k-fair presentation flexible packaging -...

Confidential

Hartmut SiebertBU Additives / BL Polymer AdditivesMarketing09.10.2013

K-fair presentation flexible packaging

Hartmut Siebert, BU Additives / BL Polymer Additives, Marketing, 09.10.2013

Table of Contents

Confidential, K-fair presentation flexible packaging2

Film Extrusion Process 8

Melt formation and extrusion 9

Processing: Cleaning power of P-EPQ 10

P-EPQ and cast film extrusion 11

Gel counting on LDPE film sample 12

Gel reduction over purging time 13

Processing: Particulate matter and screen pack 14

Processing: Enhanced Screen pack lifetime 15


Table of Contents


Cost efficient solutions for flexible packaging 16

General requirements for film 17

Multiple extrusion in a single screw laboratory extruder 18

Melt Flow Stabilization of PP 19

Color Stability of PP 20

AddWorks® LXR®– specific designed solutions 21

AddWorks® PKG and LXR for high speed BOPP 22

Critical steps of BOPP film extrusion 23

Color Stability of PPR (BOPP) 24


Table of Contents


Melt Stability of PPR (BOPP) 25

MFR protection vs processing temperature 26

Corona treatment of PP film grade: Better Dyne level retention with Hostanox P-EPQ

27

AddWorks® PKG series for BOPP and CPP films 28

AddWorks® LXR® 4 series 29

Hostastat FA 68 in BOPP films: Cast film production 30

Hostastat FA 68 in BOPP films: Stretching 31

Hostastat FA 68 in BOPP films: BOPP film finishing 32


Table of Contents


Industrial trials– Hostastat FA 68 33

Hostastat FA 68 in BOPP films Performance after X Days Storage

34

Conclusion: AddWorks® LXR® 4 series for BOPP 36

Hostastat FA 68 in BOPP films 37

Solution for low discoloration in IPP film–AddWorks® PKG 170

38

Challenge 39


Table of Contents


Results: Yellowing (YI) of IPP after Multiple Extrusion at 230 C

40

Results: MFR (2.16 Kg, 230 °C) of IPP after Multiple Extrusion at 230 °C

41

Conclusion 42

AddWorks® LXR and PKG for PP tapes 43

Requirements for PP Tapes 44

Melt protection of Polyolefins: example of PP 45

Yellowing protection of Polyolefins: example of PP 46

Water Carry Over of Polypropylene Tapes 47


Table of Contents


AddWorks® PKG series for PP Tape grades 48

Polyethylene – Low Gels with AddWorks® LXR® 49

LLDPE blown film requirements 50

Processing of LLDPE (0,918 g/cm³) at 240°C 51

Effect of Solubility of Stabilizers on Transparency 53

Gel reduction in LLDPE film 54

Confidential


Film Extrusion ProcessBENEFIT CASES

Hartmut Siebert, BU Additives / BL Polymer Additives, Marketing, 09.10.2013Confidential, K-fair presentation flexible packaging

Several critical zones for polymers in the extrusion process

Melt formation and extrusion

air/oxygen

hot barrel

heating jacket

compression zone

filling channel

screen pack

diedrive screw

melt formation zone

hopper with polymer

shear

high flowvelocity

Heat

9


Processing: Cleaning power of P-EPQ

addition of P-EPQ

charred polymer

By adding P-EPQ charred polymers can be removed P-EPQ is very effective for cleaning entire extrusion lines without disassembly

10 Confidential, K-fair presentation flexible packaging


P-EPQ and cast film extrusion

hot polymer melt

drawing direction

slit die

drawing role

P-EPQ gives a clean slit die and prevents casted film from surface defects

film


narrow bore channels in the die

Without

With P-EPQ

Challenges: Incrustation, lumps, specks and dirty slit die


12

30.04.2010

Gel counting on LDPE film sample

Gels

Confidential, K-fair presentation flexible packaging

Hartmut Siebert, BU Additives / BL Polymer Additives, Marketing, 09.10.201330.04.2010

