CW June 2012

June 2012
Focus on medical compounding

giving a boost to bioplastics
more top tips For twin-screws
well connected: trends in cables
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plastics industry, AMI is now also making its titles available free-of-
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Copyright Applied Market Information. No part may be reproduced without the prior written permission of the publisher.
www.compoundingworld.com June 2012 | compounding world 3
04 Industry news
The latest compounding industry news including international acquisitions and
alliances, plus new investments and plant openings.
13 Monitoring changes in Europes cable industry
Ami has recently completed a new guide to Europes cable industry. Andrew
reynolds looks at how the market is changing.
19 Healthy growth for medical compounding
medical compounding applications are growing in volume and sophistication.
Jennifer markarian looks at new developments.
27 Top tips for twin-screw extruders part two
How do you get the best from your twin-screw extruder? Bert Elliott of leistritz
has more practical tips in this second instalment of his two-part article.
39 PVC additives: seeking stability
Speakers at the recent pVc Formulation conference discussed new stabilizer
developments for a wide variety of vinyl applications.
45 Why green plastics are here to stay
Biodegradability no longer dominates the bioplastics marketplace. chris Smith
takes a look at the changing face of the bio-based polymers industry.
56 Compounder of the month: FKuR Kunststoff
58 Dates for your diary
coming next issue
cross-linking understanding and monitoring colour Thermoplastic elastomers
Click here to make sure you get your copy
contents
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Applied Market Information Ltd
Ami House, 45-47 Stokes croft,
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www.amiplastics.com
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direct tel: +44 (0)20 8686 8139
Huntsman is introducing
ALTIRIS infrared reflecting pigment
to the AMI Profiles Conference
June 5-6th 2012
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
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solar reection
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To learn more please visit the
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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 lead-
stabilized, 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
regain polymers has
commissioned a new
coperion twin-screw
extruder at its plastics
recycling plant in castleford
in the uK. The line, which is
ftted with a gala underwa-
ter pelletizing system, lifts
the facilitys compounding
target to 50,000 tonnes/year.
The companys technical
sales director, mark
roberts said: The
twin-screw extruder went
into full production as
planned at the start of June,
increasing our extrusion
capacity by 40%.
Earlier this year, regain
acquired Express recycling
& plastics based in
rainham, Essex, uK.
www.regainpolymers.com
regain buys
new twin-
screw line
A Schulman is forming a 50:50
joint venture with national
petrochemical industrial
company (natpet) to establish
a polypropylene compounding
operation in Saudi Arabia.
The business, which will be
called natpet-Schulman
Engineering plastics com-
pounds, will be located at
natpets site at Yanbu and is
expected to commence
production before the end of
2014. it will cost around uS$70
million to build the facility.
uS-headquartered
Schulman said its share of the
initial equity investment in the
project amounts to around
uS$14 million; the JV partners
will also seek funds from the
Saudi industrial development
Fund and other lenders.
The operation will manu-
facture and sell a range of
engineered plastic compounds
for use in durable goods and
transport applications in the
middle East, Africa and india.
Schulman will sell product
from the venture itself directly
outside of these markets.
The agreement with natpet
also allows Schulman to
distribute the Saudi Arabian
frms polypropylene resins to
specifed customer segments
in Europe.
Several aspects of this
deal will accelerate A Schul-
mans expansion and visibility
in its priority growth markets
of Africa, india and the middle
East while better serving our
existing global customers with
high-quality polypropylene
compounds, said Bernard
rzepka, general manager and
chief operating offcer of A
Schulman, Europe, middle
East, Africa.
www.aschulman.com
www.natpetpp.com
A Schulman and natpet
form pp compounds JV
Tnsmeier Kunststoffe of
Hxter, germany, has added
another Battenfeld-cincinnati
twin-screw extrusion line for
recycling and pelletizing
reclaimed pVc from the pipe
and profle industries.
The new line features a
Battenfeld-cincinnati BEX
2-135-28V twin-screw
extruder, a continuous
screen-changer and a gwH
130 hot-cut pelletizer. marc
Schmidt, managing director of
Tnsmeier Kunststoffe, says
that the line was selected
because of the overall
package of reliability, user-
friendliness and service.
Tnsmeier adds pVc pelletizing line
Tnsmeier works closely
with the german plastic pipe
Association KrV on the
collection and recycling of pipe
materials. it is also a member
of rewindo, a recycling
initiative formed by germanys
leading profle manufacturers.
Schulmans Bernard Rzepka
says the deal will accelerate
growth in priority markets
The company produces
more than 70,000 tonnes/year
of secondary raw materials at
seven facilities in germany,
Austria and poland. in addition
to selling the reclaimed
polymers to other companies,
Tnsmeier Kunststoffe also
uses some of the recycled pVc
in-house for the production of
profles.
www.toensmeier-kunststoffe.de
www.battenfeld-cincinnati.com
Tnsmeier has added a new
Battenfeld-Cincinnati line for
pelletizing reclaimed PVC
from pipes and profles
compounding world | June 2012 www.compoundingworld.com 6
news
delta Kunststoffe has installed
a new coperion compounding
line at its plant in weeze,
germany, to produce electri-
cally conductive compounds.
The ZSK megavolume plus
twin-screw extruder is being
used to compound carbon black
with a range of resins including
pp, pE, pS and pA. it has
76 mm diameter screws and
can produce compounds with
carbon black loadings of
15-40% at throughputs between
1,000 and 1,500 kg/hour.
The deep-fighted screws
with an od/id ratio of 1.8 work
well with the downstream
metering of the conductive
carbon black into the molten
polymer using a ZS-B
twin-screw side feeder.
Effcient degassing is achieved
with a ZS-Eg twin-screw side
devolatilization unit.
The screws feature special
mixing elements to distribute
the carbon black uniformly,
delta invests in line for
conductive compounds
plus was certainly the right
choice. Thanks to its volu-
metric capacity and its effcient
metering of the conductive
carbon black into the melt we
are able to achieve high output
rates. Above all, however, we
can now beneft from the high
quality of compound achieved
with this twin-screw extruders
excellent mixing behaviour.
www.delta-kunststoffe.de
www.coperion.com
delivering the desired
conductivity with relatively low
levels of carbon black. Testing
carried out in coperions lab
showed that the electrical
resistivity in the compound will
be reduced by up to 10
12
when
flled with a specialty carbon
black at loadings between 16
and 20 %.
manfred Fiedler, works
manager at delta Kunststoffe,
said: The ZSK 76 megavolume
lanxess is investing
E75 million to construct a
new 90,000 tonnes/year
plant to produce high
performance polyamides at
Antwerp in Belgium.
The new facility is being
built near to the companys
caprolactam plant and is
scheduled to commence
production in the frst
quarter of 2014.The
polymers produced on the
site will be converted to
durethan brand products at
lanxess compounding
facilities worldwide.
The company expanded
its caprolactam capacity on
the Antwerp site to 220,000
tonnes/year in 2011 and is
in the process of renewing
the frst of its two glass
fbre ovens as part of a
two-year programme that
will expand capacity to
66,000 tonnes/year by 2014.
www.lanxess.com
lanxess
plans new
pA plant
Automotive components
supplier Johnson controls is
using a natural fbre reinforced
polymer composite to
manufacture the door trim
panels for the new Bmw
Series 3 car, claiming a 20%
weight reduction over current
alternatives.
The company says that the
non-visible door panel
structural elements are
manufactured from a light-
weight wood-fbre-reinforced
polymer compound. The
Jci adds natural fbres to Bmw 3 Series
weight of the part has been
further reduced through the
development of a new trim
technology called groove
Managers from Delta Kunststoffe and Coperion conclude the
sale of the new ZSK compounding line
The latest BMW 3 Series benefts from natural fbre reinforced plastics
lamination, which allows the
fabric or leather trim materi-
als to be joined in recesses in
the moulding. This eliminates
the need for additional
sub-structure parts, according
to the company.
www.johnsoncontrols.com
news
georgia gulf is developing new
fexible pVc compounds based
on Javelin bio-plasticizers
from Segetis. The two
uS-based companies signed a
collaboration agreement
covering the technology last
month.
Segetis says that it makes
the Javelin bio-based plasticiz-
ers using cellulosic-based
uS-based biopolymers
company danimer Scientifc
and the compounds and
additives group Standridge
color have announced
plans to manufacture
biopolymers for the
European market at
Standridges facility in the
czech republic.
The two companies have
worked together in the uS
for almost 10 years with
georgia-based Standridge
providing manufacturing
services to danimer, which
is now aiming to increase
its presence in Europe.
Standridge color
continues to be a signifcant
asset to danimer due to
their fawless ability to
produce our proprietary
biopolymer compositions as
well as interact with our
international client base,
said Scott Tuten, vice
president of danimer
Scientifc.
www.danimer.com
www.standridgecolor.com
uS frms
expand in
bioplastics
georgia gulf and Segetis collaborate
heavy metals, said william
doherty, vice president for vinyl
compounds at georgia gulf.
The company is also
developing fexible vinyls using
drapex Alpha natural oil-
based plasticizers from galata
chemicals (see Compounding
World, April 2012, page 5).
www.ggc.com
www.segetis.com
Toho Tenax plans to double pro-
duction capacity for nickel-
coated carbon fbres at its
mishima plant in Japan by
January 2013. The company,
which is part of Teijins carbon
Toho Tenax invests in coated fbres
levulinic ketals. They are
claimed to be highly effcient
with excellent permanence,
delivering faster processing
speeds and elevated tempera-
ture performance.
georgia gulf has begun to
introduce new fexible
compounds based on the
Javelin plasticizers into toys
and decorative construction
materials, plus it is developing
new compounds for a growing
range of applications.
The addition of the
specialty bio-based plasticizers
from Segetis expands our
sustainable product portfolio
and underscores our commit-
ment to offer a range of
solutions to our customers that
are free of phthalates and
fbre and composites business,
has set a sales target for the
products of more than 2 billion
(E20 million) in 2013.
The nickel-coated carbon
fbres are used to produce con-
ductive plastics for electronic
device applications, and Toho
Tenax aims to expand into
other industries where
demand for electromagnetic
shielding is expected to
increase, such as the aviation
and electric vehicle markets.
The companys proprietary
nickel-coated carbon fbres
add metal-equivalent conduc-
tivity to the superior mechani-
cal characteristics of the fbres.
They can then be compounded
into a plastic and moulded into
strong chassis structures and
other electromagnetic
shielding components.
www.tohotenax.com
Toho Tenax predicts
growing demand for
its nickel-coated
fbres in conductive
compounds
compounding world magazine is now available
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To access the new com-
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which is sponsored by leistritz,
search for Ami plastics in
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Android app for compounding world
news
Japanese frms mitsui
chemical and prime polymer
have announced an expansion
of their polypropylene automo-
tive compounds operations in
the uS, mexico and china
totalling 63,000 tonnes/year,
along with a frst move into the
Brazilian market.
