multilayer film presentation - tie layers - mpb / polieco
TRANSCRIPT
Presentation Overview
• Industrie Polieco – MPB Srl
group and divisions
• Compounding Division overview business units, some facts and figures
• Multilayer film
production process, lab. and R&D facilities, product range
2
Divisions
Industrie Polieco – MPB Srl.
Compound Division
(MPB)
Black, Colored and Modified
Polyolefin Compounds
Performance and Special
Polymer Compounds
Grafted adhesives &
Tie layers
Pipe Division
(Polieco)
Corrugated Twin Wall HDPE
Sewage and Drainage Pipes
Corrugated HDPE Cable
Conduit Pipes
HDPE Couplings & Fittings
KIO® Composite Manhole Covers
3
Group Organisation & Production Facilities
4
Pipe Division – Polieco
European leader and largest
producer of corrugated double wall
HDPE pipes and HDPE cable conduit pipes.
Manufacturing by rotomolding technic of fittings
and inspection manholes. Engineering department to provide to
the market turn-on-key pipe line solutions for sewage and drainage
pipe line projects
50.000 ton
(installed capacity)
5
Compounding Division – MPB
One of Europe largest producers
of black and coloured ready-made
(ready-to-use) polyolefin compounds
Production of complete range of
polyolefin compounds (LLDPE, LDPE, MDPE, HDPE and PP).
Production range of grafted adhesives for different applications,
such as steel pipe coating, multi layer film,
multi layer pipes and compatibilizers -
80.000 ton (installed capacity)
6
MPB – Global Compounding Capacity
Production facilities Italy annual capacity 80.000 tons
MPB Cazzago S Martino Italy
7
Industrie Polieco – MPB Srl
Compounding Division - (MPB)
MPB enjoys sales activities in Europe, Middle East, Africa, Asia,
South & North America, Russia and C.I.S. Countries
MPB is Clients’ focused granting services, quality and
competitiveness thanks to the fact that the group yearly
processes more than 100 Kt of polyolefins
8
MPB – Compounds Established Brand Names
Luxene® PE compounds
Procoat® PP compounds
Coesive® PE modified grafted adhesives
Proesive® PP modified grafted adhesives
9
MPB – Overview Business Units
Primarily market targets for MPB are:
Steel Pipe Coating
- EU leader, 2° largest global player
- unique R&D centre, pilot line
Multi Layer Applications:
- multi layer pipe,
- multi layer film (packaging)
- fuel tanks in automotive industry
Wire & Cable
- coupling-agents in HFFR compounds
No pressure irrigation pipes (LDPE, HDPE)
Coupling agents in special compounds
- RGF/PP
- RGF/PA
- WPC
10
Steel Pipe Coating Wire & Cable – HFFR compatibiliser
Multi Layer Pipes
WPC compatibilizer
Multi Layer Film
11
COESIVE® &
PROESIVE®
Safe & Sealing
Tie-Layers
12
13
Reactive Extrusion - Free radical grafting process
COESIVE® PROESIVE® Buss technology process
14
COESIVE® PROESIVE® Equipment K-Tron ‘loss-in-weight’ feeders
15
COESIVE® PROESIVE® Maleic anhydride handling: liquid injection
• Hazards Identification
• Classification of the substance or mixture
• Classification according to Regulation (EC) No 1272/2008 [EU-GSH/CLP]
• Acute toxicity, Orale (Category 4)
• Skin corrosion (Category 1B)
• Respiratory sensitization (Category 1)
• Skin sensitization (Category 1)
16
COESIVE® PROESIVE® Production process - PLC control and complete historical data
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COESIVE® PROESIVE® Production process - Continuous monitoring of process parameters
• Temperatures
• Pressures
• Throughput for each feeder
• Drives absorption
Temperature Z mescolatore
163,93
173,93
183,93
193,93
203,93
213,93
223,93
233,93
11/01/2010
14.00
11/01/2010
14.29
11/01/2010
14.57
11/01/2010
15.26
11/01/2010
15.55
11/01/2010
16.24
11/01/2010
16.53
11/01/2010
17.21
11/01/2010
17.50
Data
Te
mp
era
tura
Z1 Z2 Z3 Z4
18
COESIVE® PROESIVE® Production process - Optycal control system (OCS)
Granule optical classification and separation
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COESIVE® PROESIVE® Production process - Optycal control system (OCS)
Granule optical classification and separation
20
O
O
O
Reactivity
MAH
Miscibility
PE
COESIVE® PROESIVE® Adhesion mechanism
21
COESIVE® PROESIVE® Adhesion mechanism
2
O
O
O
COESIVE ®
HO
H N
OH
+
O
O
N
O
O
O
PA-6
EVOH
22
COESIVE® PROESIVE® Adhesion mechanism
O
O
N
O
O
N
Free MAH-content
Blocking reactive groups
LOW adhesion strength
MAH effective = Grafted MAH – Free MAH
HIGH grafted MAH-content
