternative polymers with comparable properties. Teknor Apex says the improved heat stability of the such as benzoates and lower molecular weight plasticizers such as BBP. The company says it is particularly suitable for plastisol applications, as well as for use as a co-plasticizer in newer non-phthalate plasticizers where customers have sacrificed performance or productivity andin applications where bio-based content is perceived to be beneficial. PolyOne marketing director for specialty coatings and resins James Gray says this first reFlex grade will soon be supplemented with a second grade offering 99% bio-based content and BioPreferred certification. This second grade is designed as a one-for-one replacement for DINP and other general purpose phthalates. We believe the bio-based nature of our products is a differentiating feature which can generate additional value for our customers, says Gray. For example, brand owners may be able to have their products certified according to the USDA BioPreferred programme, providing them with unique marketing opportunities including the potential to obtain Federal Preferential Procurement status. The reduced carbon footprint may support their sustainability initiatives as well. While the reFlex products are bio-sourced, a tag which may carry a perception of improved safety in the minds of consumers, Gray says bio-based plasticizers need to be held to the same standards of health and safety as traditional alternatives. Many traditional
Alternatives to phthalates offered by Teknor Apex in its medicalgrade Apex vinyl and Flexalloy vinyl elastomer compounds
PolyOne says its reFlex 100 is one of the first bio-based plasticizers to be recognised by the USDA BioPreferred programme
32
BioVinyl compounds means processors experience reduced polymer degradation during production, while finished products display lower levels of colour change in accelerated testing. The company says it has also developed anti-fungal additive systems for the BioVinyl products that ensure compliance with ASTM G21. A number of applications for the BioVinyl products have already been commercialised in the US: Okabashi
The biggest little story in blending.