The expansions, which are
all due for completion before
the end of next year, include:
the addition of a new 28,000
tonnes/year line to the
Advanced composites
business in the uS that will
take total annual capacity to
254,000 tonnes; a 25,000
tonnes/year line for the
Advanced composites
mitsui adds to compound capacity
mexicana facility lifting annual
output to 70,000 tonnes; and, a
10,000 tonne line at the mitsui
Advanced composites plant at
Zhongshan in china taking
total capacity to 70,000 tonnes.
The companies have also
made a frst move into the
Brazilian pp compounding
market with the acquisition by
prime polymer of a 70% stake
in produmaster industria e
comrcio, which has been
renamed produmaster
Advanced composites
industria.
The company is Brazils
third largest compounder,
according to prime polymer,
with 38,000 tonnes of pp
compounding capacity in Sao
paulo and a 50% stake with
Alberto de Boni neto in a
17,000 tonne unit at Bahia.
mitsui chemicals owns a
65% stake in prime polymer,
which generates annual sales
of 280 billion (E2.8 billion).
www.mitsuichem.com
www.primepolymer.co.jp/english
milliken
launches
ipad app
milliken has introduced a
new ipad app that demon-
strates the energy saving
potential of its millad nX
8000 clarifying agent for
polypropylene. The app also
estimates cycle times and
co
2
reductions for clear pp
parts produced using the
additive compared to those
made using traditional
clarifed pp.
The free millad nX 8000
Savings calculator app is
available in iTunes for ipads
(visit: http://bit.ly/Millad),
while an iphone version is
scheduled to be introduced
before the end of June. The
calculator is also available
online at:
http://bit.ly/Milliken.
lichtenfels, germany-based
masterbatch frm lifocolor
Farben has acquired micro-
color masterbatch, based in
Straufhain, also in germany,
for an undisclosed sum.
The move gives lifocolor an
additional manufacturing
The Advanced Composites plant in the US is one of several sites
benefting from new investments
operation in the german
market, as well as its existing
facilities at Brno in the czech
republic, Bellignat in France
and Bydgoszcz in poland.
lifocolor claims a group
production capacity of more
than 5,000 tonnes a year of
colour and additive master-
batch. in February this year, it
announced a E2 million
investment in a new 1,000
tonnes/year masterbatch
manufacturing plant at its
facility at Bydgoszcz in poland.
www.lifocolor.de/en
lifocolor acquires microcolor
Elasto seals chilled lunches
Elasto developed a custom grade of its dryfex TpE to
produce the seals on the novel Frozzypack lunchbox,
which incorporates an integrated cooling pack. moulded
in Sweden by Eskilstuna-based Bonaj, the
lunchbox was designed by carolina Sundberg
and is claimed to keep food cool for up to
seven hours.
The dryfex TpE seals are over-moulded onto
the pp box to provide a permanent bond. The TpE
complies with Eu and Swedish normpack food
contact regulations and withstands exposure to
dishwashers and freezers.
www.elastotpe.com
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Organic
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wire and cable
You name it, we produce it
Our range of crosslinking peroxides for the wire
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as an extensive range of clay, whiting, silica and
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Formulations with different phlegmatizers can be
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www.akzonobel.com/polymer
European cable trends | markets feature
AMI has recently completed a new
guide to Europes cable industry.
Andrew Reynolds looks at
how the market is changing
cables continue to be at the forefront of technical
innovation in the plastics sector in terms of the
formulation and modifcation of resins and the develop-
ment of additives, particularly concerning fame
retardant applications and use of low smoke and fume,
zero halgoen (lSFoH) polymers.
in the past three years there has been a consolidation
of the cable market as companies look to expand their
geographical reach and boost their negotiating power
both with raw material suppliers and the end users of
cables. many companies have been refocusing their
product range with plants specialising in the manufac-
ture of particular cables supplied to certain markets.
These changes are often driven by local demand.
Polymer demand in cables
Applied market information (Ami) has recently com-
pleted a new edition of its Guide to the Cable Industry
in Europe with full details of 326 production sites. its
analysis of the production of these companies reveals
that Europes current annual consumption of cable
compounds is more than 1.2 million tonnes. despite the
impact of the global fnancial crisis in 2008 and 2009
and the current eurozone crisis, production of cable
appears to be growing in Europe overall, although it is
still below the volumes seen in 2007.
The European cables market is diffcult to analyse as
a whole because there are such a wide variety of
material options available and these tend to vary
considerably on a geographical basis. despite attempts
at European harmonisation, standards still vary
signifcantly from country to country and this also
affects material selection.
pVc remains the main polymer material used in
cable production in Europe, and indeed the world, with
close to 90% of cable extrusion sites processing pVc. it
accounts for close to half of the European cable
industrys polymer demand.
The resin has been favoured for so long by cable
producers because of its competitive price, technical
performance and ease of processing. many cable
producers also have their own in-house pVc compound-
ing facilities, ensuring a commitment to this material.
However, over the past decade its use by west
European cable extruders has declined steadily by
around 2-3% per year. This trend is forecast to continue
monitoring changes in
Europes cable industry
markets feature | European cable trends
for the foreseeable future, especially now that fnished
pVc cables are increasingly being imported into west
Europe from russia, central Europe and even china.
polyethylene cable grades account for more than
40% of the market and overall they have fared better in
the past few years. However, a number of grades within
this category are experiencing mixed fortunes. demand
for conventional ldpE and cellular pE in cable produc-
tion has declined, while the use of linear grades of pE
and low smoke fume zero halogen materials (lSF0H)
has grown very rapidly, although volumes are still
relatively small. other polyethylene materials, such as
cross-linked materials, have seen steady growth, while
demand for high or medium density polyethylene has
been lower, refecting some material substitution as
well as market maturity. The overall effect has been for
the market for polyethylene to grow relatively modestly
at between 1 and 2% per year over the past decade.
polypropylene materials have experienced healthy
growth in European cable applications over recent years,
although this market remains very small. pp is
mainly used in fbre optic cables. The main
other polymers used in cables are various
types of elastomer materials and TpEs.
demand for cables has generally
been depressed in recent years
because of the impact of the sovereign
debt crisis in Europe which has seen
massive cutbacks in infrastructure
projects. However, there remain
pockets of new development helping to
drive the market. The need for renewable
energy sources, particularly investment in
wind farms, including offshore facilities, is
helping to support demand in the energy cable segment.
For example, ABB of Sweden has recently an-
nounced plans to double capacity at its Karlskrona plant
to supply the renewable energy segment. ABB won a
signifcant order from the dutch-german transmission
grid operator TenneT to supply a high-voltage power
transmission link connecting nordergrnde, an offshore
north Sea wind farm, to the mainland grid in germany.
Jdr cables, with two production sites in the uK, has
also beneftted from growth in the renewable energy
sector and has been supplying cables for use at The
london Array wind farm in the Thames Estuary.
Distribution of the market
in terms of polymer consumption, the german and
italian cable industries still lead the way with demand of
15% and 14% respectively. The gap between the two
countries seems to have closed up as the European
market leader, prysmian, has consolidated its produc-
tion in italy with the acquisition of the plants operated
by the dutch group draka and the closure of its plant in
livorno Ferraris. Europes traditional industrial
powerhouses - germany, France and Spain - still make
up the lions share of the market. The demand of
polymers for cable in Scandinavia remains very strong
thanks to the developments in the renewable energy
market in northern Europe. uK has suffered most
though with demand dropping by around 15% in the
past four years.
whilst many European economies continue to
struggle, poland has remained relatively untouched by
the recession. Thanks to production shifting from west
to east, poland now accounts for more than 10% of
European polymer consumption for cable manufactur-
ing. This growth has been driven by the countrys attrac-
tive overheads and labour costs, plus its local construc-
tion and infrastructure market, which has been lifted by
ABB is
connecting the
Nordergrnde
offshore wind
farm to the
mainland grid
in Germany
Central
Europe
Other
West
Europe
Germany
Italy
France
Spain
Scandinavia
UK
Benelux
CoNsumptioN
of CompouNds
for CABle
produCtioN iN
europe (2012)
source: Applied market
information 2012
B
U
S
S

K
N
E
A
D
E
R

T
E
C
H
N
O
L
O
G
Y
Cutting-Edge Compounding Technology
MX and quantec
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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:
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Buss AG
Hohenrainstrasse 10
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Phone +41 61 825 66 00
Fax +41 61 825 68 58
info@busscorp.com
www.busscorp.com
quantec
96 EV-10C
markets feature | European cable trends
hosting the European 2012 football championships.
despite having half the number of cable manufacturing
sites as Spain, poland now uses the same volume of
polymer in cable applications.
Structure of the industry
This consolidation of the market, coupled with an
unfavourable economic climate, has led to a slight
reduction in the total number of sites listed in Amis new
guide. in 2012 there are 326 sites listed compared to 340
in the previous edition which was produced in 2008.
prysmian of milan now dominates the cable industry
in Europe. prysmian confrmed its position as market
leader in early 2011 when it beat rival offers from chinas
Xinmao and Frances nexans to take over the dutch
group draka. with over 40 manufacturing sites spread
over the continent from catalonia
in the west to Hungary in the east,
prysmian now owns more than
10% of Europe cable plants.
other large groups with a
strong European presence include
nexans of France, polands
Tele-Fonika Kable, danish group
nKT, Finnish company reka
(owned by neomarkka), leoni
from germany and italys la
Triveneta. in may 2011, the dutch Engineering group
Fugro acquired the Jdr cable Systems division in
Krimpen aan den lek in the netherlands. it was renamed
de regt marine cables while its product portfolio of
subsea cable systems remains the same.
in June 2009, HEw Kabel, a german custom cable
extruder using TpEs and fuoropolymers, reverted to
being a privately owned company having previously been
a subsidiary of the Belden group. changes have also
taken place in the uK market. in 2009, the refex group
acquired the British Allen group to form refex & Allen,
which supplies the automotive sector. in the same year,
the italian cable manufacturer Tratos completed its
acquisition of uK-based north west cables.
www.amiplastics.com
Offshore wind
farms like the
London Array
project are
lifting demand
for Europes
cable makers
more information
The Guide to the Cable Industry in Europe has
just been published in both book and cd form. it
lists 326 cable production sites with contact
details plus information on the polymers
processed and the types of cables that are
manufactured. To fnd out more, visit
http://bit.ly/CableGuide.
Amis Cables 2013 conference will be held
in cologne, germany, on 5-7 march. For
information about attending, sponsoring,
exhibiting or speaking at the event, visit
http://bit.ly/Cables2013.
The American version of this conference,
Polymers in Cables 2013, is being held in miami,
Florida, on 23-24 April. For information about
attending, sponsoring, exhibiting or speaking at the
event, visit http://bit.ly/USACables2013.
A team led by noru Tsalic, senior vice president
at Ami, is currently researching a multi-client study
on the European wire and cable industry. Sched-
uled for completion later this year, it will provide
detailed analysis of market, technology, legislative
and strategic trends. For more information, contact
him at nt@amiplastics.com, Tel: +44 117 924 9442.
SINO-ALLOY MACHINERY INC.