Gel reduction over purging time

0

5

10

15

20

25

30

35

40

45

50

12 24 36 48 60 72 84

Num

ber o

f gel

Purging time (min)

Gel reduction over purging time

virgin2% PEPQ

Significant improvement of film quality with AddWorks® solutions based on Hostanox P-EPQ Faster start-up of film line



Processing: Particulate matter and screen pack

particles are clogging the filters rapidly

without P-EPQ particles are formed intensely

Very short screen pack lifetime Very short maintenance intervals



Processing: Enhanced Screen pack lifetime

lifetime100%

Utilizing P-EPQ extend screen pack lifetime significantly Long maintenance intervals and lower costs

up to +35% increase in lifetime

polymers with standard stabilization

polymer melt protected with P-EPQ


screen pack

Without

With P-EPQ

Confidential


Cost efficient solutions for flexible packagingBENEFITS OF ADDWORKS®

LXR®(ƏLɪKSɪR)


General requirements for film

– Melt and Colour Stability

– High Transparency

– Low Gels

– Even film thickness profile



Multiple extrusion in a single screw laboratory extruder

Screw - compression ratio 1/3

Screw speed - 50 rpm

Temperature regime (feeder - die): 240 to 260 °C



19

0

1

1

2

2

3

3

MFI

(230

°C/2

.16k

g)

AddWorks®LXR® 537 PS 168 PS 9228

Multiple Extrusion at 230 °C

MFI1MFI3MFI5

Stabilization: 0.1 % CaSt + 0.05 % Hostanox O 10 + 0.07 % Processing Stabilizer

LAP 2000.158

Melt Flow Stabilization of PP

AddWorks®LXR® 537 improves melt stability



20

0

2

4

6

8

10

12

14

Yel

low

ness

Inde

x

AddWorks®LXR®537 PS 168 PS 9228

Multiple Extrusion at 230 °C

YI-1YI-3YI-5

Stabilization: 0.1 % CaSt + 0.05 % Hostanox O 10 + 0.07 % Processing Stabilizer

LAP 2000.158

Color Stability of PP

Superior colour performance of AddWorks®LXR®537



AddWorks® LXR®– specific designed solutions

AddWorks®LXR®537 shows high colour and melt protection

at reduced formulation cost

AddWorks®LXR®537 is ready to use, easy to handle with good hydrolytic stability

AddWorks® LXR®by Clariant boosts performance and

enhances customers competitiveness


Besides of AddWorks®LXR®537, AddWorks®LXR®538 and AddWorks®LXR®539 are available for cost efficient MFR and colour protection of polyolefin films

AddWorks® LXR®

by Clariant boosts performance and enhances

my competitiveness

Confidential


AddWorks® PKG and LXR for high speed BOPP


Critical steps of BOPP film extrusion

Heat

Shear

Heat

Heat

AddWorks® solutions based on Hostanox P-EPQ helps to control degradation attacks throughout the entire process


Needs for MFR and colour retention

Low Migration

and excellent

Dyne level retention

Corona Treatment Metallizer


Color Stability of PPR (BOPP)

-2

-1

0

1

2

3

4

None 0.1% PS 168 0.05% PEPQ

Processed at 230°C

1st pass 3rd pass 5th pass

24

Stabilization : 0.1% Ca-stearate, 0.05% AO 1010,

Hostanox P-EPQ in BOPP: Better yellowness prevention with better colour stability at half concentration


Yello

wne

ss In

dex


Melt Stability of PPR (BOPP)

2

3

4

5

6

7

8

9

10

None 0.1% PS 168 0.05% PEPQ

1st pass 3rd pass 5th pass

25

Stabilization : 0.1% Ca-stearate, 0.05% AO 1010

MFR

230°C

/2.1

6 kg

Can result in lowertensile properties

Better MFR retention lower variations

Hostanox P-EPQ in BOPP: Better MFR protection and better processability


Processed at 230 °C


MFR protection vs processing temperature


T Plot

1.80

3.32

4.85

6.38

7.90

MFI

(2.1

6)