Steve Maguire, President and Founder Maguire Products, Inc. MaxiBatch Blender, Maguires largest blender at 14,000 lbs/hr is ideal for high throughput applications, compounding and wood composite applications). It can handle up to twelve ingredients including powders.
MicroBlender, Maguire's smallest blender; stainless steel hoppers; enhanced mix blade/static dam; improved handling of poorly flowing materials.
Leading bumper to bumper warranty in the industry.
When Steve Maguire popularized the gravimetric batch blender in the 80s, he started out small, working from his attic. From those early blenders, the line has grown both larger and smaller; big and little, if you will. Now, the new Maxi Batch is the largest volume blender at 14,000 lbs/hr and the littlest one- the Micro Blender- is still wellmicro. The concept however remains the same, actually improving through field trials. The real-world test is having nearly 40,000 units installed worldwide. Steve Maguire remembers his days as a processor and the ever-present pressure to produce. Technology, after all, is supposed
Maguire Headquarters: 11 Crozerville Road, Aston, PA 19014 Tel: 610-459-4300, 888-459-2412 Fax: 610-459-2700 E-mail: info@maguire.com Maguire Europe: Tel: +44 1827 265 850 Fax: +44 1827 265 855 E-mail: info@maguire-europe.com Maguire Asia: Tel: +65 6848 7117 Fax: +65 6744 3370 E-mail: magasia@singnet.com.sg
U.S. Patent 6,154,980. Other U.S. and International patents pending.
to work for you, not against you. Thats why Maguire sees blender logic as the gateway to process control in the future. Accuracy, precise dosing, economy of materials never go out of fashion. And little things count, especially as resin costs rise. With nearly 150 patents in the U.S. and internationally, Maguire is committed to developing unique products and systems in blending and beyond. So the big story is really about combining productivity with savings. Why not make a little move today and contact us? Who knows? It could make a big difference.
The perfect blend of simplicity and control.
www.maguire.com
HallStar offers several Plasthall grades as alternatives to DEHP, DOP and DINP
plasticizers, including many phthalates, have a long history of safe use. It will be incumbent upon us, working with our customers and the appropriate agencies, to establish the safety of our products for their intended applications, he says. At the AMI PVC Formulation conference in Germany earlier this year the company presented data comparing the performance of reFlex 100 when used as an accelerator against BBP, DPGDB , IDB and ESBO in blends with DINP, showing that the bio-based product delivered lower hardness values at similar loadings along with acceptable levels of volatility and heat loss. The ability of the reFlex 100 grades to deliver lower hardness values means processors can reduce total plasticizer content and, because the plasticizer is also said to act as a thermal stabiliser, save on stabilisation additives, according to PolyOne. Air release is also said
to be improved in paste and plastisol applications. Vinyl has always offered the market significant value across a broad range of applications due not only to its relatively sustainable performance in terms of carbon footprint but also to its versatile mechanical, electrical, chemical resistance, weathering and self-extinguishing properties, as well as its long-lived performance and the value it offers versus alternative materials, says Gray. Enhancing the carbon footprint of flexible vinyl products by incorporating bio-based plasticizer alternatives is just one more option adding to vinyls versatility. US-based stabilisers and additives manufacturer Galata Chemicals introduced its first bio-based primary plasticizer earlier this year. Based on natural plant oils, Drapex Alpha products are said to be suitable for a wide range of general purpose and specialty applications, offering PVC compound producers improved extraction resistance, VOC emissions and easier processing. The
Thi s M ul ti fu n c t i o n a l Ad d i t i ve i s a
POWERFUL LITTLE PELLET
STRUKTOL TR 063A
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:
Increased Productivity Longer Flow Lengths
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
company says the Drapex Alpha product line currently extends to four grades, with several others in the final stages of commercialisation, including a product for food contact applications. The products join the companys existing range of Drapex lubricants and secondary stabilisers based on epoxidised soybean oil. We believe the various grades of Drapex Alpha to be the first series of bio-based primary plasticizers to be competitive with conventional phthalate and non-phthalate plasticizers on a cost performance basis, says Galata Chemicals global business director Drew Clock. Drapex Alpha products are being used commercially by our customers in a number of applications as an alternative for a broad range of phthalate and nonphthalate plasticizers, including general purpose plasticizers such as DINP, DIDP, DOTP as well as high performance C9-C11 linear plasticizers and trimellitates such as TOTM. One of the first PVC compounding companies to work with the Drapex Alpha plasticizer is US-based Georgia Gulf Corporation, which has established a collaboration agreement with Galata. The company, which uses a range of phthalate-alternative plasticizers, says it will work with customers to develop application-specific PVC compounds using the Drapex Alpha product. We have used our decades of experience producing engineered vinyls to develop a line of bio-based compounds that are free of phthalates and heavy metals. These non-petroleum-based compounds are specifically designed to enable customers to meet their sustainability goals without compromising product quality or processing stability, says William Doherty, Phthalate restrictions have driven interest from the toy industry in alternatives such as BASFs Hexamoll DINCH
>compounding
& extrusion
>materials
handling
>service
>>The advance into a new performance dimension of compounding technology. The new
ZSK Mc18 twin screw extruder of Coperion, formerly Werner & Peiderer, is the most productive high performance ZSK of all time. With a specic torque of 18 Nm/cm3 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
ageing for seven days at 100C, while plasticizer migration was eight times lower than DOP. The V-Ziclus plasticizer showed five times less volatility in activated carbon tests and considerably lower losses in standard immersion tests. Varteco Quimica bio-based chemicals project manager Diego Garcia Touza told delegates the Argentinian PVC compounds market has been shifting away from traditional plasticizers since 2002. While the move from phthalates may have been driven by regulation or consumer concern in Varteco Quimica says that soybeans are now used to make most of the plasticizers used in Argentina vice president of Georgia Gulfs PVC Compounds business. Georgia Gulf is also working with the Javelin plasticizer products introduced by Segetis, a US-based company developing technologies for the production of solvents, plasticizers and polyols from agricultural products. Its plasticizers are built on cellulosic-based levulinic ketals and are said to be compatible across a wide range of addition levels, and to produce compounds that process at high speed and display good elevated temperature performance and low extractables. Segetis has been working with Kem One (the former Arkema vinyls business that was acquired by Klesch earlier this year) to determine the suitability of its bio-based plasticizers for replacement of commonlyused phthalates. At AMIs PVC Formulation conference, Kem Ones R&D director for chlorochemicals and PVC Dr Patrick Morel detailed some investigations it has carried out with two Segetis products in primary and secondary plasticization of PVC. Kem Ones researchers looked at the use of Segetis SGP9100D as a primary plasticizer for a flexible PVC compound and at SGP9200D as a secondary plasticizer in a plastisol application. Morel reported that the SGP9100D plasticizer displayed good absorption and volatility results in flexible PVC formulations, delivering hardness, migration, stability and optical performance similar to compounds plasticized with DINP. The SGP9200D plasticizer was compared against BBP as a secondary plasticizer in combination with DINP in a plastisol formulation and was said to function well. Argentinian chemical group Varteco Quimica presented data at AMIs PVC Formulation conference showing how its bio-based V-Ziclus GP general purpose plasticizer which is based on epoxidised soybean oil is providing a suitable alternative to DOP for an unnamed PVC compound manufacturer. Test data showed that elongation at break, tensile strength and tensile modulus are similar for compounds formulated to provide the same Shore A hardness value. In addition, tests showed that the V-Ziclus grade displayed better retention of mechanical properties after accelerated
Europe and North America, product availability and cost have been the key factors in Argentina, which is a major soybean producer. Touza estimates that 70% of the 45,000 tonnes of plasticizers used in Argentina are now based on ESBO, with penetration around 90% in the PVC compounds sector. US-based HallStar has a number of monomeric esterbased phthalate alternatives in its product line, including the renewably-sourced Plasthall PR-A610 product, which is said to be suitable for replacement of DEHP in PVC at 1:1 levels. Other HallStar phthalate alternatives include Plasthall LCOA, which offers performance similar to DOP, and Dioplex VLV, which is said to be a suitable replacement for DOP, DINP and linear phthalates. The company also offers a tailor-made plasticizer development programme. Marketed under the Paraplex Approach name, the computer-based system is said to allow it to develop an ester-based plasticizer that will meet the specific needs of customers. HallStar further extended its ester-based plasticizer portfolio in July of this year with the acquisition of the TP-series of specialty plasticizers from Dow Chemical. The deal includes both trade names and manufacturing technology for the product range, which includes products suitable for plasticising PVC and a wide range of elastomers. The TP trade name is known worldwide as an integral part of polymer formulations and will significantly expand the types of plasticizer-based solutions we can provide to our customers, says Louis Pace, executive vice president of HallStar. Daniscos Grindsted Soft-n-Safe plasticizer, an acetylated monoglyceride based on glycerine, castor oil and acetic acid, is one of the longer established bio-based options having been on the market since 2005. The company, which was acquired by DuPont last year, says the product is biodegradable, digestible and is approved by most regulatory authorities for use in food contact. It also claims an outstanding toxicological profile, making it suitable for replacement of DEHP in medical applications. Another well established supplier of bio-based alternatives to phthalates is Switzerlands Jungbunzlauer, a
Gain-In-Weight Batching
Continuous Feeding
Supervisory Control Integration
Recipe Optimization
Silo Inventory Management
The Process of
Railcar/Truck Unloading
Our advanced approach to building process systems puts complete control at your fingertips.
K-Tron is known worldwide for engineering and delivering superior systems that make industrial processes efficient, reliable and profitable. With world-class mechanical design, precision weighing technology, and cutting-edge control systems, K-Tron means productivity throughout your process and throughout your business.
Filtration
George Cuneo
Senior Systems Engineer K-Tron
Learn how K-Tron can solve your material handling and feeding challenges. Visit us at ktron.com
Polymers
Conductive Carbon Black electrical conductivity easy-dispersion high purity
For electronic packaging, fuel hoses, ooring, power cables and accessories, conveying belts, ATEX applications.
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.
www.timcal.com
More information
AMIs PVC Formulation 2013 conference will take place on 12-14 March in Dsseldorf, Germany. For details, visit http://bit.ly/PVC2013 or contact Sabine Prack, sp@amiplastics.com, +44 117 924 9442. The proceedings for PVC Formulation 2012 can be purchased from Plastics Information Direct. Order on-line at http://bit.ly/PVCpapers. Click on the links for more information:
Jungbunzlauer, a leading producer of citric acid, produces citrate esters for flexible PVC applications
leading producer of citric acid. It has several grades of its Citrofol citrate esters for flexible PVC applications. Citrofol AHII is aimed at high-performance technical applications especially where fogging needs to be minimised or eliminated and where the lowest migration is required. Target applications include cables, artificial leather, textile coating, flooring and automotive components. The company also has a special grade Citrofol BII for use in medical products and in gaskets for closures. Jungbungzlauers Citrofol C can be used as an alternative to DOTP, delivering fast fusion and highly efficient plasticizing, while Citrofol D can be used as a DINP replacement, matching key properties such as migration, thickening factor and shore hardness. Target applications for the C and D products include wall coverings, textile coatings, hoses, flooring, dip coating and calendered films. Citrofol D can also be used in artificial leather.
www.ecpi.org www.echa.europa.eu www.eastman.com www.basf.com www.oxea-chemicals.com www.emeraldmaterials.com www.ispcorp.com www.lanxess.com www.bio-amber.com www.dow.com www.teknorapex.com www.polyone.com www.adm.com www.biopreferred.gov www.galatachemicals.com www.ggc.com www.segetis.com www.kemone.com/en www.varteco.com www.hallstar.com www.danisco-softnsafe.com www.jungbunzlauer.com www.amiconferences.com
Maag Group is the innovative solution provider for pump, pelletizing and filtration systems. We deliver high-quality components and complete systems, from extruder tips to pelletizers. In addition to our primary locations in Switzerland and Germany, we have eight sales and service offices around the globe to provide our customers with full service par excellence.
brands of maag group
Automatik Plastics Machinery GmbH Ostring 19 63762 Grossostheim Germany T +49 6026 503 0 info@maag.com Maag Pump Systems AG Aspstrasse 12 8154 Oberglatt Switzerland T +41 44 278 82 00 welcome@maag.com www.maag.com
PLASTICS IN PHOTOVOLTAICS
2 0 1 2
The international technology and business conference on plastics, adhesives and elastomeric materials in solar modules CLICK HERE FOR DETAILS
September 19-20, 2012

Hyatt Regency Phoenix, Phoenix, Arizona, USA
Background image courtesy of: Evonik Industries AG. Foreground image: Duke Energy Renewables 15-megawatt (AC) Bagdad Solar Project in Yavapai County, Arizona - Image courtesy of: Recurrent Energy.
FINAL REMINDER BOOK NOW