Extrusion Solutions
www.sinoalloy.com
mikechen@sinoalloy.com
PH: +886-3-483-8475 FAX: +886-3-483-9052
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nd
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Tao-Yuan Hsien, 32853 Taiwan
*Clamshell barrel available on PSM20A
don@sinoalloy.com
sindy@sinoalloy.com
pharmaceutical compounding | processing feature
The use of compounding extruders is growing in some
very different segments of the medical industry.
Application areas such as diagnostic equipment
housings, hospital equipment, medical devices and
pharmaceuticals each have their own formulations,
requirements and regulations.
compounding has for some time been used to
incorporate ingredients such as radiopaque additives
and custom colours in materials for healthcare
equipment and medical devices, but now a greater
variety of polymers and additives are being used. For
example, antimicrobial additives are increasingly being
added to compounds for devices such as catheters and
medical equipment housings (see Specifying silver
antimicrobials for medical devices in Compounding
World, February 2012, page 33).
Another growing application area is the compound-
ing of bioresorbable polymers. Tony listro, managing
director at Foster Delivery Science, a pharmaceutical
contract organization that specializes in hot-melt
extrusion for drug delivery, explains that bioresorbable
compounds are used in medical devices such as bone
screws and anchors. They are meeting growing
demands for bioresorbable implants, especially in
orthopaedics.
ConMed Linvatec Biomaterials of Finland is also
active in this market and is using a KraussMaffei
Berstorff ultra glide laboratory twin-screw extruder to
produce bioresorbable polymers based on polylactic
acid (plA). The company manufactures a range of
implants under cleanroom conditions, including screws,
plates or pins for fxing broken bones. As the bone
heals, the implants biodegrade and are absorbed by the
body. This helps the healing process and eliminates the
need for repeat surgery to remove the implant.
in such compounds, the plastic matrix is the
functional piece, but the compound often includes a
bone growth additive. Active pharmaceutical ingredients
(Apis) are also being compounded into polymers for
medical devices in which they deliver localized,
controlled release, such as some implants (long-term
devices) or catheters (short-term devices) that release
anti-infammatory drugs.
one of the most recent emerging technologies is
Healthy growth for
medical compounding
medical compounding applications are growing in volume
and sophistication. Jennifer Markarian looks at new
developments using a variety of active components
processing feature | pharmaceutical compounding
direct compounding extrusion of Apis into devices
whose primary function is controlled release of a drug.
Examples include drug-eluting patches, implantable
rods, and profles of various shapes, such as coextruded
vaginal rings imbedded with anti-HiV or contraceptive
drugs for controlled release from the drug-loaded core
through the exterior layer
(1)
.
Hot-melt extrusion
Apis are also being melt compounded into inactive
polymeric carriers (i.e. excipients) to manufacture
drugs in solid dosage form, such as tablets. while the
plastics industry calls this mixing process compounding
extrusion, the pharmaceutical industry calls it hot-
melt extrusion (HmE). use of twin-screw melt
extrusion in pharmaceutical applications emerged in
the past decade, and is increasingly being used to
manufacture drugs. Examples of common polymeric
excipients include polyvinylpyrrolidone (povidone) and
cellulose derivatives like hydroxypropyl methylcellulose
(Hpmc or hypromellose).
A key driver for the use of melt extrusion is to
improve the oral bioavailability (i.e. how much of the
drug eventually reaches the bloodstream) of Apis. Some
Apis are poorly water soluble, which means that the
rate at which they dissolve limits their absorption and
oral bioavailability. melt extrusion has the capacity to
enhance dissolution rates and oral bioavailability of
some poorly soluble drug substances, which makes it a
valuable tool
(1)
. Since an increasing number of new drug
candidates are poorly soluble, the need for melt
extruders is growing.
This trend is further driven by the desire in the
pharmaceutical industry to improve effciency by moving
away from batch processing to continuous processing in
some applications. The uS Food and drug Administration
(FdA) is promoting the idea of quality-by-design (Qbd) for
pharmaceutical processing, including a process
analytical technology (pAT) initiative, in which critical
process parameters are measured and controlled,
preferably in-line, in order to ensure fnal product quality.
The FdA views continuous processing as a way to
improve quality and safety by managing variability
(2)
.
continuous processes, which are more predictable and
consistent than batch processes, are more repeatable
and lend themselves more easily to controlling process
parameters in order to control variability. melt extrusion
is one type of continuous process that the pharmaceuti-
cal industry is adapting.
Regulatory requirements
A distinguishing characteristic of medical compounding
is the need to comply with regulatory requirements,
which are specifc to the country in which the product will
be sold. production of drugs and devices for the uS must
follow current good manufacturing processes (cgmp),
which are quality system guidelines from the FdA.
These guidelines cover a broad range of areas from
the code of Federal regulations (21cFr 211: organiza-
tion and personnel; buildings and facilities; equipment;
control of components and drug product containers and
closures; production and process controls etc). The FdA
wants manufacturers to guarantee quality, safety,
identity, and effcacy (i.e. the potency) of each batch,
explains dr. Andrew loxley, director of new technologies
at Particle Sciences. This contract research organization
provides drug development services, including develop-
ment of formulations using hot-melt extrusion.
under cgmp guidelines, the materials of contact
(moc) with the drug product, which would include parts
of the extruder and auxiliaries, must be evaluated. in
general, all mocs should be cleanable, non-corrosive,
and non-additive (i.e. not add to or change the products
that touch them).
Because some Apis can interact with even hardened
stainless steels, the appropriate moc depends on the
formulations being run in the equipment. Equipment
ConMed
Linvatec is
using a
KraussMaffei
Berstorff lab
extruder to
make PLA
compounds for
absorbable
implants
Particle
Sciences is
using this
Leistritz ZSE 18
mm extruder to
develop
thermoplas-
tics-based
drug-eluting
products
p
H
o
T
o
:

A
n
d
r
E
w

l
o
x
l
E
y
processing feature | pharmaceutical compounding
manufacturers must document the materials of
construction used and their raw material sources.
processors using the equipment must develop cleaning
procedures for each formulation, and validate or prove
that they are effective.
materials of construction used in extruders for
medical applications generally require smoother
surfaces than typical plastic applications, since proces-
sors must document cleanability, notes Johannes
donner, process engineer for hot-melt extrusion at
Coperion. unlike most plastic compounds, pharmaceuti-
cal compounds are typically water-soluble, and proces-
sors generally use water to wash extruders between
different products. Todays extruder and peripheral
equipment designs, such as modular components with
quick disconnects that were built for easy cleaning in the
plastics industry, translate well into the cleanability
needs of the pharmaceutical industry, adds donner.
drug products for human use must be manufactured
in a clean room, which controls the environment to
avoid contaminating the drug. it also affects aspects of
the equipment such as how maintenance is performed.
The extruder drive can be placed outside the clean
room, with the processing section inside, notes donner.
HmE for drug-eluting devices that are not sterilized
must be done in at least a class 100,000 clean room,
which is equivalent to iSo 8. clean room classes range
from iSo 1, which is the most stringent, to iSo 9, which
is the least stringent.
Twin-screw extruders in medical development
Because many Apis are expensive or are only available
in limited quantities, developers often want to use as
small a sample as possible in the r&d process.
micro-compounding extruders have been designed to
process gram-size batches.
For example, the Thermo Scientifc bench-top Haake
minilab micro compounder processes samples as
small as 5 grams. others options include the Rondol
microlab 10 mm and DSM Xplore Xcelera (see the Big
ideas for small machines article in Compounding
World, December 2011, page 21).
A limitation of some of these very small extruders is
that they do not scale up to commercial size. However,
extruder manufacturers in the past few years have been
introducing extruders in the 12-20 mm diameter range
that run at rates appropriate for pharma process
development or small-scale commercial runs. These
extruders typically have the same geometry (od/id
ratio, similar screw profle and mixing elements) as
their larger-scale counterparts, which enables scale up
to commercial size extruders with diameters in the
range of 26 mm and larger.
Leistritzs nano-16 twin screw extruder, with 16 mm
diameter screws, 1.2 od/id ratio and 1 cc/diameter free
volume, is targeted for applications such as this and can
process batches as small as 20-100 grams. Batches in
the 20-50 gram range are made possible using
leistritzs patented plunger feeder that pushes
materials into the feeding zone at a specifed rate, less
than the rate of the feed screw, to allow starve feeding.
The nano-16 also uses tri-lobal screw elements
because of the geometric differences inherent with the
smaller od/id ratio, explains charlie martin, president
of the uS operations of leistritz. The nano-16 design
with the plunger feeder replicates the mechanisms of
production-scale equipment, and helps developers
determine if an Api-excipient formulation is amenable
to hot-melt extrusion, explains martin. The nano-16 can
also be scaled up to leistritzs micro-18 mm TSE with
bi-lobal screw elements and a 1.5 od/id ratio by using
the same motor, gearbox, and controls and exchanging
the process section.
Coperion offers an 18-mm co-rotating twin-screw
ZSK for the pharmaceutical development market. it has
the same 1.55 od/id ratio as the companys larger
mega compounding extruders. The barrel heating and
cooling system has been redesigned to increase
temperature control precision to +/- 1c and to give the
extruder the ability to change temperatures more
quickly during lab experiments, which is especially
important when working with expensive Apis.
other twin-screw extruders in this size range include
the Thermo Scientifc pharma 16, C.W. Brabenders
12-mm and 20-mm TSEs, and Steers o-micron 12-mm
TSE. process developers can use these smaller-scale
extruders to refne formulations and run processing
trials to optimize variables such as temperature and
Leistritzs
Nano-16 twin
screw extruder
can process
batches as
small as
20-100 grams
ENTEK_TammyStraw_CW_A4_060412_x1a.indd 1 6/4/12 3:30 PM
processing feature | Pharmaceutical compounding
screw profles before scaling-up to larger
extruders for commercial production. In some
cases, pharma compounders can use multiple
mid-size extruders to run their larger volume,
commercial applications, thus eliminating any
changes that might result
from scale up, notes
Martin.

Upstream and
downstream handling
APIs are typically powders,
but in addition to appropri-
ate powder handling
equipment, some APIs are
toxic or highly potent and must
be handled under containment to
avoid harming operators. Some
formulations are pre-mixed, while
others, particularly when using
powdered API and a pelletized
polymeric excipient, must be split-fed.
of less than 1 mm are under development.
Direct extrusion, which eliminates a heat-history for
heat-sensitive APIs, is also used in the industry and is
another area of development. Direct extrusion applica-
tions include flms for drug-eluting patches, rods for
implantable drug delivery, or profles for a variety of
devices.
While development cycles in the medical industry are
much longer than those of typical consumer or
industrial plastics applications, we should continue to
see new, innovative products in the coming years as
plastics industry experts apply their knowledge and
skills to medical markets.
Click on the links for more information:
www.fostercomp.com
www.conmed.com
www.kraussmaffei.com
www.particlesciences.com
www.coperion.com
www.thermoscientifc.com
www.rondol.com
www.xplore-together.com (DSM)
www.leistritz-extrusion.com
www.cwbrabender.com
www.steerworld.com
Coperions
18-mm ZSK has
improved barrel
heating and
cooling for extra
precision when
developing
pharmaceutical
products
References
1. J.DiNunzio, C. Martin, and F. Zhang, Melt Extrusion:
Shaping Drug Delivery in the 21st Century, Pharm.Tech.
supplement on Drug Delivery (Nov. 2010).
