Functional Additive Masterbatches for Plastic Packaging: An Overview

Dean Dodaro Polyvel, Inc 100 Ninth St Hammonton, NJ 08037

Outline • About Us • Additive Functions:

– Antiblocks – Antifogs – Antimicrobials – Antistats – Chain Extender – Chemical Foaming Agent – Clarifiers – Fragrances – Nucleators – Process Aids – Slips/Lubricants – Stabilizers

• Biopolymer developments • Other additive considerations

About Us

• Compounding and development of specialty additive masterbatches – Proprietary masterbatches – Custom masterbatches/concentrates

• Auxiliary processes: – Mixing, blending – Drying – Laboratory

• Toll manufacturing • ISO 9001 certified since 2002 • Headquarters and manufacturing:

– 46,000 sq/ft located in Hammonton, NJ – >10+ MM lb annual capacity

• Privately held - founded in 1982

Antiblocks - 1

• Why use antiblocks? – Plastic film and sheet, PE in particular, will adhere to itself making it

difficult to handle – Applications:

• Typical antiblock additives: – Minerals: talc, CaCO3, silica – Others: spherical particles/particulates

• Particle size is critical

Antiblocks - 2

• How antiblocks work – Surface is modified to reduce contact area between layers

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• Why use antifogs? – Aesthetics: moist or humid air gets trapped in a closed system, water

condenses on cold surfaces (<dew point) – Agricultural films: disrupts light transmission – Applications: disposable containers, greenhouse films, hot/cold flexible

food packaging • Typical antifog chemistries:

– Fatty acid surfactants, amides, glycerols – Characteristic lipophilic and hydrophilic portion of molecule

Antifogs - 1

Material Surface energy (dyne/cm)

Polyolefins 29 – 31

PET 41 – 44

Water 72

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• How antifogs work: – Migration of additive, surface orientation

Antifogs - 2

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Antimicrobials

• Why use antimicrobials? – Protection of sensitive

materials/parts – Dust control – Applications: water purifiers, trays

• Typical antimicrobial additives: – Silver salts, trichlosan, propionates,

sulfur – Migratory and non-migratory types

• Need to be careful with claimed performance

Antistats - 1 • Why use antistats (antistatic)?

– Protection of sensitive materials/parts

– Dust control – Applications: electronic packaging,

packaging for sensitive powders, POS appearance enhancement

• Typical antistat additives: – Temporary: surfactants, typically

with hydrophilic heads and lipophilic tails

• Non-food contact applications: amines – Permanent: create a network for

charges to dissipate within the polymer

• Polymeric, carbon-based chemistries

• How migratory antistats work: – Migration of additive, surface orientation

Antistats - 2

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Chain Extenders

• Why use chain extenders? – Improve IV – Increase regrind use – Combat hydrolysis – Applications: recycle streams

• Typical chain extender additives: – BASF Joncryl

• How chain extenders work – One molecule with two or more

‘activateable’ sites that will bond with multiple polymer chains

– Only available for condensation polymers (PET, PC, etc)

Chemical Foaming Agents • Why use chemical foaming agents (CFA)?

– Lower density – Reduce material cost – Insulating properties – Alternative to gas injection – Aesthetic improvement – Applications: Hot/Cold containers

• Typical CFA additives: – Heat sensitive additives that are

classified by their degradation mechanisms: Exo- and Endo- thermic

– Azodicarbamide, sodium bicarbonate • How CFAs work: Generation of inert gases that become

entrapped in polymer

Clarifiers

• Why use clarifiers? – Aesthetics: improve transparency – Applications: containers, lidding

• Typical clarifier additives: – Sorbitol derivatives – Suppliers: Milliken, Amfine

• How clarifiers work

Courtesy of Milliken

Fragrances

• Why use fragrances? – Consumer impression – Masking foul odors – Repellents – Applications: trash bags, sachets

• Fragrance limitations – Heat sensitive

• Polymer selection

– Emission control – Subjectivity – Scent transfer

• How fragrances work – Deliver VOCs – Low MW additives (C6 – C18)

Nucleators • Why use nucleators?

– Improve physical properties – Decrease cycle time – Applications: sheet

• Typical nucleator additives: – Minerals: talc, silica – Organics: Milliken, Amfine

• How nucleators work:

Process Aids

• Why use process aids? – Increase throughput – Improve quality – Applications: blown film, extruded sheet

• Typical process aid additives: – Fluoropolymers – Metal stearates

• How process aids work – ‘Lubricate’ polymer melt, aid wet out – Coat metal surfaces

Slips/Lubricants

• Why use slips/lubricants? – To reduce the tendencies of certain polymers from adhere to

themselves and metal surfaces – Applications: film/sheet, molded parts

• Typical lubricant additives: – Fatty acid esters, waxes, metal stearates, amide

• Related uses: – Antifog/Antistat – Metal Release – Dispersing

• Commonly used with antiblocks for synergistic affect

Stabilizers

• Why use stabilizers? – Combat discoloration – Ward off loss of mechanical properties due to processing or use

conditions – Applications: long shelf-life materials, aggressive processes

• Classes of stabilizers: – UV Absorbers – Antioxidants – Light Stabilizers

• Use conditions: – Processing parameters – Substrate material – Film/sheet structure – Temperature gradient

Biopolymer Additives

• Common biopolymer issues: – Ductility/Impact – Heat resistance – Supply

• Typical applications: – Thermoformed packages – Blown film packaging

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Other Additive Considerations

• Color • Desiccants: zeolites, silica gels, or CaO for limiting moisture

exposure • Ethylene oxide absorbers: helps keep produce fresh, includes

chemistries such as Ca/K permanganate • Flame retardants • Matte/Degloss: reduce ‘shiny’ surface, aesthetic effect • Odor managers: mineral based and organic, non-fragrant • Oxygen scavengers: primarily aids food preservation,

includes iron, sulfites, and calcium based chemistries • Permeability regulators: additives and polymers that can be

used to introduce barrier or selective barrier layers • Plasticizers

Innovation

Thank You

Booth 754 Dean Dodaro Sales Engineer/ISO Coordinator Polyvel, Inc. 100 Ninth Street Hammonton, New Jersey 08037 P: 609-567-0080 M: 609-760-2701 E: ddodaro@polyvel.com