Organized by: Applied Market Information LLC Media supporters:
Amanda Schaeffer Conference Coordinator as@amiplastics-na.com Ph: +1 610 478 0800 Fx: +1 610 478 0900
Medical Grade Polymers 2012

International technology and market conference on polymer materials in medical device manufacturing
September 25-26, 2012

The Hilton Boston/Woburn, Woburn, Massachusetts, USA
FINAL REMINDER BOOK NOW

Organized by: Applied Market Information LLC Supported by: Media supporters:
Marissa Hann Conference Coordinator mh@amiplastics-na.com Ph: +1 610 478 0800 Fx: +1 610 478 0900
Reactive extrusion | processing feature
Chain reaction
The intensive mixing performance of a twin-screw extrusion system and the ability the technology provides to optimise thermal and mechanical exposure of the polymer in the barrel makes it a good choice for reactive extrusion processing. Key applications include the chemical integration of bonding agents to improve adhesion between the polymer matrix and fibre or particulate fillers, and more recently the direct polymerisation of thermoplastic polyurethane (TPU) elastomers from liquid components. KraussMaffei Berstorff has developed systems for the production of impact modifiers and bonding agents for used in applications such as WPC extrusion and highly filled compounds. The company says a prime consideration for this type of reactive extrusion application is the use of screws and barrels with a corrosion resistant coating. Typical screw configurations include LD ratios of up to 50, with the installed drives selected according to the specific melting and dwell times required for the individual processing requirements. The company has also developed systems for the production of TPUs, comprising a twin-screw extrusion unit which is fed with the liquid components and catalysts. The reacted TPU polymer is extruded via an underwater pelletizing system. The TPU production lines require high precision gravimetric or mass flow metering systems to ensure the liquid components are delivered to the extruder throat in the correct ratio. LD ratios of up to 60 are typical for such applications.
The polymer modification potential of reactive extrusion is being used in a variety of applications ranging from polymerisation and polymer modification to the production of novel bio-based blends. Compounding World reports
According to KraussMaffei Berstorff, dynamic regulation of melt temperature is a critical consideration in any reactive extrusion process. Its systems use direct heating of the barrel elements in combination with liquid cooling. Heating is performed using high power cartridge heaters or heater bands; cooling is achieved with either high pressure water or oil circulated through a network of cooling bores. French technology company Setup Performance provides reactive extrusion technology support to a wide range of clients. Earlier this year, it commissioned a new 43 mm diameter LD 60 twin-screw extruder in its laboratory at Frontonas near Lyon to handle pre-industrial pilot volumes. Aside from expertise in TPU production and the grafting of polyolefins with maleic anhydride, it has also
processing feature | Reactive extrusion
The abrasion resistance of TPU is exploited in Andaluz Accessibilidades tactile pedestrian surfaces, produced in Bayer MaterialSciences Desmopan
worked on projects such as the development of bio-based polyamide by polycondensation. Setup specialists have been involved in a wide range of reactive extrusion projects, including Evoniks process for the production of TPUs using fumed silica and the development of its Aerobatch processing aids. The company also has a technique for the production of a polypropylene homopolymer that can be crosslinked in a secondary process, which it markets as PPX. Most recently, Setup worked with French agricultural products company Roquette in the development of its Gaialene biopolymers, which are based on grafted starch blends and are claimed to offer performance considerably improved on current starch blends. biopolymer blends at its site at Lestrem in northern France at the end of last year. Meanwhile, Switzerland-based List has developed a kneader reactor that provides an alternative to solventbased polymerisation. It is claimed to have found applications in a variety of polymer reaction and compounding applications. Aside from eliminating the additional costs involved in handling solvents, the kneader technology also provides improved thermal control compared to stirred tank systems due to the incorporation of thermal regulation circuits within the mixing shafts and elements as well as the reactor jacket. According to List, the benefits of using its technology which is available in both single-shaft and twin-shaft variants - include higher outputs from smaller production systems, simple scalability, reduced product handling, and lower energy consumption. List has a wide range of kneader reactors available for project development at its technology centre at Arisdorf in Switzerland. The company also works closely with the Fraunhofer Institute, which has a semi-commercial scale kneader reactor installed at its Polymer Pilot Plant Centre at Schkopau in Germany. Click on the links for more information:
KraussMaffei Berstorff twin-screw extruder configured for production of polymer bonding agents
Roquettes patent details a reactive extrusion process that brings together starch, plasticizer, polyolefin, compatibilizers and a variety of bonding agents to create a durable starch/polyolefin blend suitable for processing using conventional techniques such as injection moulding or extrusion. Roquette commissioned a 25,000 tonnes/year production scale plant to manufacture Gaialene
www.kraussmaffei.com www.setuperformance.com www.roquette.com www.list.ch
AMI Strategy Seminars

These one-day seminars are given by an AMI director and provide invaluable insights into market trends and industry strategies. They are held in small groups and provide ample opportunities for questions and discussions.
16 October 2012: Cologne, Germany 5 November 2012: Philadelphia, USA 12th November 2012: Dubai
Click here to download our 2012 brochure

www2.amiplastics.com/Seminars
BOSTON NOVEMBER 07, 08, 09, 20l2

Boston Convention & Exhibition Center
250,000 PROFESSlONALS WORLDWlDE
WIN MO R E B U SI NESS W IT H
JEC NETWORK
lNVOLVlNG THE WHOLE COMPOSlTES VALUE CHAlN
AERONAUTlCS AUTOMOTlVE AUTOMATlON
WlND ENERGY
CONSTRUCTlON
RECYCLlNG
For more information and to book your stand:

info@jeccomposites.com
TRADE SHOW & DEMO ZONE l.C.S. / FORUMS & CONFERENCES BUSlNESS MEETlNGS lNNOVATION AWARDS & SHOWCASE TECHNlCAL SALES PRESENTATlONS JOB CENTER
Foam moulding | technology
The need to reduce part weight and cost without sacrificing on performance is seeing growing interest in foamed injection moulding. Chris Smith considers the latest innovations.
Expanding interest in lightweight parts

Growing demands from OEMs and from the automotive industry in particular to save weight is driving interest in new process technologies that allow foams to be created during the moulding process, simultaneously reducing part cost and improving part quality. The latest to announce an interest in this area is French automotive components group Mecaplast, which believes it will be able to reduce the weight of interior and exterior trim parts by between 30 and 50% through the use of a proprietary injection moulding process in combination with specially developed PP compounds. The Monaco-headquartered company is leading a tion of parts made by the Plume process could lead to a total vehicle weight reduction of between 5 and 7 kg, says Elsa Germain, research and innovation engineer at Mecaplast. This will have an important knock-on effect on fuel consumption, with resulting carbon dioxide emissions falling by around 0.5-0.7 g/km. In the Plume process, the polymer containing a chemical blowing agent is injected into a mould with movable surfaces that are initially in the forward position. Once all material has been injected and the skin of the part has solidified, the entire mould surface is retracted to enlarge the cavity. This lowers the pressure so the chemical blowing agent comes out of solution in the areas of the part still molten, resulting in
Main images: IP carriers for Fords Escape and Kuga models require around 0.5 kg less material through the use of Mucell technology
E2.4 million two-year multi-participant French