200 212

225 238

250

700

950

1200

1450

1700 Temp

QB 1202

Degradation by chain scission

Resin protection

Dosing of AddWorks® PKG 902 can be customized in order to overcome the degradation effects at the customer specific processing temperature with lowest possible costs

DESIGN-EXPERT Plot

• Constant:• CaSt = 350 ppm

• Variables:• Process Temperature• Concentration of

AddWorks® PKG 902, a P-EPQ based solution


Corona treatment of PP film grade: Better Dyne level retention with Hostanox P-EPQ

0 5 10 15 20 25 30Days

Time until dyne ≤ 36

Hostanox P-EPQ at half concentration PS 168

Base Stabilisation: Hycite® 713 + phenolic AO

27

Initial Dyne level after Corona treatment: 52 dyne/cm

Hostanox P-EPQ at half concentration provides significantly better dyne retention Solutions as AddWorks® PKG 902 and AddWorks® PKG 112 make use of this advantage


Film Thickness 50 μm


AddWorks® PKG series for BOPP and CPP films

AddWorks® PKG 902 and AddWorks® PKG 112: Cost efficient solutions for BOPP and CPP

− Cost efficient solutions for BOPP stabilisation,− Providing excellent colour and MFR protection− Low dosage and no migration ensuring outstanding metallisation process− Enabling longer dyne level retention after corona treatment− Film breakage prevention − More even film thickness profile − Broader range of processing temperatures, high extrusion speed (>400 m/min)− Allows for higher recycling rate − Not affecting printability or metallization− Longer screen pack lifetime− Clear and non coloured films

AddWorks® PKG 112 is especially suitable for metallised films


− Combines the benefits of AddWorks® PKG 902 with high acid scavenging power and no migration

Confidential


AddWorks® LXR® 4 seriesANTISTATIC BENEFIT THROUGHOUT THE ENTIRE PRODUCTION PROCESS


Hostastat FA 68 in BOPP films: Cast film production

1. Production of primary film with compression of the melt, filtration, casting and cooling

2. Heating the film for stretching process

30

1100

1200

1300

1400

blank film Hostastat FA 68

elong

atio

n at

bre

ak [%

]

750 µm cast film

Hostastat FA 68 enhance the stretching potential Lower BOPP film thickness could be achieved



Hostastat FA 68 in BOPP films: Stretching

3. Longitudinal stretching

4. Transverse stretching

31

0

20

40

60

80

100


elon

gatio

n at

bre

ak [%

]

25 µm BOPP film

Hostastat FA 68 does not affect BOPP Films mechanical properties



Hostastat FA 68 in BOPP films: BOPP film finishing

5. Dimensional stabilization by heating the film

6. Winding process

32

0

0.1

0.2

0.3

0.4

0.5


YI (DIN 6167)Delta E (a, b)Haze (d% )

25 µm BOPP filmOptical properties

BOPP film appearance not affected with Hostastat FA 68: Good Color and transparency retention



Industrial trials– Hostastat FA 68

0

10

20

30

40

0.15% FA 68

Electro static performance

Electro Static Half Time (0 day)Electro Static Half Time (2 days)Electro Static Half Time (5 days)

> 180 s


Hostastat FA 68 reduces electrostatic halftime to less than two seconds

Test set up: 3 layer 20 µm BOPP Corona treated Line Speed: 345 m /

minute (~3,000 kgs / hour)

Width: 8,100 mm MFR = ~ 3 g/10 min



1.0E+09

1.0E+10

1.0E+11

1.0E+12

1.0E+13

1.0E+14

1.0E+15


after production

after 7 days storage


34

Sur

face

resi

stiv

ity [Ω

]