2. P. Van Arnum and R. Whitworth, Continuous Progress in
Continuous Manufacturing, Pharm.Tech. 35 (9), 44-47 (2011).
Since pharma applications, especially at the pilot or
laboratory scale, often run at lower rates than typical
plastics applications, feeders that can accurately dose
at low rates must be used. Other requirements include
cleanability and GMP certifcation.
Downstream, compounds are often pelletized,
although the method must be compatible with the
formulation. Bioresorbable polymers, for example,
must be cooled with dry air because they begin to
degrade in the presence of moisture, notes Foster
Delivery Sciences Listro. Pelletizers for micro-pellets
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Frankfurt, Germany
June 18-22, 2012
hall 8, booth C38
hall 5, booth C33
Top tips for twin-screws | processing feature
How do you get
the very best from
your twin-screw
extruder? Bert
Elliott of leistritz
has lots more
practical tips in
this second
instalment of his
two-part article
There are many techniques known to operators and
plant engineers for increasing the performance of a
twin-screw extruder. Because of their informal nature,
however, most of these methods do not appear in any
equipment manuals. nor are they generally mentioned
in textbooks and technical papers. But sometimes
attention to several small details can add up to making
a big difference in extruder performance. The tips
described in this article fall into three broad categories:
processing techniques, machine modifcations and
maintenance procedures.
The frst part of this article (Compounding World,
June 2012, Page 27) featured eight useful tips for
improving twin-screw-extrusion. Here are 10 more
practical ways to improve the effciency and effective-
ness of compounding operations.
Acid fushing of barrel cooling
bores
water-cooled extruder barrels are heat exchangers,
and like all other heat exchangers the coolant bores are
subject to fouling from scale build-up. most operators
notice that the cooling performance of a new extruder is
much better than an extruder after three or four years
of running. This is because the new extruder barrel has
smooth, shiny, freshly-drilled cooling bores. The older
machine has a layer of crusty mineral deposits lining
the bores, that effectively act like a good insulator.
if left unchecked, scale build-up can lead to a much
more serious problem. Eventually the cooling bores can
become completely blocked, and zero water fow means
a lack of cooling ability. if this happens, the only
solution is to remove the barrels from the extruder and
drill out all the cooling bores (Figure 1), which is a time
consuming procedure
[1]
.
Top tips for twin-screw
extruders part two
9 0
Figure 1:
Drilling out a
barrels cooling
bores is time
consuming but
can be avoided
by using
scale-removal
chemicals
s
processing feature | Top tips for twin-screws
There is a simple preventive maintenance procedure
to avoid these problems and keep the extruder cooling
effciency like new. The recommended procedure is to
circulate a scale-removal chemical through the barrels
periodically. with production extruders, this is recom-
mended to be done every three to four months. on a lab
extruder seeing much less use, probably once every two
years is suffcient.
many of the tower and chiller manufacturers make a
small, inexpensive recirculating de-scaler unit on a
roll-around cart, with an integral reservoir and pump.
This unit is designed specifcally for fushing out mould
cooling passages, and is also ideal for extruder barrels.
Laser barrel alignment
in the old days, extruder barrels were aligned simply
with a machinists level. or, in the case of single-screw
extruders, an optical bore-scope. But unlike a single-
screw machine, a twin-screw extruder doesnt have an
open bore through the gearbox, so a bore-scope cannot
be used.
The most accurate way to align a twin-screw
extruder is with a laser (Figure 2). The laser is mounted
concentrically to one of the gearbox output shafts in a
holding collar, and the laser light is projected all the
way down the barrel to a target mounted on the
discharge fange. The end target is made from clear
plastic, and has vertical and horizontal crosshairs
accurately etched into it. when the extruder is perfectly
aligned, the laser dot
will appear in the exact
intersection of the
crosshairs. if the dot is not
in the centre, the barrel
supports are adjusted to bring
it into alignment.
Extruders do not need to be checked
for alignment on a periodic basis, but there
are some specifc situations when it is advisable:
a) if the extruder has been moved to a new location
b) if the concrete foor is settling, causing uneven
support of the extruder
c) if screws or barrels are wearing at an abnormally
high rate, or wearing in an abnormal pattern
d) if shafts keep breaking for unexplained reasons
e) if the machine vibrates more than normal
f) if the screws are diffcult to slide in/out of couplings
g) if somebody changed the barrel support adjusters
h) if the machine has been hit with a forklift (yes, it
happens!)
Switch to synthetic gear oil
The gearbox is the heart of a twin-screw extruder. if it
fails (Figure 3), its likely to be expensive to repair, and it
may lead to lengthy downtime. There is one thing
everyone can do, easily, to avoid gearbox problems:
switch to synthetic gear oil (Figure 4). Synthetic oil is a
huge advance in lubrication technology, offering the
following benefts
[1]
:
a) Synthetic oil is more slippy, causing less friction
b) gears, bearings and seals last longer
c) gearboxes run cooler and quieter
d) Synthetic oil does not lose viscosity from mechanical
shearing
e) maintains higher viscosity at high temperatures
f) improves overall effciency of the gearbox
Anti-Seize
most people in the plastics industry are aware of the
need to use anti-seize. There are several different types
of anti-seize, such as copper-based, moly, lithium and
so on. For something like a bolt thread, any type should
work. But there is one application within the extruder
where the choice of anti-seize is much more critical: the
spline shafts (Figure 5).
Screw elements ft onto the spline shafts with a very
0 1
1 1
2 1
Figure 2: The
most accurate
way to align a
twin-screw
extruder is
with a laser
Figure 3:
Gearbox
failures can be
expensive and
time-consum-
ing to repair
Figure 4:
Switching to
synthetic gear
oils offers a
range of
benefts
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
www.maguire.com
When Steve Maguire popularized the gravimetric batch blender
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is the largest
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Blender
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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
to work for you, not against you. Thats why Maguire sees blender
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precise dosing, economy of materials never go out of fashion.
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Steve Maguire, President and
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MicroBlender
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small gap tolerance, plus low viscosity polymers tend to
creep down between adjacent elements and get into
this gap. with time and heat, this polymer forms a
high-strength adhesive just like an epoxy. if screws are
left together in an extruder without being taken apart
periodically, then they can be extremely diffcult to
remove from the shafts. This is why the choice of
anti-seize is so important.
many types of anti-seize are acceptable for a short
period of time, but when used over long periods at high
temperatures, they can degrade into a fne powder. This
makes them a poor choice for spline shafts, where you
need the anti-seize to perform when youre ready to
disassemble the screws, which can be months or years
after it was applied.
After testing a very wide range of anti-seize brands on
the market over a period of many years, leistritz has
found one which is ideal for this application: gleitmo 820,
which is manufactured by Fuchs, a leading global
supplier of lubricants (www.fuchs.com). The product is a
white grease containing high solids, with very slippery
qualities. it is rated for 1,150c. what makes it perfect
for spline shafts is that it does not degrade into a powder.
when the screw elements are removed after months of
use, the gleitmo 820 is still a slippery grease
[1]
.
Purging techniques
purging is a technique widely used as an easy way to
clean out materials from the extruder and die to avoid a
time-consuming strip-down cleaning. There are many
types of materials used for purging, with both commer-
cial purge products and home engineered purges
being used extensively (Figure 6).
purge materials generally fall into two categories:
chemical purges, and mechanical abrasive purges.
many materials combine both chemical and abrasive
actions
[2]
. chemical purges work by attacking the plastic
residue like a solvent. many of them also incorporate a
foaming action, and are intended to be run to fll the
machine, and then the extruder drive is shut off for
around fve minutes to allow the chemical action to
work. The drive is then restarted to run the purge out of
the front end.
mechanical abrasive purges work by scouring and
scrubbing material off the metal surfaces, using friction
and shear. most processors do a lot of trial and error
experimentation to fnd the right purge material and
technique. Since there is such a wide variety of plastics
and additives being processed, there is no magic
purge material is going to work best for all materials.
cost is also a factor. commercial purge products are
generally more expensive per lb/kg than home
engineered purges. However, if you can use less
material with the commercial purge, or get the job done
quicker, then the total cost may not be more.
probably the most important habit to get into is to
purge often. The object is to prevent old materials from
being baked on to the metal surfaces. once this
happens, purging will generally not be able to remove
the material, and a manual strip-down cleaning will be
the only remedy.
one mistake many processors make is to run the
purge only at a fxed screw rpm. its much more
effective to vary the screw rpm, alternating from low to
medium to high speeds, running for perhaps 30
seconds at each level. This induces different shear rates
against the metal surfaces, helping to dislodge old
material from the walls.
Home-brewed extruder/die
cleanout methods
processors have run all sorts of materials through
extruders, in the quest for a cheap and effective purge
material. For instance, in the midwest uSA many
operators use cow corn, because it is readily available
and does a fairly good job of scouring the machine out.
3 1
4 1
Figure 5: It is
very important
to select a
suitable
anti-seize for
spline shafts
Figure 6: Screw
set being
pulled from
extruder after
purging
There are two homemade purges which can be
particularly effective:
mix #1: 50% poly, 50% diatomaceous earth: diatom-
aceous earth is actually fnely milled fossilized shells of
tiny sea organisms. it is used in gardening among other
things, so it is readily available in garden supply stores.
The material looks like a fne powder, but on a micro-
scopic scale the particles have very sharp, angular
edges, which produces the scouring action. processors
who run sheet and flm use this purge, as it can
sometimes get rid of die lines, saving a time-consuming
die tear-downs.
mix #2: poly with kitchen cleanser and water: mix a
slurry of water and three or four cans of comet or Ajax
kitchen cleanser in a bucket. Feed poly at a normal
purging rate and temperature, and slowly pour the slurry
into the main feed port. For safety reasons, warn any
nearby operators that steam may be discharged from
extruder openings. in addition, do not look into the die or
vents unless wearing a full polycarbonate face shield and
long-sleeved shirt. The water in the slurry will fash to
steam, which gives a very good cleaning effect combined
with the abrasive in the kitchen cleanser.
Effcient colour/product
changeovers
colour or product changeovers tend to create problems.
Extrusion people would ideally like to always have nice
long runs. But in the real world, demands from
customers mean frequent changeovers to make 40 kg
of product A, followed by 100 kg of product B, and so on.