government-sponsored project, which begins in September and aims to take the process to commercial application. Other participants include Saint-Martin de Crau-based compounder Sumika Polymer Compounds (a Sumitomo Chemical Group company), Nantes-based mouldmaker Cero, the IMP polymer science research laboratory at the University of Saint-Etienne, and the Sophia Antipolis-based Cemef process simulation research laboratory at the Mines ParisTech institute. The process, named Plume, makes use of a combination of moving mould elements, chemical blowing agents and lightweight reinforcing fillers. Incorporawww.compoundingworld.com
technology | Foam moulding
As part of the project, Mecaplast will trial the process on two automotive components: a tailgate interior trim and an exterior belt-line moulding. The belt-line moulding will be produced in two versions, one with a grained surface that will require no painting and another that will be paintable. Japanese car maker Mazda has been exploring the weight saving potential of foamed moulding since the middle of the last decade working with microcellular foam moulding technology developer Trexel. Mazda has a number of patents referencing the use of movable mould surfaces, which it and Trexel call core-back expansion moulding. The core-back expansion moulding process differs from Trexels traditional Mucell moulding process in allowing the creation of a very low density core in the Above: A Wittmann Battenfeld machine equipped for the CellMould system the creation of a cellular structure that expands to fill the newly-created space. Germain says the formation of the foam depends on a number of factors, including the mould and part design, and the properties and temperature of the polymer. The company says the foaming on its own enables a weight reduction in the part of at least 30% compared to a conventional compact moulding. Mecaplast says the technique, which it has made a patent application for, is similar to that already used in Japan for production of parts by automotive companies such as Honda and Toyota. However, it claims the Japanese technique has limitations in terms of surface finish because it uses talc-filled PP compounds. The Plume process will use compounds that incorporate new reinforcing fillers that improve surface quality but also help reduce part weight by as much as 7% without loss of mechanical properties. The company has previously published results of trials it has carried out using Millikens Hyperform HPP-803i reinforcing agent (see Compounding World, May 2012, page 55) in Below: Foam structure in a moulding made using the CellMould fine structural system TPO formulations. Germain says the Plume project will focus on the development of a range of compounds using a variety of fillers in impact modified PP copolymers. The resins are being developed specifically for the Mecaplast process, which requires high flow products with melt flow ratings of more than 50 g/10min. part. In industrial trials carried out with Mazda it has achieved weight reductions in parts such as door panel liners of up to 30% using the technique; using the Mucell conventionally typically results in weight savings of around 10%. According to Trexel, the initial phase of the core-back process results in the formation of a skin layer with a low level of foaming and relatively good aesthetics. When the mould is opened (or cored-back), the pressure in the mould drops and the gas in the molten core rapidly comes out of solution to create a core with a very low density. Trexels Mucell technology is being used by Ford in its Escape and Kuga instrument panel (IP) carriers, where it has saved about 0.5 kg per part. Volkswagen is also using the technology in its Golf IP carriers. Meanwhile, UK-based Coraltechs Coralfoam technology produces lightweight foamed parts using a combination of core-back injection moulding techniques and foam producing additives, claiming potential weight savings of 30% or more along with improved stiffness to weight ratios in parts designed to utilise the technology to the full. Wittman Battenfeld has been active in the structural foam and gas assisted moulding sectors for more than 40 years. However, the company also has its own direct nitrogen injection system for production of foamed parts. The system is marketed under the Cellmould
46
PolymerFoam2012
International conference on blowing agents and foaming technology for thermoplastics and elastomer
October 9-10, 2012

Images courtesy of: Sealed Air Corporation & Reedy International Corporation
DoubleTree by Hilton Hotel Newark Airport, Newark, New Jersey, USA
SPECIAL OFFER: Save $190 if you register before August 31, 2012
Organized by: Applied Market Information LLC Sponsored by: Media supporters:
Kelly Cressman, Conference Coordinator kc@amiplastics-na.com Ph: +1 610 478 0800 Fax: +1 610 478 0900
name and earlier this year the company announced it can now offer the technology as an option on its latest MacroPower line of large tonnage machines (which extend from 650 to 1,100 tonnes). The company says the Cellmould system can be used to save material, reduce frozen-in stress and warpage, eliminate sink marks, ease mould filling and reduce clamping requirements. The system comprises a special screw and barrel drilled for the gas injector and pressure and temperature sensors, a gas regulator, pneumatic needle-type shut off nozzle, compressor, and additional control software. Wittmann Battenfeld CEO Georg Tinschert says the company refers to the Cellmould technology as a fine structural process, distinguishing it from the Mucell microcellular technique. German injection moulder Schrder Kunststofftechnik has used the Cellmould technique in production of automotive components for several years, some of which also use two-component moulding methods to combine compact and foamed elements. The company added four more Cellmould equipped machines to its park of 33 moulding units last year, using them to process mostly glass-reinforced PBT and mineral-filled Below: The UK-developed retrofit Streamoulding nozzle and controller (right) doses water into the melt during injection to create a foam structure PP. It reports typical density reductions of 7-10%. While most foamed moulding techniques use either chemical blowing agents blended in with the polymer or direct injection of a gas such as nitrogen into the molten polymer in the barrel, UK-based R&D Factory is marketing an alternative solution using water as a foaming agent. The system is sold as a retrofit kit on an equipment-only basis there are no on-going licensing or royalty fees. Marketed as Streamoulding, the patented technique introduces water into the molten polymer using a modified nozzle, where the heat in the melt turns the
water to steam which saturates the molten plastic. R&D Factory director John Heaton says the technique offers many of the performance benefits associated with structural foam or gas-blown techniques such as Mucell, including reduced density, easier mould filling, shorter cycle time, and lower energy usage. The company claims the technique can be used with existing moulds and requires no machine modifications beyond the installation of the new nozzle and integration of the controller unit. Heaton says corrosion is not an issue and no special mould alloys or surface treatments are required. The Streamoulding nozzle houses two diffusers, which divide the melt flow into numerous mini-melt streams. Water is introduced into the molten polymer in the first diffuser, with the flow controlled by a specially-developed valve. Auxiliary heaters allow the temperature of the melt to be adjusted in the second set of diffuser channels to compensate for the cooling caused by conversion of the water from the liquid to vapour state. The molten polymer is then passed through a static mixer to ensure consistency of temperature and foam content. Heaton says very little water is required to create the foam it can be as little as a few pin-head amounts. The high temperatures and pressures in the nozzle mean the injected water vaporises almost immediately and simultaneously diffuses into the core of each melt stream. The entire process is electronically regulated. A Siemens controller controls the water injection valve, adjusting the duration and timing of injection and the delay before injection commences as required. It also controls the two heaters in the nozzle one positioned at the tip and the other around the main body to maintain the temperature required in the melt to maximise the foaming effect. At the time of water injection, the temperature of the melt falls rapidly, says Heaton. This reduction is recorded by the PLC and used to compute the required gain to compensate for this heat loss. The gain is then spent on the subsequent cycle. The controller anticipates the fall in melt temperature and compensates for it. Trials carried out on a thick oval-section kitchen tool handle (with a cross section measuring 15 mm by 25 mm) have shown a 40% weight saving using PS and up to 30% using PP. Mechanical tests carried out by the Composites Centre at Swansea University in Wales
48
FIRE RESISTANCE IN PLASTICS 2012

Trends and technical developments in the international flame retardant industry
27-29 November 2012