HIGH covalent bonding
HIGH adhesion strength
23
COESIVE® PROESIVE ® Regulation - Food contact compliance
Determination of the Content of Free Maleic Anhydride (CAS 000108-31-6)
Our products have a very low content of free maleic anhydride, lower than the detectable level. This assures a good
adhesion performance and the compliance with PIM requirements
COESIVE® F30 (u)
Solvent: Distilled Water-Ethanol -50:50
Contact Condition: 6 hours at reflux temp
Mesaured unit: mg/kg
Measured Value Average Value Standard deviation
<5
<5 -- <5
<5
REFERENCE 9403
Solvent: Distilled Water-Ethanol -50:50
Contact Condition: 6 hours at reflux temp
Mesaured unit: mg/kg
Measured Value Average Value Standard deviation
<5
<5 -- <5
<5
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0
5
10
15
20
25
30
35
10% 20% 30% 40%
ADHESION (N/15mm)
COESIVE® F30 (u)
COESIVE® F30 (u) Adhesion on EVOH
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COESIVE® F30 (u) Adhesion on PA
0
5
10
15
20
25
30
35
10% 20% 30% 40%
ADHESION (N/15mm)
COESIVE® F30 (u)
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COESIVE® F30 (u) Adhesion curve. PA vs. EVOH
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QC - R&D Laboratories
● Highly skilled and competent technical team
● Modern and complete equipped laboratories
● Unique technology, research and training centre for
pipe coating with complete intergrated laboratory for
testing, training and research on all coating systems
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QC - R&D – Rheological tests
• Viscosity Measurements
– Capillary rheometer
– Once per Batch
• Melt Flow Index
– Plastometer
– Every hour in production
– Once a day in QC lab.
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QC - R&D – Thermal analysis
• Differential Scanning Calorimeter
– High precision and accuracy
• DSC Analysis
– Melting points
– Melting enthalpy
– Crystallinity
• OIT Oxidation Induction Time
– Polymer stability during extrusion
• Once for each batch produced
30
QC and R&D – Maleic anhydride concentration by FTIR analysis
• Fast Fourier Transform Infra Red
– Molecular spectroscopy
– Qualitative quality control
– Quantitative analysis of MAH concentration through the peak at 1791 cm-1.
• Measurement of MAH concentration is performed at least every four hours during the
production of adhesive grades
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QC and R&D – Film inspection system
Automatic gel and black spot counting system installed on a laboratory cast film line
32
QC and R&D 5-Layer blow film pilot line
Extrudable Polymers on the 5-layer Pilot Plant
LDPE - LLDPE – HDPE
PP
EVA
EVOH
PA 6
PA 6.66
PET
PS
Thickness,
µm
Extruder
Ø 25
A
Ø 20
B
Ø 25
C
Ø 20
D
Ø 25
E
Lower 20 µm 2 µm 4 µm 2 µm 20
µm
Higher 55 µm 10 µm 20 µm 10 µm 55
µm
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QC and R&D – Film testing
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COESIVE® PROESIVE Regulation - Food contact compliance
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COESIVE® PROESIVE ® Regulation MSDS REACH compliance
36
COESIVE® & PROESIVE® in blow & cast film for high barrier
Typical Polyethylene structure of film:
LLDPE/COESIVE®/PA/COESIVE®/LLDPE
LLDPE/COESIVE®/EVOH/COESIVE®/LLDPE
LLDPE/COESIVE®/PA/EVOH/PA/COESIVE®/LLDPE
MPB polyethylene adhesives
COESIVE® F30 (u)
COESIVE® LL20F
COESIVE® LL20FPA
COESIVE® LL15M
In case of structure with Anti-fog properties:
COESIVE® LL40M
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COESIVE® & PROESIVE® in blow & cast film for high barrier
Typical Polypropylene structure:
PP/PROESIVE®/PA/PROESIVE®/PP
PP/PROESIVE®/EVOH/PROESIVE®/PP
MPB polypropylene adhesive
PROESIVE® PP70 F
PP/COESIVE® /PA/COESIVE®/PE
PP/COESIVE®/EVOH/COESIVE®/PE
MPB polyethylene adhesive
COESIVE® LL40M
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COESIVE® & PROESIVE® in casing & shrink high barrier film
Multilayer, bi-axially oriented, shrinkable films require a specific tie-layer that can withstand specific
stresses received during orientation in the production process. A specific product is developed for triple
bubble application to bond polyethylene to EVOH or PA:
Polyethylene Adhesives for triple bubble
MPB polyethylene adhesive
COESIVE® L850 F
39
COESIVE® & PROESIVE® in sheet
Sheet films are produced by thermoforming into cups and trays.