> 1015 > 1015

25 µm BOPP film

1500 ppm dosage Hostastat FA 68

Static control upper limit

Hostastat FA 68 significantly reduces surface resistance in BOPP Films Static control is effective after some days Static control still effective after more than 1 year




1.0E+09

1.0E+10

1.0E+11

1.0E+12

1.0E+13

1.0E+14

1.0E+15


after production


35

Sur

face

resi

stiv

ity [Ω

]

> 1015 > 1015

25 µm BOPP film

1500 ppm dosage Hostastat FA 68

Static control upper limit

Hostastat FA 68 significantly reduces surface resistance in BOPP Films Static control still effective after more than 1 year



Conclusion: AddWorks® LXR® 4 series for BOPP

36

Long lasting performance on a high level:

outstanding results can be achieved with Hostastat FA 68

Hostastat FA 68 still effective after more than 1 year

AddWorks® LXR® 4 solutions based additional on Hostastat FE 1 or FE 2 highly recommended for immediate antistatic effect

BOPP processing properties not affected by Hostastat FA 68

Hostastat FA 68 does not modify BOPP films properties:

mechanical properties

color



Hostastat FA 68 in BOPP films

BenefitsBenefits

Processing stability

Dimensional stabilityHigher thickness range

Colour stabilityNo transparency change

Long term static control

Added valueAdded value

Better productivityBroader film offer

Better article quality

Better article quality


Hostastat FA 68 provides outstanding antistatic properties to the BOPP films along service life time. Film properties are maintained even under critical processing conditions

Confidential


Solution for low discoloration in IPP film–

AddWorks® PKG 170


Challenge

• Standard antioxidant package AO 215 shows high discoloration to IPP film

• Usually this is not accepted by the market

• In this price sensitive market a cost performance optimized solution is needed$


Hartmut Siebert, BU Additives / BL Polymer Additives, Marketing, 09.10.2013Confidential, K-fair presentation flexible packaging40

Results: Yellowing (YI) of IPP after Multiple Extrusion at 230 C

AddWorks® PKG 170 shows at half of the concentration outstanding colour stability after multiple extrusion

-30

-25

-20

-15

-10

-5

0

YIPass 0 Pass 1Pass 3 Pass 5


Results: MFR (2.16 Kg, 230 °C) of IPP after Multiple Extrusion at 230 °C


AddWorks® PKG 170 shows good protection of the MFR already at low dosage

0

2

4

6

8

10

12

14

16

MFR

(g/1

0 m

in)

Pass 0 Pass 1 Pass 3 Pass 5

Hartmut Siebert, BU Additives / BL Polymer Additives, Marketing, 09.10.2013Confidential, K-fair presentation flexible packaging42

Conclusion

– The formulation with 850 ppm AddWorks® PKG 170 shows half of the colour reduction in comparison to AO 215.

– At half concentration of AO 215, AddWorks® PKG 170 impressively improves colorstability of the IPP during processing and shows good MFR retention.

AddWorks® PKG 170

Confidential


AddWorks® LXR and PKG for PP tapes


Requirements for PP Tapes

1. Tapes / Yarn break prevention (affecting factors are: impurities, recycle,

high melt flow)

2. Even Profile thickness (usually with polymer stability)

3. Water Carry Over (usually with drawn speed, additive package and

temperatures)

4. UV stability (achieved with light stabilizers)



Melt protection of Polyolefins: example of PP

45

0

3

1,5

2

2,5

1

0,5

1st cycle

3rd cycle

5th cycle

MFI@230 °C (g/10 min)

-31%

-27%

-35%

BS = 0,05% AO 10 + 0,1% CaStBS: Base Stabilization,AO: Phenolic Antioxidant CaSt: Calciumstearate