Images courtesy of: IMAST (Portici-Naples)
* + 19% German VAT
Special offer: Save 210* if you register before 19th October 2012
Adele Brown Senior Conference Organiser ab@amiplastics.com Ph: +44(0)117 924 9442 Fax: +44(0)117 311 1534
Right: Schrder of Germany uses Cellmould and two-component techniques to produce automotive components weighing 10% less than compact parts showed stiffness improvements of up to 5%, compared to a compact moulded equivalent. Strength-to-weight ratios showed a gain of up to 10% and stiffness-toweight ratios a gain of up to 19%, depending on the degree of foaming. The Streamoulding process has been under development for more than five years but the company only started to market it commercially in February of this year. The technology is undergoing trials at various different stages both at our factory and at potential
customers premises in Europe. Applications vary from thick and thin wall packaging products to composite materials for the automotive sector, says Heaton. Heaton says the process has been proven to work with PP, PS, PVC, PA and a range of TPEs. It has been trialled successfully in multi-cavity tooling with hot runner systems, while a special nitrided nozzle has been manufactured for one potential customer for processing PA reinforced with 35% glass fibres. No special post-moulded conditioning is required, he says. The process is also highly controllable, says Heaton. In trials on a prototype mould for German thin wall packaging producer Spies Kunststoffe, the Streamoulding technology has eased filling of a prototype container with almost no visible evidence of a foamed structure in the 0.7 mm wall. Click on the links for more information:
www.mecaplast.com www.trexel.com www.coralfoam.com www.wittmann-group.com www.rndfactory.co.uk
AMIs Guide to:
THE CABLE INDUSTRY IN EUROPE

AMIs Guide to THE CABLE EXTRUSION INDUSTRY IN EUROPE
AMIs Guide to THE CABLE EXTRUSION INDUSTRY IN EUROPE
A comprehensive review of the industry with key information on the location and production of 325 extrusion sites in Europe.
NEW
Click here to order and enter CWREADERP278 at checkout
edition
6 6
Invaluable data at your fingertips
6
Applied Market Information Ltd. AMI House, 45-47 Stokes Croft, Bristol BS1 3QP, United Kingdom Tel: +44 (0) 117 924 9442 Fax: +44 (0) 117 989 2128 E-mail: sales@amiplastics.com www.amiplastics.com
edition
6 6
Market data & analysis including facts and figures on polymer demand for cable production Company information including full addresses, contacts, polymers processed and type of cables manufactured
Europe Europe
6
www.amiplastics.com E-mail: sales@amiplastics.com Fax: +44 (0) 117 989 2128 Tel: +44 (0) 117 924 9442 Bristol BS1 3QP, United Kingdom AMI House, 45-47 Stokes Croft, Applied Market Information Ltd.
edition
A new directory of 325 cable extruders in Western and Central Europe SUBSCRIBERS TO COMPOUNDING WORLD WILL RECIEVE A SPECIAL 15% DISCOUNT DURING AUGUST
edition
EPORUE NI YRTSUDNI NOISURTXE ELBAC EHT ot ediuG sIMA
EUROPE INDUSTRY IN CABLE EXTRUSION THE AMIs Guide to
Order online plus Enter CWREADERP278 at checkout Full prices before discount are: Book format 255, Standard CD 650 and Gold CD 975 For more information contact Matt Wherlock sales@amiplastics.com Tel: +44 117 9249442
AMI Guides - Must have information for the global plastics industry
inerals in Compounding 2012

Global conference on minerals as additives, pigments and fillers in polymers
November 27-28, 2012

Images courtesy of: Omya Inc. / Evonik Industries
Hyatt Regency Atlanta, Atlanta, Georgia, USA
SPECIAL OFFER: Save $200 if you register before October 19, 2012
Organized by: Applied Market Information LLC Sponsored by: Media supporter:
Jessie Ceriello Conference Coordinator jc@amiplastics-na.com Ph: +1 610 478 0800 Fx: +1 610 478 0900
agricultural film 2012

International industry conference on greenhouse, tunnel, mulch and agricultural films and covers
6-8 November 2012

Hotel Meli Castilla, Madrid, Spain
* +18% Spanish VAT
Images courtesy of: Aspla S.A., Britton Unterland GmbH, Frilvam S.p.A., RKW SE
Special offer: Save 100* if you register before 5th October 2012
Rocio Martinez Conference Organiser rmm@amiplastics.com Ph: +44 117 924 9442 Fax: +44(0)117 311 1534
Polymers and additives | products
pvc additives
Clariant makes lubricant from castor oil

Clariant has launched a new lubricant based on renewable resources for rigid PVC applications. It is particularly suited to compounds using calcium/zinc and tin stabilizers and is claimed to offer superior technical performance compared to traditional fatty acid derivatives and complex ester mixtures. Called Licocare SBW11 TP, the chemically-modified wax is produced from soya beans and is used in relatively low concentrations in the region of 0.3 to 1.0 phr. The additive works as an internal and external lubricant offering a number of benefits for processors. These include: good release and anti-sticking effects; excellent thermal stability; low volatility and good compatibility with PVC; plus broad lubricating effects that contribute to a balanced rheological behaviour in the vinyl compound. Target applications include extruded products, such as films for photovoltaic systems, as well as injection moulded parts. In the latter, flowability is said to be significantly improved with less influence on the Vicat softening temperature compared to common internal lubricants such as fatty acid ester derivatives. As a result, Licocare SBW11 TP can achieve better dimensional stability in the injection moulded product as well as delivering excellent flow improvement.
www.clariant.com
artificial turf
So.f.ter develops a compound that is also a finished product

The whole point of a thermoplastic compound is that it is subsequently processed into a finished product, such as a moulded part or extruded profile. Now the Italian compounder So.f.ter is turning that conventional wisdom on its head by producing a pelletized compound that is also a finished product. Its patented Holo SP pellets are used as infill for artificial grass. The companys TPE formulation is directly compounded and pelletized using a Gala underwater pelletizer with a special die face that creates hollow, tubular granules. These have the required infill properties for the latest artificial grass structures used in football pitches and they meet the requirements of the FIFA Quality Concept. So.f.ter developed the technology in conjunction with its Terra Sports Technology subsidiary based in the Netherlands. The hollow pellets help to provide the required combination of shock absorption, vertical deformation, rotational resistance, stud deceleration, stud slide, skin/ surface friction, ball rebound and ball roll. In addition, they resist compaction, provide consistent performance, remain flexible in freezing conditions, stay cooler in summer conditions, deliver improved drainage and are recyclable. The SEBS formulation for Holo infill was developed to provide the required balance of elasticity and resilience. Compared to other infill materials, Holo is claimed to deliver a more natural feeling. At AMIs Grass Yarn and Tufters Forum 2012 , which was held in Zurich in February, Bart Wijers of Terra Sports Technology reported that Holo had already been used in 15 pitch installations since its introduction in 2011.
masterbatch
RTP shines a light for medics