So it is important to approach changeovers in a way to
minimize operator effort and problems.
l understand how critical machine cleanliness is for
the next product to be run. There are anecdotes around
any extrusion shop of somebody purging for 16 hours, to
avoid pulling the screws to brush them off. The point is,
if you know the next product requires a thorough
manual brush-cleaning, dont waste time and material
trying to get by with purging.
l if possible, plan runs in order of decreasing cleanli-
ness requirements. in terms of colours, this means
from lightest to darkest. This means you should only
face one diffcult changeover, when going from the dark
colour back to a light colour.
l Have written purging or strip-down procedures to run
each product. This helps operators plan their time, and
eliminates arguments later on about product being
scrapped because the operator did not clean the
machine properly.
l use the right size extruder for the lot size. This may
seem obvious, but many processors do not plan runs for
the right machine. For example, they end up running a
200 kg lot on a 75-mm extruder, producing 130 kg of
scrap while getting it to run correctly.
l Help operators by organizing the necessary tools,
cleaning supplies, screens, die plates and other
required products near to the extruder. if frequent
changeovers are required, set up a workstation to have
everything the operators need right by their side.
l Study the fow of raw materials and end products in
and out of the process area. Try to arrange it to
minimize operator effort. The less operators have to
hoist drums and gaylords around, the more they can
concentrate on maximizing running time.
Warm-up and cool-down
procedures to avoid degradation
Warm-up: Extrusion people tend to keep the machinery
hot, all the time. operators typically turn the heat zones
on the minute they come in the plant at 7:00 Am. if
youre really going to start the extruder at 8:00 Am, then
theres nothing wrong with this. But many times people
get distracted with maintenance chores, and the extrud-
er sits idle, heated to full operating temperature for
hours at a time.
The reason this is a bad practice, is because it allows
polymer to bake onto the screws and barrels (Figure 8).
once baked on, the material will continue to degrade and
carbonize. purging will not remove this material. Even
worse, as the extruder is running product, black specks
will periodically fake off the screws and barrels, contam-
inating the product and causing customer complaints.
s
5 1
6 1
Figure 7:
Proper
planning for
colour changes
can save
signifcant
amounts of
time
Figure 8: Take
simple steps to
avoid baking
degraded
polymer on to a
screw
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The best way to handle warm-up is to plan the time
you really want to start running the extruder. Then start
heating up only as far ahead of this time to allow for
complete warm-up plus adequate soak time.
Cool-down: There are preferred shutdown procedures
also, to avoid problems with black specks. Before
shutting the extruder down, it is good practice to fll the
extruder and die to the maximum degree of fll with
some inert polymer, such as HdpE, to seal the
machine. The HdpE displaces oxygen, and coats the
metal surfaces to greatly slow down oxidation and the
formation of carbon.
After the extruder has been sealed, it is better to
crash cool the machine, rather than let it cool from
ambient air over the next 18 hours. A crash cool
involves turning all the temperature set-points down to
zero, to force the cooling solenoid valves to open. with
the coolant pump running, this will force cool water
through all the barrels, bringing the temperature down
quickly. A quick cool-down does not give the polymer a
chance to degrade and carbonize.
Key process indicators
most extruder operators tend to be like the old-time
pilots, preferring to fy by the seat of their pants. And
many of them have excellent instincts for knowing when
the process is running right, and when it is not. But as
products become more complex with tighter processing
windows, it is much better to have some kind of quantita-
tive way of assessing how the machine is running.
A common example of this is when the operator is
convinced something is different about the material.
The line is just not running the same. if the material
supplier is contacted, they are probably going to say
their Qc records show that the material is the same as
its always been. without some real numbers, how can
you prove to the material supplier, as well as yourself,
that the material is indeed different?
Indicator 1: Specifc throughput
Specifc throughput is the throughput divided by the
screw speed (eg kg/h divided by rpm). it gives you a
number which is representative of the degree of fll.
This fgure is useful especially if records are kept over a
period of time for many different products, as it can
help you predict how best to run a new product. it also
helps you plan machine hours, as a product which
needs to run at a low degree of fll will take longer to
run a certain lot size. Finally, degree of fll is helpful in
scaling up (or down) runs on different size extruders.
Indicator 2: Specifc energy
Specifc Energy is how much drive power is being
expended to process each kg of material. it is a
measure of how much mechanical work is being
performed on the material. it has to be calculated in
two steps:
kw (applied) = kw (motor rating) x % running torque x
(running rpm/max rpm) x 0.97
Specifc energy = kw (applied) divided by
the throughput in kg/h
Again, it is useful to keep records of this fgure for
products over a long period of time. After a while,
operators will get to know which processes are energy
hogs, and which are not. This will help in planning runs
for new products, and estimating the production
capacity of any given line.
Specifc energy is also very helpful in pinpointing
problems. if a product is known to always run with a
specifc energy value of around 0.25, and one day it is
only running 0.16 when all other conditions are the
same, then this would be a reason to suspect a change
in the material
[3]
.
Table 1: Producing a test grid can show the optimum combination of screw-speed and throughput
(shown in bold in this example)
RPM Rate Tensile strength Impact Colour Surface Degree of fll Specifc energy
200 300 27.2 16.2 7 7 0.68 0.165
400 400 29.4 16.0 7 7 0.45 0.200
600 500 29.6 15.6 8 7 0.38 0.287
200 400 28.5 16.1 8 8 0.91 0.142
400 500 32.5 17.3 9 8 0.57 0.178
600 300 30.1 16.8 7 7 0.23 0.255
200 500 26.7 16.3 7 8 1.14 0.262
400 300 28.9 15.8 8 8 0.34 0.197
600 400 30.4 15.9 8 7 0.30 0.259
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Top tips for twin-screws | processing feature
References
1. G. Elliott, Guidelines for Installation, Operation, and
Maintenance of Twin-screw Extruders, (1996)
2. D.B. Todd, Plastics Compounding Equipment and
Processing, Hanser, New York, (1998)
3. V.L. Streeter and E.B. Wylie, Fluid Mechanics, McGraw-
Hill, New York, (1975)
Finding the optimum
degree of fll
Most products will run acceptably on a twin-screw
extruder under a wide variety of conditions. For instance,
on a 50 mm extruder, a given formulation might be able
to run at 400 lb/h (180 kg/h) using any RPM from 200 to
600. To the average operator, there may seem little or no
difference in the mixing or material quality. However, we
know that there has to be a difference, because the
shear imparted to the material will be different from low
to high degrees of fll.
The way to answer this question is by running a test
grid, which is a basic SPC (statistical process control)
technique. The grid should be set up to test combina-
tions of low, medium, and high values for RPM and
throughput rate, within a realistic range. The grid also
needs to have columns for key physical properties and
quality parameters.
For example, Table 1 clearly shows the best combi-
nation of properties (in bold), running 500 lb/h at 400
RPM. But if nobody takes the time to do the tests, the
product could be extruded for years under conditions
which produce less than optimum properties.
Summary
An extruder seems like a very simple machine at frst
glance, but there are many interactions of components
and sub-systems involved. If the operator has an
awareness of how these details affect the overall
process performance, he or she will have the capability
to tune the factors to optimize the process.
About the author
Bert Elliott is engineering manager at Leistritz Corpora-
tion in New Jersey, USA. If you missed the frst part of
his Top tips for twin-screw extrusion feature, then it can
be found in the May issue of Compounding World
http://bit.ly/leistritz. For more information on
Leistritzs twin-screw extruders, visit:
www.leistritz.com
8 1
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pVc stabilizers | additives feature
Speakers at the recent pVc Formulation
conference discussed new stabilizer
developments for a wide range of vinyl
applications including profles, pipe,
sheets and foamed products
Stabilizers play a critical role in pVc com-
pounds, protecting the resin from degradation
during polymerisation and processing as
well as throughout its working life. They
were the subject of a special session at
Amis pVc Formulation 2012 conference,
which took place in march in dsseldorf,
germany. leading suppliers of such
additives gave updates on their latest
developments for a range of applica-
tions including fexible sheets, rigid
profles and foamed products.
Baerlocher provided an update on
formulation trends in window profle
extrusion. According to the company,
approximately 2.5 million tonnes of pVc
window profles were produced in Europe
in 2010, with Turkey emerging as the leading produc-
er with a total of 590,000 tonnes. it was ahead of germany
with 580,000 tonnes and russia with 443,000 tonnes.
The big trend in stabilizers for such applications in
Europe has been the on-going phase out of lead stabiliz-
ers. under the Vinyl 2010 initiative, the industry made a
voluntary commitment to end the use of lead-based
stabilizers by 2015 in the 27 Eu countries. An interim
target of a 75% reduction in the use of such stabilizers
between 2000 and 2010 has already been met, with
calcium organic products being the main replacement.
Baerlocher estimates that the ratio of lead-based to
calcium-based stabilizers used in western Europe in
2010 was 30:70. The corre-
sponding ratio for the whole
of Europe, including russia
and Turkey was 50:50. This
compares to 97:3 for Asia
including china, and 93:7 for
the middle East and Africa.
lead is also still widely used
in South America, where the
ratio is 80:20, but the north
American market is domi-
nated by tin-based stabilizers.
looking at specifc formulations,
Baerlocher highlighted the requirement
for organic co-stabilizers alongside inorganic
stabilizers in one-pack systems for white pVc
profles. The co-stabilizers provide thermo-stability plus
early colour and colour hold. The other elements of the
one-pack typically include processing aids, external and
internal lubricants, plus metal soaps.
For brown profles, there is a reduced requirement for
co-stabilizers in the one-pack system as dark colours do
not require a low b-value and are not sensitive to b-value
drift. This means that cost savings can be made.
For plants producing both white and brown profles,
it may be advantageous to use the same base stabilizer
for both colours and add a booster for the white
products. For example, the base stabilizer could be
selected from Baerlochers range of Baeropan one-
pack systems, while the booster for white formulations
Seeking stability
Producers of
white and
brown profles
can use the
same base
stabilizer for
both colours,
while adding a
booster for the
white products
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PVC stabilizers | additives feature
Galata is
developing
new liquid
mixed metal
stabilizers for
fexible PVC
formulations
used in roofng
applications
could be one of its Baerostab products.
The use of a twin-pack approach allows the base
stabilizer product to be supplied as pastilles produced in
a melt process such pastille products are labelled TX by
Baerlocher. This means that the main part of the product
mix roughly 80-90% can be base stabilizer in pastille
form for easier storage, conveying and dispersion.
Some co-stabilizers are not suitable for melt
processing, so the booster component is typically
supplied as a powder or pressed granule. These can be
more diffcult to handle and dosage of the booster
component is sensitive.
According to Baerlocher, a twin-pack approach can
be advantageous for plants producing a considerable
proportion of brown profles, particularly if they have
accurate dosing systems in the mixing plant and silo
storage for the stabilizer. However, in other cases, using
two separate one-packs for the brown and white
products may be more attractive, as both formulating
and materials handling are simplifed.
Baerlocher also used the PVC Formulation confer-
ence to highlight new stabilizer systems for improved
processability. They are available without calcium
acetylacetonate to ensure no reddish deposits.
The stabilizer systems can be supplied as easy-to-
handle pastilles incorporating processing aids and
well-balanced lubricant systems to reduce plate-out. In
addition, they use the latest metal soaps to improve
dispersion behaviour.
Galata Chemicals discussed developments in its
liquid mixed metal stabilizers for fexible PVC formula-
tions, such as those used in roofng and membrane
applications.