Typical structure are 5-layer barrier film laminated with PET.
LLDPE/COESIVE®/EVOH/COESIVE®/LLDPE laminated to PET
LLDPE/COESIVE®/PA/COESIVE®/LLDPE laminated to PET
COESIVE® F30 (u)
COESIVE® LL20F
COESIVE® LL20FPA
COESIVE® LL15M
In case of retortable trays the typical structure is:
PP/PROESIVE®/EVOH/ PROESIVE®/PP
PROESIVE® PP70 F
40
COESIVE® & PROESIVE® in floor heating multi-layer pipes
Multilayer pipes for floor-heating application are structured with cross-linked polyethylene
(PEX) and EVOH.
PEX/COESIVE®/EVOH/COESIVE®/PEX
MPB polyethylene adhesives for pipes
COESIVE® LL30M
41
COESIVE® & PROESIVE® in tube
Tooth pastes, creams frequently contain perfumes that have the tendency to migrate from traditional
tubes.
Multilayer tubes reduce the migration of the perfumes and the drying of the cream or tooth paste.
Also mayonnaise and sauces can be packaged with barrier tubes.
LDPE/COESIVE®/PA/COESIVE®/LDPE
LDPE/COESIVE®/EVOH/COESIVE®/LDPE
MPB polyethylene adhesives for tube:
COESIVE® LL20F Successfully tested at
42
COESIVE® & PROESIVE® in wood plastic composite WPC
WPC are composite materials made of wood fibers within a thermoplastic matrix resin (PE, PP). A
coupling agent is always used in WPC’s formulations to improve the compatibility and the adhesion
between polar cellulosic substrates and non-polar polymeric materials.
MPB polyethylene compatibiliser and coupling agent for WPC
COESIVE® LL54W
43
COESIVE® & PROESIVE® in wire & cable
MAH-grafted coupling agents are used in the wire & cable industry for the production of Halogen Free
Flame Retardant (HFFR) compounds: in these products mineral fillers such as Al(OH)3 (ATH) or
Mg(OH)2 (MDH) are added to poly-olefins to meet the flame retardant requirements.
Coupling agents, together with other additives, are necessary to improve mechanical properties of the
compounds and to obtain high filler loads.
MPB polyethylene compatibiliser and coupling agent for HFFR Cable:
COESIVE® F50 (u)
COESIVE® LL15M
COESIVE® EV350
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COESIVE® & PROESIVE® Packaging and storage
• 25 kg bags on pallet – 1.375 kg or 1.500 kg
• 500 kg octabins on pallet
• 1.000 kg big bags on pallet
The products shall be stored indoor, in dry conditions at temperatures below 50°C,
protected from UV-light in closed (original) packaging. Improper storage can initiate
degradation which can have a negative influence on the physical properties of the products.
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Additinal Information: http://www.mpb.it/view.php/film-packaging-products
COESIVE®
PROESIVE®
great idea!
great choice!
46
SYNERGY! Collaboration with
barrier producers
(PA, EVOH, Al,
metal, etc)
SUPERIOR PROPERTIES! Adhesion
(to a variety of materials PO, PA, EVOH,
PET-g, PS, metals),
Optics & Processability
SYNERGY! Collaboration with
machinery
manufacturers
READINESS! Large stock
Worldwide
presence
EXPERIENCE! 1977 compounds
1995 adhesives
FLEXIBILITY QUALITY! EU feed-stock
REACH & FDA Compliance, food-
contact compliance,
(EU PIM; USA FDA)
TAILOR-MADE
ADHESIVES! (min.project size: 50 t/y)
PILOT LINE! Technical service
to/at Clients
A winning & different
approach…
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Head Office Contacts:
Loredana Pernici
Commercial & Marketing Director
T: +39 030 7241521
M:+39 335 6173889
Email: [email protected]
Sales North America:
CCC GROUP – CCC Plastics Division
Mauricio Fernandes
Business Development Manager
T: +1 905 454 6929
M: + 1 416 529 8590
Email: [email protected]