PP sample stabilizedwith 0.07% Phosphite 168

PP sample protectedwith 0.07% P-EPQ


Superior MFR retention of PP stabilized with solutions based on Hostanox P-EPQ


Yellowing protection of Polyolefins: example of PP

46

0

14

2

4

6

8

10

12

1st cycle

3rd cycle

5th cycle

-27%

-72%

-90%PP sample stabilizedwith 0.07% Phosphite 168

PP sample protectedwith 0.07% P-EPQ

BS = 0,05% AO 10 + 0,1% CaSt

Yellowness Index processed @230 °C

BS: Base Stabilization,AO: Phenolic Antioxidant CaSt: Calciumstearate


Outstanding YI protection for PP stabilized with solutions based on Hostanox P-EPQ


Water Carry Over of Polypropylene Tapes

2527293133353739414345

Max

. Lin

e Sp

eed

to W

CO

[m/m

in]

+ 0.1% Specialty Phenolic AO and 350 ppm Hycite® 713

127µm thickness filmSlit Tapes : 51 µm thickness x 2.54 µm width after stretching

Melt Temperature 260ºC; Die Gap 1.27 mm; Water Bath 25°C ; Draw Ratio 6:1

47

0.05 % dosage insufficient for some processing stabilizers !!!

Comparativeperformance data.


AddWorks® PKG 110 shows lower water carry over and allows for higher line speed AddWorks® PKG 110 is a ready to use solution based on Hostanox P-EPQ and Hycite® 713


AddWorks® PKG series for PP Tape grades

AddWorks® PKG 110: Cost efficient solution for PP tapes

− Proven high efficiency in PP tapes process− Higher line speed due to lower water carry over− Providing excellent colour and MFR protection: Film breakage prevention− More even film thickness profile − Broader range of processing temperatures, high extrusion speed − Allows for higher recycling rate− Longer screen pack lifetime

AddWorks® PKG 110 for PP tapes is especially suitable for metallisation and low water carry over


Confidential


Polyethylene – Low Gels with AddWorks® LXR®


LLDPE blown film requirements

– Low gel formation

– Low Haze

– Smooth Processability

– Broad processing window

– Good bubble stability


Blown Film Line


0.2

0.5

0.8

1.1

1 2 3 4 5

Extrusion Passes (30 sec/pass residence time)

Melt F

low

Inde

x (MF

I, 190

°C/2,

16 kg

) [g/

10m

in]

0,15% P-EPQ

0,12% P-EPQ

0,20% PS 168

without Proc. Stab.

Processing of LLDPE (0,918 g/cm³) at 240°C

Base stabilization: 0,1% AO 1076 + 0,1% Ca-stearate

Superior MFR retention of LLDPE stabilized with solutions based on Hostanox P-EPQ



-4

0

4

8

12

1 2 3 4 5Extrusion Passes (30 sec/pass residence time)

Yello

wnes

s Ind

ex [p

ellet

s]without Proc. Stab.

0,20% PS 168

0,08% P-EPQ

0,12% P-EPQ

0,15% P-EPQ

Base stabilization: 0,1% AO 1076 + 0,1% Ca-stearate

Processing of LLDPE (0,918g/cm³) at 240°C

Outstanding YI protection for LLDPE stabilized with solutions based on Hostanox P-EPQ



Hostanox P-EPQPS 168

Strong exudation / “blooming”

Effect of Solubility of Stabilizers on Transparency

53

Excellent solubility of Hostanox P-EPQ in LLDPE, no blooming


LLDPE film samples (Density = 0.917 g/cm3)After 1 Year Storage at 23 °C (73 °F)

Additive formulation: 200 ppm AO + Processing Stabilizer


Gel reduction in LLDPE film

* - Gels count done by visual observing, gels on 6 samples were counted by the same person

- Size of film specimen : 10.0 x 10.0 cm2

0

20

40

60

80

100

120

ZnSt + AO1076 +TNPP

AddWorks® PKG 114+ TNPP

Big-Medium Gels

Small Gels

TNPP Standard Stabilization

AddWorks® PKG 114

Gels Count

Significant reduction of Gels by using AddWorks® PKG 114


k-fair presentation flexible packaging -...

Documents