Its new developmental Mark BZ grades meet the
requirements of Reach legislation, while matching or
beating the discoloration and transparency perform-
ance of grades that are not Reach compliant. In
addition, they have been shown to match the latters
initial colour and colour hold in a variety of transparent
and pigmented formulations
The company also highlighted the advantages of its
Mark OBS grades for plastisol applications. The
heavy-metal-free additives provide good initial and
middle colour, combined with good long-term ageing
properties. In addition, they deliver low odour, VOC,
fogging and emission levels.
The Mark OBS grades can be used with Galatas
Mark CE boosters to provide excellent initial colour and
colour hold. Alternatively they can be applied in
combination with its Mark CZ stabilizers with similarly
impressive results.
read more at www.norner.no / post@norner.no
NORNER - additive qualication testing
How can we help you?
NORNER is an industrially focused plastics institute.
A key capability is plastics additives. We engage in recipe
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moulding and extrusion, life time testing and additive analysis.
And we offer additive pre-qualication services on a global basis.
s
additives feature | PVC stabilizers
Reagens focused on new
stabilization systems for the
production of foamed sheets and
profles using both free-foam and
Celuka process technology. For
free-foam applications, lead and
organo-tin stabilizers are most the
widely used options, while calcium organic
systems (COS) are the usual choice for the
Celuka process, although organo-tin products are
also used.
Going forward, the company sees several stabilizer
trends for cellular PVC applications. These include the
use of booster technology with organo-tin additives to
improve heat stability and reduce costs. For example,
impressive results were shown for a formulation
featuring 1.3 phr of Reagens Reatinor 804 octyl-tin plus
0.3 phr of the companys Reapak B/NT 7444 booster.
Reagens also predicts the simplifcation of COS
one-packs, offering core stabilizers which allow
processors to make adjustments more easily. Other
developments include the fne-tuning of COS one-packs
to improve initial colour and surface fnish, plus the
replacement of octyl-tin products with optimised COS
one-packs.
Chemson focused on the sustainability benefts of
organic heat stabilizers (OBS) and the benefts that they
can bring to biaxially-oriented PVC pipes.
In addition, the same class of additives is fnding
success in the Dincel Construction System, which was
developed in Australia. It involves a hollow framework
made from rigid PVC profles. These can be easily
assembled on site prior to being flled with concrete to
create walls or columns that are load-bearing and
fre-resistant. In addition, they have been shown to
withstand magnitude nine earthquakes. The system
speeds up construction and is also energy effcient.
According to Chemson, using an optimised OBS-
based PVC formulation helps to create a profle with the
required stiffness to survive earthquakes. It also
provides the required stiffness and rigidity to maintain
the integrity of Dincels patented snap-lock design.
More information
Copies of the complete proceedings
for the PVC Formulation 2012
conference are now on sale at
Plastics Information Direct. For more
details and to purchase on-line, visit:
http://bit.ly/PVCpapers.
The next PVC Formulation confer-
ence will take place on 12-14 March
2013 in Dsseldorf, Germany. For information about
attending, sponsoring, exhibiting or speaking at the event,
visit: http://bit.ly/PVC2013.
www.baerlocher.com
www.galatachemicals.com
www.reagens.it
www.chemson.com
www.dincelconstructionsystem.com
The Dincel
Construction
System is built
using PVC
profles that
are then flled
with concrete
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Biodegradability no longer dominates
the bioplastics marketplace.
Chris Smith takes a look at the
changing face of the bio-based
polymers industry.
s
A study carried out last year by the university of Applied
Sciences and Arts at Hanover in germany for trade
association European Bioplastics predicted global
bioplastics production capacity will reach 1.7 million
tonnes by 2015, more than doubling 2010 capacity
levels. This headline fgure, however, masks a consid-
erable change in the structure of the bioplastics
industry, with traditional biodegradable and composta-
ble polymers seeing only modest growth while the focus
of attention shifts to bio-derived versions of todays
existing petrochemical plastics.
our market study shows that biobased commo dity
plastics, with a total of around one million tonnes, will
make up the majority of production capacity in 2015,
according to professor Hans-Josef Endres, who headed
up the study at the Uni versity of Applied Sciences and
Arts of Hanover.
it is a remarkable shift. According to the report, in
2009 durable bioplastics accounted for just 7% of the
estimated global bioplastics production capacity of
318,000 tonnes. By 2010, durable bioplastics accounted
for 40% of a global capacity of 724,000 tonnes, helped in
no small part by Brazil-based Braskems introduction of
its HdpE products based on sugar cane ethanol.
By 2015, the trade association expects durable
bioplastics including bio-based commodities such as
pE, pp, pET and pVc as well as high performance pA
polymers to account for close to 60% of its predicted
why green plastics are
here to stay
market update | bioplastics
global bioplastics production capacity of 1,700,000
tonnes. That translates to a more than 40-fold expan-
sion in durable production capacity, from 22,500 tonnes
in 2009 to 996,000 tonnes by 2015.
The study predicts HdpE will retain its position as
the dominant durable bioplastic with an estimated
production capacity in 2015 of 450,000 tonnes, followed
by bio-based pET at 290,000 tonnes (it does not make a
distinction between partly or fully renewable content).
plA will come in at third place with a global production
capacity of 220,000 tonnes. The European Bioplastics
study predicted pHA taking fourth place in its global
bioplastics capacity ranking by 2015 but that must be in
question following the decision by agricultural products
group Archer Daniels Midland to pull out of its Telles
biopolymer joint venture with Metabolix (compounding
world, Jan 2012, page 8).
bioplastics | market update
The biodegradable challenge
The relatively modest growth predicitions for traditional
biodegradable bioplastics come despite the consider-
able progress that has been made in terms of their
performance and cost. Few would disagree, however,
that performance still falls short of traditional petro-
chemical plastics in many areas and that costs are too
high for applications that cannot take advantage of the
unique end-of-life disposal route. This effectively leaves
biodegradable bioplastics as niche players.
The higher price for bio-based plastics can be
accommodated in niche markets such as organic food
or cosmetics but generally the premium is rather
small, says martin patel, assistant professor in the
department of Science, Technology and Society at
Utrecht University in the netherlands and contributor
to many studies looking at production of chemical
products from bio-based feedstocks.
while it is likely that an increased focus on sustain-
ability will present further opportunities for biodegrad-
able bioplastics, patel says the picture is blurred by the
wide variety of somewhat contradictory lcA analysis of
the benefts they deliver. my understanding on this
aspect is that good bio-based plastics allow users to
reduce non-renewable primarily fossil fuel use and
greenhouse gas emissions by around 40-50%. But there
are trade-offs, with probably the most important ones
being related to land use, including toxicity and biodiver-
sity impacts due to herbicide and pesticide use. we need
to work on these to reduce the impacts, he says.
PolyOne has been one of the leaders in developing
added value compounds and additive systems based on
bioplastics. The companys global marketing director
for biosolutions marcel darte agrees it has been
diffcult to exploit the value of biodegradability in real
applications and this has acted as a brake on market
development.
Biodegradability will continue to be embraced as a
functional attribute in, for example, agricultural flms
and other agricultural applications, for use in organic
waste bags and some other applications, he says. But
it has proven to be very complex to exploit composting
as an additional waste management option for com-
postable plastics and thus realise its full potential. if
you cannot use the compostable waste stream to
dispose of your compostable items, then how can you
capture the beneft?
This diffculty in exploiting the biodegradability
attributes of bioplastics such as starch blends, plA and
pHA, together with their higher cost, is also seen as a
big obstacle by lon mentink, product manager at
French starch processing company Roquette, which has
developed its own line of durable grafted starch
polymers with more than 50% renewable content under
the gaialene brand (last month it commissioned a
25,000 tonnes/year production unit at lestrem in
northern France).
[Traditional biodegradable bioplastics] are con-
ceived to be biodegradable/compostable, that is to say
designed for niche markets which are very dependent
on local regulation and local structures. The market is
looking now for green durable and semi-durable
products which can be used as classical plastics the
same applications, same physical performance, same
machines, same speed of production, he says.
while it has proved diffcult to exploit biodegradabil-
ity in some applications, there are still signifcant niche
opportunities yet to be exploited and investment in this
GlObal
PROdUctiOn
caPacity Of
biOPlastics
source: European
bioplastics/
University of
applied sciences
and arts Hanover
(status May 2011)
biOPOlyMERs PROdUctiOn caPacity 2015 (by tyPE)
source: European bioplastics/University of applied sciences and arts Hanover
1
,
0
0
0

m
e
t
r
i
c

t
o
n
s
2008 2009 2010 2015
biodegradable (incl. not biobased) Prognosis
durable (biobased) total capacty
in metric tons
1
only hydrated cellullose foils
market update | bioplastics
sector continues, especially in plA production.
cSm subsidiary Purac recently commissioned a
75,000 tonnes/year plA monomer plant in Thailand,
claiming that its scale of production will improve pricing
while the new technologies it is using will allow plA to
match the thermal resistance of pS and pp and shortly
the impact resistance of ABS.
meanwhile, the decision by Thailands PTT Chemical
to take a $150 million stake in the Natureworks plA
operation opens the way for the company to expand its
presence in Asia. natureworks, which currently has just
one manufacturing plant in the uS, says it plans to set
up a second manufacturing operation in Thailand to
come online in 2015. in a separate move, natureworks
has partnered with bio-based succinic acid producer
BioAmber in a new joint venture Amberworks to
develop a line of improved performance bio-based
polymers based on compounds of plA and pBS
(polybutylene succinate).
And uS-based bioplastics group Cereplast has
acquired a site at Assisi in italy where it plans to install
50,000 tonnes of annual manufacturing capacity for its
bioplastic and bioplastic blends, taking its global
capacity to 86,000 tonnes/year.
performance and processibility of biodegradable
bioplastics are critical areas for development as,
while shortfalls in either can be accommodated
by processors, both carry a cost above the bulk
resin premium. This has proved to be one of the
key drivers towards bio-based versions of
traditional polymers, according to Braskem
marketing and marketing intelligence
manager rodrigo Belloli, who says the
immediate appeal of traditional biodegrad-
able bioplastics to brand owners often fades
once detailed investigation into the cost/value
balance begins.
Traditional bioplastics such as plA,
starch-based, biodegradable polyester and
pHA face hard challenges regarding cost,
physical performance, processing and environmental
issues, he says.
on the cost side, Belloli says the resin price premium
is typically pushed further by less obvious factors such
as higher density (plA has a density of 1.25 against 0.91
for pp), investment in process development and
machine modifcation, and how the product fts into
existing recycling or disposal infrastructure. Taking
these costs together with uncertainty over the value the
new material will deliver to the brand leaves many brand
owners unwilling to risk adoption, he says.
Switching to a bio-based version of a traditional
plastic such as pE or pp, however, reduces the risk to a
simple cost premium on the resin, says Belloli. As they
[bio-based commodity polymers] are drop-in replace-
ments, all the other characteristics remain the same -
the same processibility, same performance, recyclabil-
ity and product weight. At the end this means much less
effort and investment in developing biopolymer
applications, he says.