RTP is supplying a glow-inthe-dark masterbatch for the moulding of the Rip Shear Firefly, which allows medics to slice through clothing so that they can access and treat wound sites more quickly. Rip Shear worked with Icon Injection Molding on the development of the device that attaches to standard trauma shears. The companies original Ripper design , which does not glow in the dark, is moulded using an RTP 200 Series glass fibre reinforced polyamide 6,6 compound. The latest glow-in-thedark Firefly design incorporates an RTP phosphorescent colour masterbatch in the PA compound. Its afterglow effect lasts for up to eight hours, assisting medics working at night or in low-light conditions.
www.softerspa.com www.tpeinfill.com
www.rtpcompany.com
products | Polymers and additives
antimicrobials
Water storage tank benefits from anti-bacterial protection

campylobacter, MRSA, e.coli and pseudomonas on the inner surface of the water storage tank by up to 99.9%. The Rainstream RXL tanks modular design allows any storage capacity to be created and it features an integral pre-storage filter.
packaging applications
Addmaster is supplying its Biomaster antimicrobial additive to Polypipe to produce an anti-bacterial lining for its Rainstream RXL high-volume water storage tanks. These are designed to harvest rainwater for re-use. Biomaster is described as a safe, effective and permanent antimicrobial additive based on silver ion technology. It has been independently tested to ISO 22196:2011 and has been proven to reduce the growth of harmful, pathogenic bacteria such as legionella, listeria,
Tosaf adds permanent slip to films

Tosaf has launched a new additive that offers both hot and permanent slip for packaging films. The companys Combined Slip Antiblock SB6484PE achieves a coefficient of friction below 0.2 when used at a dosage of just 5%. Suitable for use in both cast and blown film processes, the additive does not contain volatile components and has been developed to withstand heat, glue and printing. Optimal results are achieved in multi-layer films with an outer layer of about 5 microns, although the permanent slip can also be
www.addmaster.co.uk
technical compounds
used successfully with single-layer films and with films that have a larger external layer thickness. Tosaf says the additive offers improved performance in all types of films for food packaging, adding that producers of lamination films or films for metallization will find it especially beneficial.
Velox offers Repol FR compounds

Velox of Germany is offering new flame retardant grades of polypropylene and polyamide produced by the Spanish compounder Repol. The Dinalon and Dinaplen grades incorporate glass and mineral reinforcements and they are halogen- and phosphorus-free. Offered in a range of RAL colours, the low-density compounds are already being used in industrial and electrical engineering applications. Examples include PA 6 grades with 30% glass fibre reinforcement and rated at V0, which are available in natural or grey colours, plus a naturalcoloured PA 66 grade with the same glass loading and FR rating.
www.velox.com www.repol.com
www.tosaf.com
processing aids
Ter Hell takes on SureFlo additives

Ter Hell of Germany has been appointed the exclusive European distributor for the SureFlo processing aids produced by the US company Flow Polymers. The additives are already being successfully used in America to improve the
54
efficiency of injection moulding, extrusion, blow moulding and thermoforming processes. In injection moulding applications, for example, SureFlo has been shown to deliver significantly faster mould filling and therefore
reduced cycle times, combined with lower filling pressure. In addition, it is claimed that SureFlo can optimise the surface properties of plastic products and improve the homogeneity of polymer blends. The additive can be
used in virgin and recycled polymers, including polyolefins, styrenics and engineering plastics, plus it has proved its performance capabilities in masterbatches.
www.tergroup.com www.flowpolymers.com
The international conference on advanced elastomer, composite and thermoplastic materials in oil and gas applications
23-25 October 2012

Millennium Gloucester Hotel, London, United Kingdom
Images courtesy of: Harald Pettersen/Statoil *+20% UK VAT
Special offer: Save 150*/135* if you register before 21st September 2012
Organised by: Applied Market Information Ltd. and Sponsored by: Media supporters:
This months free brochure downloads

Simply click on the brochure cover or link to download a PDF of the full publication
Poly.ERP: case study

Get To Know Struktol
Quick Guides
Struktols vast polymer additive experience is translated into the most intelligent solutions available anywhere. Each of our additives are tested and retested to insure maximum product quality and performance consistency.
Struktol: additives for plastics

Struktol Company of America
Struktol Company of America is a member of the Schill & Seilacher family of companies, with representation in over 100 countries around the world. A global organization with over a century of specialty chemical expertise, Schill & Seilacher markets most of their polymer processing products under the brand name STRUKTOL a name that has become synonymous with both quality and performance. Struktol manufactures chemicals for the plastics and rubber industry, foam inhibitors, polydispersions, silicone emulsions, products used in latex processing, and POLYDIS, a line of epoxy prepolymers and flame retardants.
Struktol manufactures a complete line of additives that function individually or in combination as adhesives, lubricants and surfactants, all accompanied by a wide range of benefits.
Case Studies
Improved Processing
Improved Performance
Cost Reduction
This 16-page case study from Kirchhoff Datensysteme examines the development of its Poly.ERP customised ERP system for compounders and how it was successfully implemented at Polymer Chemie.
A compounder of flame retarded polypropylene was unable to efficiently mold their compound due to the high temperatures and pressures required during processing. The molding conditions caused problems with the flame retardant system. By adding 1% of STRUKTOL TR 251 the industry benchmark. the customer was able reduce the process temperature fill the mold. by 20C and reduce the pressures required to completely A compounder of polycarbonate resin was able to reduce the viscosity of his product by 25% using 1% due to the additive. This viscosity reduction led to a corresponding reduction in molded-in stress which of STRUKTOL TR 044W without sacrificing any clarity
Struktol Company of America 201 E. Steels Corners Road P.O. Box 1649 Stow, OH 44224-0649 330-928-5188 800-327-8649 Fax: 330-928-0013 Email: customerservice@struktol.com
The Struktol approach to the rubber and plastic additives business is by no means typical or ordinary. Chemistry is at the heart of everything we do. Providing Intelligent Additive Solutions, Struktol products are designed to meet the challenges and exacting demands of our customers. Our technical specialists, R&D chemists and compound laboratory are dedicated to creating innovative solutions for the ever-changing polymer industry solutions that keep you ahead of your competition with increased productivity, better quality parts and lower overall cost. In addition to premium product performance, Struktol Customer Service initiatives have become
improved the mechanical performance of the material. In addition the additive provided improved mold filling and release.
www.4struktol.com
This brochure from Struktol covers its wide range of additives for thermoplastics, including products for superior viscosity control, improved mixing and filler dispersion, plus reduced friction and plate out.
A rigid PVC profile extruder was able to increase the
addition level of regrind into his product by adding a
costabilizing STRUKTOL V Series product. The additive maintained the heat stability of the compound resulting in substantial cost per part savings due to the increased level of regrind added. No performance reduction was seen.
Many Struktol Intelligent Additive Solutions are the result of a partnering effort between our customer and our sales and technical staff. If we dont have the product that meets your needs you can count on us to develop something that exceeds your requirements.
Click here to download
TEB0047/2012
Intelligent Additive Solutions for Todays Thermoplastic Industry
Timcal: carbon addtives

This new 24-page technical brochure from Timcal covers the companys carbon additives for polymer compounds, including its Ensaco conductive carbon blacks and its Timrex graphite and coke.
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 classifiers.
K-Tron: producing LFTs