Bioplastics with tradition
production of traditional plastics from
bio-based feedstocks is not in itself new
castor oil has been used as a feedstock for a
number of speciality polyamides for many
years. Extending bio-based feedstocks to
the more everyday resins such as pE,
pp and pET is an obvious move, accord-
ing to dr Sally Humphreys, chair and
Ami consultant at the green polymer
chemistry conference (which next takes
place on 19-21 march 2013 in cologne,
germany see http://bit.ly/GPC2013).
The plastics industry has spent over a
hundred years developing materials for
long term critical applications like polyeth-
ylene pipes and barrier packaging, both of
which conserve food and water for the
worlds rapidly expanding population.
Above left:
PLA granules
grown by
Natureworks
Above right:
Natureworks is
planning a
second PLA
manufacturing
plant, which it
will build in
Thailand
Left: Coca-Cola
says more than
10bn bottles
have been
produced with
its PlantBottle
PET resin
These materials cannot currently be matched for
performance by the new bioplastics, so it makes sense
for the polymer industry to look for renewable replace-
ments, she says.
But one of the issues with growing your own plastics
is that the important chemicals may be one or two
reactions away, for example cellulose takes several steps
to break down to extract ethanol, says Humphreys.
Fortunately for the plastics producers following the
bio-based agenda, around two thirds of all of todays
polymers are comprised totally or in part from olefns
and these can be fairly easily produced from biologi-
cal feedstocks, says utrechts patel. He points out
that the new bio-based feedstocks ft easily into
existing production chains, while expanding
consumption means green investments
will augment rather than replace
existing capacity.
There is decades of experi-
ence on the dehydration of
ethanol to ethylene, and the
production of bio-based
propylene and butadiene is
nowadays also technically
feasible, patel says. olefn
demand also continues to
grow, making it possible for
bio-based versions to
capture part of the addi-
tional capacity, he says.
polyones darte also sees the relatively
straightforward integration of bio-based
feedstocks into existing plastics production chains as a
real beneft in the development of new bioplastics.
Economic routes to bio-based monomers increasingly
are available and these streams feed directly into
traditional polymerisation processes. So while up-
stream the world is changing completely, downstream
nothing much is changing at all. The chemical industry
is proving very capable of adapting by focusing much of
its attention on developing these routes or forming
strategic alliances with companies that have developed
bio-based monomer technologies, he says.
Examples of this trend include Dow and Mitsui,
which are moving ahead with joint venture plans to
create a production platform in Brazil for bio-based
plastics for the packaging, hygiene and medical
markets. First phase in the programme is the establish-
ment of a sugar cane to ethanol plant at dows sugar
cane growing operation at Santa Vitoria, which is
scheduled to start up in 2013.
in italy, bioplastics company Novamont has joined a
joint venture operation with Eni groups Polimeri
Europa that aims to set up a fully integrated vegetable
oil to biochemicals operation at porto Torres in
Sardinia. The E500 million six-year investment project
includes the closure of almost all the fossil fuel-based
operations on the site and construction of seven new
units capable of producing 350,000 tonnes of bio-based
chemical products a year.
French chemicals group Arkema, already a player in
the bioplastics arena with its castor oil-based perform-
ance rilsan pA11, has underpinned its position in the
bio-based polyamides sector with the acquisition of two
chinese companies bio-based pA 10.10
producer Hipro polymers and sebacic acid
manufacturer casda Biomaterials.
other signifcant moves include
coca-colas announcement earlier this
year it is partnering with three plant-
based chemical development groups
Virent, Gevo and Avantium in
efforts to convert its packaging to
plant-based alternatives
(injection world, Jan/Feb 2012,
page 10). it is already using
bio-derived mEg in production of its
plantBottle pET which has been used in
more than 10 billion bottles to date but it now
wants a bio-derived version of the pTA compo-
nent (pTA comprises 70% of pET).
coca-cola is without doubt one of the leaders
in bio-based pET but even it is uncertain of how far
or fast conversion to 100% plant-based polymers
may be. At a petcore symposium last year, coca-cola
Europes then director of sustainable packaging cees
van dongen told delegates that the company hoped to
see a limited amount of bio-based pTA on the market
within 10 years. However, he added: we dont think the
future is to take every inch of arable land and convert it
to sugar cane.
Above: Toyota
selected
DuPonts
bio-based
Sorona
polyester for
the air vent
louvres on its
latest Prius
Right: DuPonts
biobased Zytel
RS PA12
engineering
resin is used in
this injection
moulded race
car brace
s
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despite Braskems major investments in bio-based
pE and planned commercialisation of bio-based pp -
30,000 tonnes of bio-based pp capacity by the end of
2013 Belloli also advises against expecting a rapid
conversion from petrochemical to bio-based polymer
production.
i see two main challenges: the cost of the biosourc-
es as the main raw material for these biopolymers and
consumers willingness to buy bio-products or to
perceive value in brands that adopt them, he says.
we will probably not see in the next 10 years the
biopolymers market grow to levels comparable to the
conventional polymers market.
Fears over shortages of land for feedstock
production or concerns over competition with food
production should not, however, be considered
insurmountable problems for the long term,
according to Franois de Bie, marketing director
for bioplastics at purac. in agriculture and the
food industry, large amounts of the crop and its
by-products are wasted today. minimising these
losses and agricultural improvements will push
up the yield per hectare of land so we believe
plenty of biomass can be made available to fuel
the bio-based economy. he says.
in a few years from now second generation
raw materials, which do not compete with food,
will also be available. in the meantime, we
should not be afraid to convert traditional crops
into biobased chemicals in order to develop new
technologies and start the transition to a biobased
economy, he says.
italian company M&G Group is one of the companies
working on second generation biochemical production.
it says construction of the frst industrialscale plant
using the proesa second generation bioethanol
technology it has developed with Chemtex is on track,
with a 40,000 tonne/year unit expected to start opera-
tion in the second half of this year. The unit will use
commercially grown reeds and straw as a feedstock.
The company says it is also working with graalBio
investimentos to set up a cellulosic ethanol plant in
Brazil and has licensed the proesa technology to
uS-based genomatic for production of Bdo (butanediol)
from bio-mass.
Elsewhere, research continues into technologies that
can capture co
2
and use that as a polymer feedstock.
Bayer MaterialScience has set up a pilot plant at an
rwE coal-fred power station that uses co
2
from the
fue gases to produce polyether polycarbonate polyols,
which can be used as pre-cursors in pu production. The
company hopes to begin commercial production in 2015
using this catalytic technology.
meanwhile, technology commercialisation company
norner Verdandi, a subsidiary of norways norner
plastics institute, has taken a 30% stake in Econic,
which is developing catalysts enabling production of
polymer feedstocks from co
2
for pu and pc polymeri-
sation. norner Verdandi says its investment will allow
Econic to scale up its catalyst manufacturing processes.
Pressure from the top
The pressure to move to bio-based plastics is not just
coming from brand owners. regulators are also moving
to incentivise investment in these new technologies. in
the uS, president obama last month issued a memo to
heads of all executive departments and agencies
reminding them of their responsibility under the uS
department of Agricultures Biopreferred programme
to increase procurement of bio-based products.
Also last month, the European commission an-
nounced the adoption of a strategy designed to ensure
development of a sustainable bio-economy. in a launch
statement, commissioner for research, innovation and
science mire geoghegan-Quinn said: Europe needs to
make the transition to a post-petroleum economy.
Braskems bio-based ethylene
plant at Triunfo in Brazil
Right: Bayer
hopes to be
producing CO
2

based feed-
stocks on an
industrial scale
by 2015
Below: US juice
frm Odwalla
packages all its
single-serve
drinks in
Braskems
bio-based
HDPE
s
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C;:?7?D<EHC7J?ED(&'(
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Brought to you by Applied Market Information, the leading
provider of market intelligence and conferences for
the global plastics processing industries.
For more information, contact our advertisement manager,
Claire Bishop. E-mail: claire@amimagazines.com
Tel: +44 20 8686 8139 www.amimagazines.com
OpEnIng up
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bioplastics | Market update
Greater use of renewable resources is no longer just an
option, it is a necessity. We must drive the transition
from a fossil-based to a bio-based society with research
and innovation as the motor.
European Bioplastics has welcomed the EUs new
strategy but said it would like to have seen more
specifc measures to encourage better market access
and feedstock supply, and to incentivise public procure-
ment. What we need are strong measures to support
the market development of bioplastics products, said
Andy Sweetman, who chairs the board of European
Bioplastics.
Some might disagree that, with a growing number of
big name chemical frms investing in biochemical
feedstock production, this market needs further
support. But Utrechts Patel sees good reason to want
to continue to encourage the development of new
biodegradable polymers.
Plastic marine litter, litter on land and plastics
found in sea animals is growing and causing increased
concern. Some of the existing biodegradable
polymers and a completely new genera-
tion of biodegradables could maybe
substantially alleviate this problem.
We need to work on this in parallel,
with the goal of developing green
and harmless polymers, combined
with unproblematic additives, inks
and sealants, he says.
Right: Danone
packs its
Actimel brand
in Braskems
bio-based PE
for Brazil
Purac started up
its 75,000 tonne/
year lactide
monomer plant
in Thailand this
year to realise
performance
PLA applications
en.european-bioplastics.org
www.fh-hannover.de
www.adm.com
www.metabolix.com
www.uu.nl
www.polyone.com
www.roquette.com
www.purac.com
www.pttchemgroup.com
www.natureworksllc.com
www.bio-amber.com
www.cereplast.com
www.braskem.com.br
www.dow.com
www.mitsuichem.com
www.novamont.com
www.polimerieuropa.com
www.arkema.com
www.virent.com
www.gevo.com
www.avantium.com
www.gruppomg.com
www.chemtex.com
www.bayermaterialscience.com
www.norner.no
Follow us on...
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plus updates on our conferences and useful links.
www.twitter.com/plasticsworld
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Simply click on the brochure cover or link to download a PDF of the full publication
To see our full line-up of more than 25 plastics industry events
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Plastics Industry Strategy Seminars
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Agricultural Film
AMI is holding its ffth
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agricultural
f i l m 2 0 1 2
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Multilayer Packaging Films
AMIs eighth international
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held in Cologne, Germany,
on 16-18 October. This
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Polymer Foam
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The MERL Oilfeld
Engineering with Polymers
conference returns to
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October 2012. The
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Plastics in Photovoltaics
The Plastics in Photovoltaics
2012 conference takes place
in Phoenix, Arizona, USA, on
19-20 September. The
programme features leading
experts on the exciting
opportunities for polymers
in solar power systems.
Background image courtesy of: Evonik Industries AG. Foreground image: Duke Energy Renewables 15-megawatt (AC) Bagdad Solar Project in Yavapai
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The international technology and business conference on plastics, adhesives and
elastomeric materials in solar modules
PHOTOVOLTAICS
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This months free
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If you would like your brochure to be included on this page, please contact
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Entek: Extrusion Solutions
This newsletter from Entek
has cases studies on the
companys twin-screw
extruders being used by
DaniMer Scientifc, Laurel
BioComposites and ONeil
Color & Compounding, plus
details of products launched
at NPE 2012.