Smart Feeding & Conveying Solutions
B&P: Trivolution Tri-Kneader

This new brochure from B&P Process Equipment has details of the companys revolutionary Tri-Kneader for demanding compounding applications, delivering uniform dispersion at lower melt temperatures.
Application Example
Long Fiber Reinforced Thermoplastics
New Technologies
Long Fiber Reinforced Thermoplastics are a recent development in newer technologies where PP or thermoplastic material is directly compounded with long glass fibers (rovings) and then molded in one operation. Long Fiber Thermo-plastic technologies are the buzz of the auto industry in Europe and the US and are one of the most important trends in the plastics industry today. Glass fibers of (12 mm) up to 2 (50 mm) length give much higher stiffness, strength and toughness than the 1/8 (3 mm) fibers that have been used for reinforcement for decades. Long Fiber Reinforced Thermoplastics (LFT) have excellent mechanical proper ties and stiffness-to-weight ratio which is of great interest to the automotive industry. These in-line compounding processes for long fiber material offer users more flexibility, as they are able to both compound and process such materials in accordance with their own formulation and also use ready made compounds. For this process gravimetric feeders are used to feed the main polymer as well as the additives. Short term accuracy is one of the key elements because of the very short residence time in the twin screw compounder. The process requires a 58% 2Sigma deviation at a sample time of 510 sec. at a feed rate of 1.5 kg (3.3 lbs) of irregular additive pellets. and direct injection of long fiber reinforced thermoplastics. All three processes use continuous gravimetric feeders to feed accurately into the continuously operating extruder. Long fiber thermoplastics technology uses special screw configurations for both, single and twin screw extruders. predetermined ratio using vibratory loss-in-weight feeders.
Fiberglass
The glass fiber filaments are pulled into the extruder from continuous glass rovings on bobbins by the rotation of the screw shaft. The throughput of the fiber is volumetric and quite steady. Each fiber stand is monitored by an infrared sensor. The gravimetric throughput of the fiberglass can also be checked by mounting the bobbins on scales and measuring the weight loss over time.
Ingredients
The base polymer is generally fed with a single screw or vibratory loss-in-weight feeder. The integrated vacuum receiver is responsible for the steady refill of the LWF. One to three additives such as colors, stabilizers, etc. in powder or pellet form are added via smaller loss-in-weight feeders (single or twin screwfeeders, vibratory feeders or Bulk Solids Pump feeders). Edge trimmings and other recycled materials are shredded and fed back into the process at a
Processes
There are currently three technologies of interest in the current market. These are E-LFT, D-LFT and S-LFT. E-LFT is the in-line compounding and direct extrusion of long fiber reinforced thermoplastics as profiles or sheets, while D-LFT is the in-line compounding and direct compression molding of long fiber reinforced thermoplastics. S-LFT is the inline compounding
End Products
Most LFT end products are produced for the automobile industry. These molded parts include body panels, sound shields, front-end assemblies, structural body parts, truck panels and housings as well as doors, tailgates and fender sections. Development is also strong in other areas of application in the electrical and building industries.
This four-page technical white paper from K-Tron discusses the selection of optimised materials feeding systems for the efficient production of long-fibrereinforced thermoplastics (LFTs).
Long Fiber Reinforced Plastics D-LFT: Coperion Werner & Pfleiderer System
1 Polymer pellets 2 Gravimetric feeder
3 Glass rovings 4 Motor and gearbox
5 Twin-screw compounder ZSK 6 Devolatilizing
7 Cutting unit 8 Separating unit
9 Robot 10 Press
If you would like your brochure to be included on this page, please contact Claire Bishop. claire@amimagazines.com. Tel: +44 (0)20 8686 8139
Download the programmes for these forthcoming conferences

Simply click on the brochure cover or link to download a PDF of the full publication
Multilayer Packaging Films

Multilayer Packaging Films 2012
International conference on the technology and markets for specialty and barrier packaging films
Stretch & Shrink Film

STRETCH & SHRINK FILM 2012
The business conference and exhibition for the stretch & shrink film industry
AMIs eighth international conference on Multilayer Packaging Films is being held in Cologne, Germany, on 16-18 October. This brochure has the full line-up of expert speakers.
HEADLINE SPONSOR
16-18 October 2012

Images courtesy of: EXTENDO GmbH and Macchi S.p.A.
* + 19% German VAT
November 6-7, 2012

Images courtesy of: Davis-Standard LLC, ITW Muller and Lachenmeier
Sheraton Society Hill Philadelphia, Philadelphia, Pennsylvania, USA
AMIs seventh annual Stretch & Shrink Film conference takes place on 6-7 November in Philadelphia, PA, USA. This brochure has the full programme that covers key business and technical trends in this dynamic market.
SPECIAL OFFER: Save 200* if you register before 7th September 2012
SPECIAL OFFER: Save $200 if you register before September 21, 2012
Organized by: Applied Market Information LLC Also sponsored by: Media supporter:
o +44 (0) 117 311 1534
Flexible Packaging Middle East

Flexible Packaging Middle East 2012
Market opportunities for films driven by technical sophistication
Wind Turbine Blade Manufacture

WIND TURBINE
BLADE MANUFACTURE
heaDline spOnsOr
12-14 November 2012

Shangri-La Hotel, Dubai, United Arab Emirates
The Flexible Packaging Middle East conference takes place in Dubai on 12-14 November. It will cover new materials and machinery developments, as well as featuring presentations from leading packaging producers in the region.
2012
International conference and exhibition on wind blade composites design, manufacturing and markets
Images courtesy of: reifenhuser Kiefel extrusion Gmbh, norner as, Borouge pte ltd., Dow europe Gmbh
heaDline spOnsOr
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.
27-29 November 2012

Image courtesy of: siemens
Maritim Hotel, Dsseldorf, Germany

* + 19% German VAT
speCial OFFer: Save 200 if you register before 28th September 2012
Organised by: Applied Market Information Ltd. Also sponsored by: Media supporter:
speCial OFFer: Save 200* if you register before 12th October 2012
o +44 (0) 117 311 1534
Organised by: Applied Market Information Ltd.
Also sponsored by:
Media supporters:
TM
Fax back to +44 (0) 117 311 1534
Thin Wall Packaging

Thin Wall Packaging 2012
International conference on market trends and developments in plastics tubs, cups and tray packaging
Plastics Industry Strategy Seminars

AMIs one-day Plastics Industry Strategy Seminars are delivered by Andrew Reynolds and provide insights into key trends in the global polymers market. This brochure lists our 2012 events in Europe, America and the Middle East.
Images courtesy of: natureworks llC, nestl, printing Company Verstraete nV., rpC Containers ltd. and sem plastik
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.
3-5 December 2012

* + 19% German VAT
speCial OFFer: Save 210* if you register before 2nd November 2012
Organised by: Applied Market Information Ltd. Sponsored by: Media supporters:
o +44 (0) 117 311 1534
To see our full line-up of more than 25 plastics industry events over the next 12 months, please visit www.amiconferences.com
compounder of the month
Polycompound
Head office location: Date founded: COO: Ownership: No. of employees: Sissach, Switzerland 1988 Peter Imhof Privately owned 35
Sales 2011: E14.5 million Plant locations: Production 2011: Sissach, Switzerland 9,600 tonnes
Profile: Polycompound was formed in 1988 when Buss decided to concentrate on its core business of manufacturing continuous mixing and kneading machines and therefore stopped compounding plastics itself. Some employees founded Polycompound as an independent joint stock company. The companys output has grown from an initial 1,500 tonnes to up to 10,000 tonnes. Product line: Polycompound is a toll compounder specialising in producing highly-filled compounds and additive masterbatches. These include a range of cable compounds, plus high-performance engineering plastics such as highly filled and semi-conducting grades, and also specialty products. Polycompound has extensive experience and technical knowledge of compounding with Buss kneaders, from lab-scale through to large-scale production. It has particular expertise in reactive compounding, the production of shear- and temperature-sensitive compounds, and processing nano-fillers.
Product strengths:
Forthcoming features
The next issues of Compounding World magazine will have special reports on the following subjects: September Pigments and colorants Weathering resistance Fillers and coupling agents October Reinforcing fibres Titanium dioxide Screenchangers
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
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 - July Compounding Worlds July edition takes a close look at cross-linking technologies, provides tips on colour measurement, and covers the latest developments in TPEs, nanotubes and ERP systems. Click here to view Compounding World June The June issue of Compounding World is packed with articles on cable industry trends, PVC stabilizer developments, medical compounding applications, bioplastics innovations, plus more top tips for twin-screw extruders. Click here to view
Injection World July/Aug The July/August issue of Injection World is full of features on the latest developments in PET preform production, foamed moulding technologies, automation systems, in-mould labelling and energy management. Click here to view
Injection World June Injection Worlds June edition is packed with articles on thermoplastic composites for automotive applications, aluminium tooling, temperature controllers, masterbatch trends, plus the latest in John Goffs moulding masterclass series. Click here to view
Pipe and Profile July/Aug The July/August issue of Pipe and Profile Extrusion boasts articles on a pipe makers Olympics success, control systems for increased extruder efficiency, developments in pipe fittings, plus new test regimes. Click here to view
Film and Sheet June/July The June/July edition of Film and Sheet Extrusion looks at developments in polymers for photovoltaics, reviews the market for heavy duty sacks, and examines Europes leading PE film producers. Click here to view
Take out your own free subscriptions to any of the magazines. Click on the logos below to simply register on-line.
dates for your diary
Global exhibition guide

6-9 September 10-14 September 17-19 September 21-25 September 24-27 September 25-26 September 26-27 September 1-5 October 5-8 October 16-20 October 24-27 October 14-15 November 29 Nov 2 Dec 2013 7-10 January 29 Jan - 1 Feb 6-7 March 12-15 March 12-15 March 3-6 April 10-11 April 14-16 May 20-23 May Plastex, Cairo, Egypt Plastex, Brno, Czech Republic Kenya Plast, Kenyatta, Kenya TaipeiPlas, Taipei, Taiwan Plast Alger, Algiers, Algeria Mediplas, Birmingham, UK Kunststoffen, Veldhoven, Netherlands ColombiaPlast, Bogota, Colombia IndPlas, Kolkata, India Fakuma, Friedrichshafen, Germany VietnamPlas, Ho Chi Minh City, Vietnam Expoplast, Montreal, Canada Plast Eurasia, Istanbul, Turkey ArabPlast, Dubai, UAE Interplastica, Moscow, Russia Plastec South, Orlando, FL, USA Plastimagen, Mexico City, Mexico Pro-Plas Expo, Johannesburg, South Africa Tiprex, Bangkok, Thailand PlastTeknik, Malmo, Sweden Plast-Ex, Toronto, Canada Chinaplas, Guangzhou, China www.plastex-online.com www.bvv.cz/plastex www.kmgindia.com www.taipeiplas.com.tw www.plastalger.com www.mediplasuk.com www.kunststoffenbeurs.nl www.colombiaplast.com www.indplas.in www.fakuma-messe.de www.vietnamplas.com www.expoplast.org www.plasteurasia.com www.arabplast.info www.interplastica.de www.plastecsouth.com www.plastimagen.com.mx www.proplasafrica.co.za www.tiprex.com www.easyfairs.com www.plast-ex.org www.chinaplasonline.com
AMI conferences
25-26 September 9-10 October 23-25 October 27-28 November 27-29 November 29-31 January 18-20 February 25-27 February 5-7 March 19-21 March Medical Grade Polymers, Boston, MA, USA Polymer Foam, Newark, NJ, USA Polyolefin Additives, Cologne, Germany Minerals in Compounding, Atlanta, GA, USA Fire Resistance in Plastics, Cologne, Germany Thermoplastic Concentrates, Coral Springs, FL, USA The Grass Yarn & Tufters Forum, Cologne, Germany Wood-Plastic Composites, Vienna, Austria Cables, Cologne, Germany Green Polymer Chemistry, Cologne Germany
For information on all these events and other conferences on film, sheet, pipe and packaging applications, see
www.amiplastics.com
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.

CW August 2012

Încărcat de

Informații document

Descriere originală:

Titlu original

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

CW August 2012

Încărcat de

Drepturi de autor:

Formate disponibile

August 2012

ANDROID VERSIONS NOW AVAILABLE

17 Developments in masterbatch carriers

27 PVC plasticizers: the search for soft options

45 Expanding interest in lightweight parts

53 New products: polymers and additives

58 Compounder of the month: Polycompound 60 Dates for your diary

coming next issue

quan tec 96 EV-10C

BUSS KNEADER TECHNOLOGY

Cutting-Edge Compounding Technology MX and quan tec BUSS Kneader Series

Buss AG Hohenrainstrasse 10 4133 Pratteln Switzerland

Phone +41 61 825 66 00 Fax +41 61 825 68 58 info@busscorp.com www.busscorp.com

Manufacturers defend flame retardants in the US Senate

Evonik invests in its crosslinking additives

Europe adds new biocide regulation

Sabic plans to increase Stamax LGFPP capacity

Styrolution extends PW agreement

compounding world | August 2012

solar reection with color

Arkema sells stabilizers to PMC

Itochu signs CNT deal with SWeNT

Vinyl Compounds adds new line

compounding world | August 2012

Sun Chemical acquires metallic effects supplier Benda-Lutz

Georgia Gulf plans PPG deal

Schulman begins construction of new headquarters building

facility will accommodate approximately 130 employees.

compounding world | August 2012

US could face tougher chemical regulations

Solvay starts up Chinese compounding

PlastiComp develops translucent LFT

compounding world | August 2012

EPA checks decaBDE alternatives

Suzuki seeks to patent talc-free PP compound

New EU audit scheme sets the standard for recycled plastics

compounding world | August 2012

new possibilities for compounding with Vistamaxx PBE

CLICK HERE FOR DETAILS

23-25 October 2012

Carrier materials | masterbatch feature

Developments in masterbatch and additive carrier materials

masterbatch feature | Carrier materials

masterbatch feature | Carrier materials

Porous carriers for liquids

masterbatch feature | Carrier materials

The tubular structure of Applied Minerals Dragonite allows it to carry additives

compounding world | August 2012

masterbatch feature | Carrier materials

CONFERENCES ON THE MOVE

27-29 November 2012

Maritim Hotel, Dsseldorf, Germany

POLYMERS IN PHOTOVOLTAICS 2012 CONFERENCE INFORMATION

International forum on markets, materials and manufacturing of photovoltaics

The full delegate fee is 990 + 19%* = 1178.10 per delegate

Welcome cocktail reception

FEES PAID - please tick box and write amount:

___________ ___________ ___________ ___________

24-26 April 2012

Fax back to +44 (0) 117 311 1534

Brought to you by Plastics Information Direct Online Bookshop

Compatibility of Pharmaceutical Solutions and Contact Materials

compounding world | August 2012

compounding world | August 2012

compounding world | August 2012

compounding world | August 2012

compounding world | August 2012

compounding world | August 2012

_____ _ _ _____

compounding world | August 2012

compounding world | August 2012

compounding world | August 2012

compounding world | August 2012