Struktol: additives for plastics
This brochure from Struktol
covers its wide range of
additives for thermoplastics,
including products for
superior viscosity control,
improved mixing and fller
dispersion, plus reduced
friction and plate out.
Case Studies
Improved Processing
A compounder of fame retarded polypropylene was
unable to effciently mold their compound due to the high
temperatures and pressures required during processing.
The molding conditions caused problems with the fame
retardant system. By adding 1% of STRUKTOL TR 251
the customer was able reduce the process temperature
by 20C and reduce the pressures required to completely
fll the mold.
Improved Performance
A compounder of polycarbonate resin was able to
reduce the viscosity of his product by 25% using 1%
of STRUKTOL TR 044Wwithout sacrifcing any clarity
due to the additive. This viscosity reduction led to a
corresponding reduction in molded-in stress which
improved the mechanical performance of the material.
In addition the additive provided improved mold flling
and release.
Cost Reduction
A rigid PVC profle 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.
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
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.
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
the industry benchmark.
Struktol Company of America
www.4struktol.com
Intelligent Additive Solutions for
Todays Thermoplastic Industry
TEB0047/2012
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 manufactures a complete line of additives that function individually
or in combination as adhesives, lubricants and surfactants, all accompanied
by a wide range of benefts.
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.
Get To Know Struktol
Quick Guides
K-Tron: performance compounding
1
Smart
Feeding &
Conveying
Solutions
Application Example
High Performance Compounding
Introduction
The production of plastic consists
of many important process steps,
whichare neededtogenerate aho-
mogeneous application specific
plastic compound from a number
of different raw materials.
Process
The compounding process is a
continuous process. The main
steps inthe compounding process
are:
conveying
plasticizing/melting
mixing
homogenizing
blending
dispersing
devolatizing
reacting
heating/cooling
visc-breaking
cooking
pressurizing
Main Ingredients
The main ingredients which must
be continuously and very accu-
rately fed are base polymers such
as PP and PE.
Typical Additives
Stabilizers, lubricants, plas-
tifiers, colour pigments, fillers,
flame retardant, cross linking
agents, foam agents, etc.
Glass or carbon fibers for rein-
for-cement, base polymer pellets
for alloying to new compounds
Recycled material
The additives can be in the form of
powders or masterbatch pellets.
Key Requirements
One of the key requirements inhigh
speed compounding is to ensure
a continuous, uniform infeed with
very tight short-term accuracy and
repeatability.
Typical Production Output
Twin screw compounders are
equipped with dif ferent screw
diameters from 25 up to 150 mm
in various steps depending on the
manufacturer of the compounder.
The typical line rates range from
50kg/h up to 6000 kg/h.
End-Product Industries
Automotive, Building & Construc-
tion, Appliances & Housewares,
Masterbatch production using
new split feed technology
Electronics, Furniture, Health &
Hygiene, Leisure &Sport, Packag-
ing, Pipes, Textiles, etc.
Masterbatch
With high per formance com-
pounding technology, the time-
consuming step of fine grinding
of pellets and premixing in batch
quantities can be eliminated.
Pigments are fed directly into
the melt by means of gravimetric
feeders. Pigment concentrations
up to 70 percent are possible.
Compared with the old premix
feeding method, the new process
allows formulations with reduced
wax content or no wax at all. This
means that high per formance
compounding technology not only
benefits productivity and quality
but also contributes to reduced
raw material costs.
Engineering Plastics
Compounding and pelletizing of
engineering plastics (i.e. filling,
reinforcing, alloying, colouring
and degassing of PA, PP, PET, ABS,
PUR, PC or POM) are the specialty
of high performance compound-
ers.
Typical layout for filling,
reinforcing, alloying
and colouring
High Performance
Compounder
Loss-in-weight
screw feeder Loss-in-weight
belt feeder
Twin screw
side feeder
Polymer Additives Pigment
Chopped glass
fibers
Polymer A, polymer B
and additives
as a premix
Fillers
Devolatizing
Strand
die head
Strand
die head
Water bath
Air knife Pelletizer
To bagging
station
To bagging
station
High Performance
Compounder
Loss-in-weight
screw feeders Twin screw
side feeder
Devolatizing
Water bath
Air knife Pelletizer
Loss-in-weight
vibratory
feeder
This white paper from
K-Tron examines the
feeding and conveying of
raw materials for a variety
of performance
compounding applications,
including the production of
masterbatch and technical
compounds.
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.
PlasMec TRM Turbomixers
This eight-page brochure
covers PlasMecs TRM
Turbomixer, which can be
used for mixing PVC
dry-blends, producing
wood-plastics composites
(WPCs) or the hot/cold
dispersion of
masterbatches/additives.
Steer: twin-screw extruders
S
12
EXTRUDERS.STEERWORLD.COM
CO-ROTATING TWIN-SCREW EXTRUDERS
STEER GENERATION NEXT
BRANDS SPECIFICATIONS APPLICATIONS * *
This six-page brochure from
Steer has specifcations and
target applications for its
wide range of twin-screw
co-rotating extruders,
including the Alpha, Omega,
Omicron and Mega Series
machines.
Head offce location: Willich, Germany
Date founded: 2003
CEO: Dr. Edmund Dolfen (pictured right)
Ownership: Privately owned
No. of employees: 35
Sales 2011: E12.5 million
Plant locations: Willich, Germany
Profle: The roots of FKuR Kunststoff go back to 1992 with the formation of the
Forschungsinstitut Kunststoff und Recycling (FKuR) research institute. In 1998
FKuR joined forces with the Fraunhofer Institute UMSICHT of Oberhausen,
Germany, to develop sustainable plastic materials. FKuR Kunststoff was spun off
as a private company in 2003. It continues to collaborate with Fraunhofer.
Product line: FKuRs products include: Bio-Flex biopolymer blends for fexible products;
Biograde cellulose acetate based compounds for injection moulding and
thermoforming; Fibrolon wood plastic compounds; and Terralene custom-made
compounds based on Braskems Green PE. FKuRs compounds can be used in
a wide range of fexible and durable applications, including packaging, hygiene
flms, agriculture, disposables, electronic housings etc.
Product strengths: FKuRs resins can be used as a drop-in replacement for several standard
polymers, processing on standard production equipment without time consuming
adjustments. All of the grades are bio-based and/or biodegradable as well as
compostable according to the standards EN 13432 and ASTM D 6400.
FKuR Kunststoff
compounder of the month
Forthcoming features
The next issues of Compounding World magazine will have special reports on the following subjects:
July
Nanotubes
Cross-linking additives and machinery
Understanding and monitoring colour
August
PVC plasticizers
Reactive extrusion
Carrier materials
Editorial submissions should be sent to Andy Beevers: abe@amiplastics.com
For information on advertising in these issues, please contact
Claire Bishop: claire
@
amimagazines.com Tel: +44 (0)20 8686 8139
Take out your own free subscriptions to any of the magazines.
Click on the logos below to simply register on-line.
Catch up on our recent
issues for free
Simply click on the cover to see the full magazine,
or download the issue in the relevant iPad/iPhone app
Compounding World April
The April issue of Compounding
World is overfowing with
features on REACH legislation,
new antioxidants, polypropylene
nucleation, materials handling
systems, colour trends and the
Chinaplas and Plast exhibitions.
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
Compounding World May
Compounding Worlds May
edition takes a close-up look
at turnkey twin-screw
compounding systems. It also
looks at new additive
technologies for controlling
static discharge as well as the
latest developments in pellet
screening technology.
Click here to view
Injection World May
The May issue of Injection
World is a medical special
including a look at novel IML
developments. Plus the
magazine boasts features on
optical moulding, TPEs, PP
nucleation and temperature
controllers.
Click here to view
Film and Sheet May
Mays edition of Film and Sheet
Extrusion looks at the latest
trends in thin wall packaging,
as well as reviewing
developments in direct
extrusion, geomembranes and
additives to minimise the risk of
insect and vermin damage.
Click here to view
Pipe and Profle May/June
The May/June edition of Pipe
and Profle Extrusion looks at
the latest developments in
processing WPCs and recycled
resins. It also reviews how
software is being used to
improve die performance and
profles a water pipe
replacement project in
Casablanca.
Click here to view
dates for your diary
Dont miss a single issue
Register now for your free subscription at:
www.compoundingworld.com
And dont forget to tell your colleagues, customers and suppliers
about the magazine. You can use the e-mail button above
(the
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symbol in the browser) to help spread the word.
10-12 August Sri Lanka Plast, Colombo, Sri Lanka www.kmgindia.com
6-9 September Plastex, Cairo, Egypt www.plastex-online.com
10-14 September Plastex, Brno, Czech Republic www.bvv.cz/plastex
17-19 September Kenya Plast, Kenyatta, Kenya www.kmgindia.com
21-25 September TaipeiPlas, Taipei, Taiwan www.taipeiplas.com.tw
24-27 September Plast Alger, Algiers, Algeria www.plastalger.com
25-26 September Mediplas, Birmingham, UK www.mediplasuk.com
26-27 September Kunststoffen, Veldhoven, Netherlands www.kunststoffenbeurs.nl
1-5 October ColombiaPlast, Bogota, Colombia www.colombiaplast.com
5-8 October IndPlas, Kolkata, India www.indplas.in
16-20 October Fakuma, Friedrichshafen, Germany www.fakuma-messe.de
24-27 October VietnamPlas, Ho Chi Minh City, Vietnam www.vietnamplas.com
14-15 November Expoplast, Montreal, Canada www.expoplast.org
29 Nov 2 Dec Plast Eurasia, Istanbul, Turkey www.plasteurasia.com
2013
7-10 January ArabPlast, Dubai, UAE www.arabplast.info
29 Jan - 1 Feb Interplastica, Moscow, Russia www.interplastica.de
6-7 March Plastec South, Orlando, FL, USA www.plastecsouth.com
12-15 March Plastimagen, Mexico City, Mexico www.plastimagen.com.mx
12-15 March Pro-Plas Expo, Johannesburg, South Africa www.proplasafrica.co.za
3-6 April Tiprex, Bangkok, Thailand www.tiprex.com
8-12 April BrasilPlast, Sao Paulo, Brazil www.brasilplast.com.br
10-11 April PlastTeknik, Malmo, Sweden www.easyfairs.com
Global exhibition guide
AMI conferences
25-26 September Medical Grade Polymers, Boston, MA, USA
9-10 October Polymer Foam, Newark, NJ, USA
23-25 October Polyolefn Additives, Cologne, Germany
27-28 November Minerals in Compounding, Atlanta, GA, USA
27-29 November Fire Resistance in Plastics, Cologne, Germany
29-31 January Thermoplastic Concentrates, Coral Springs, FL, USA
18-20 February The Grass Yarn & Tufters Forum, Cologne, Germany
25-27 February Wood-Plastic Composites, Vienna, Austria
5-7 March Cables, Cologne, Germany
19-21 March Green Polymer Chemistry, Cologne Germany
For information on all
these events and other
conferences on flm,
sheet, pipe and
packaging applications, see
www.amiplastics.com

CW June 2012

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