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March 2013

PROMOTING PET PERFORMANCE THE LATEST TWIN-SCREW EXTRUDERS POLYMER DISTRIBUTION TRENDS GOING GREEN WITH NATURAL FIBRES

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contents
05 Industry news
PAGE 13

The latest compounding industry news including international acquisitions and alliances, plus new investments and plant openings.

13 Moving materials: trends in polymer distribution


AMI has just completed its latest market report on polymer distribution in
PAGE 21

Europe. The studys author, Karla Vittova reveals some key ndings.

21 Exploring natural options for reinforcing plastics


Bio-based bres are putting down roots in applications where eco-awareness
PAGE 31

counts. Pat Toensmeier reports on recent developments.

31 Promoting PET performance


Peter Mapleston examines the latest additives designed to boost PET in a range of applications including packaging, textiles and technical parts.

PAGE 43

43 Whats next in twin-screw extruders?


Suppliers of twin-screw extruders are racing to develop machines that meet the changing needs of compounders. Mikell Knights discusses their recent work.

PAGE 60

60 Compounder of the month: Bada 62 Dates for your diary

coming next issue


S 50th issue special S Sustainable compounding S Anti-oxidants S Wire and cable applications
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contact us
Applied Market Information Ltd AMI House, 45-47 Stokes Croft, Bristol, BS1 3QP, United Kingdom Tel:+44 (0)117 924 9442 Fax:+44 (0)117 989 2128 www.amiplastics.com Head of business publishing: Senior editor: Contributing editor: Designer: Advertisement manager: Andy Beevers Chris Smith Jennifer Markarian Nicola Crane Claire Bishop E-mail: abe@amiplastics.com E-mail: cs@amiplastics.com E-mail: editorial@compoundingworld.com E-mail: claire@amimagazines.com Direct tel: +44 (0)20 8686 8139

Copyright Applied Market Information. No part may be reproduced without the prior written permission of the publisher.
www.compoundingworld.com March 2013 | COMPOUNDING WORLD 3

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news

Tessenderlo selling CTS to Mitsubishi Chemical


Tessenderlo of Belgium has announced plans to sells its CTS compounding operations to Mitsubishi Chemical of Japan. The TPE and PVC compounding business, which was acquired by Tessenderlo in the early 1990s, has around 360 employees and had revenues of E120 million 2011. The CTS group includes four production plants: CousinTessier in Tiffauges, France; Marvyflo in Clerval, France; TCT-Polska in Sochaczew, Poland; and CTS Automotive Compounds, which opened last year in Changshu, China. It also has a research and development facility in Belgium. CTS produces its PVC and TPE compounds for applications in the automotive, construction, plant equipment, consumer goods, and wire and cable markets.

BASF in US research initiative


BASF has teamed up with three leading US universities to create the North American Center for Research on Advanced Materials. It will create around 20 new post-doctoral positions at the three universities, which are Harvard, the Massachusetts Institute of Technology and UMass Amherst. Scientists will work together with engineers within the initiative, which is initially planned for five years. The ideas and topics to be researched will be decided jointly by the researchers. Topics already identified include microand nano-structured polymers, as well as biomimetic materials that emulate nature.

www.cts-compounds.com

Coperion makes changes at Pell-Tec


Coperion is expanding production of larger strand pelletizing systems such as this SP500HD model Coperion has changed the name of Pell-Tec to Coperion Pelletizing Technology. It has also relocated its operations from Niedernberg, Germany, to the Coperion site at Offenbach, which is around 40 km away. The relocation provides extra space for expanding production, says Coperion. It is currently developing larger strand pelletizing systems for output rates above 6,000 kg/hour. Coperion acquired the manufacturer of strand pelletizing lines in January 2012. Michael Schuler and Bernhard Stern are continuing as managing directors of Coperion Pelletizing Technology.

www.coperion.com

www.basf.com

Clariant Masterbatches and Melitek collaborate


Melitek, the Danish producer of medical compounds, has signed a collaboration agreement with Clariant Masterbatches of Switzerland. Under the agreement, Clariant will sell Meliteks Meliflex polyolefin and styrenic-based medical compounds through its sales network. In addition, Melitek will have access to Clariants Mevopur masterbatches for use in its Meliflex compounds or for selling directly to its customers.
www.compoundingworld.com 

The companies say that the agreement, which excludes thermoplastic elastomers, will allow customers to have a single supplier and point of contact whilst keeping traceability. The capability to offer a clear and auditable raw material chain with control of changes is extremely important to the healthcare industry, said Steve Duckworth, head of Clariants Global Medical and Pharmaceuticals Segment. Through this partnership we can give the customer the choice from a wide range of compounds and Clariants Steve Duckworth says that the agreement will give customers a wider choice

masterbatches developed to address the needs of the healthcare market. Meliteks managing director Kim Laursen said that the companys relationship with Clariant goes back many years, adding: By this sales cooperation, we hope to grow even further in the colour compound market, offering more customers the advantage of pre-coloured compounds and masterbatches.

www.clariant.com www.melitek.com
5

March 2013 | compounding world

news

Schulman makes bid for Ferro


A. Schulman has made an offer to acquire Ferro in a deal that it values at $563 million, or $855 million including debt. The bid has been rejected by Ferro, which saw its shares rise by more than 30% on 4 March, the day that Schulmans offer was made public. Schulman says that it first contacted Ferro in November 2012 and expressed its strong intent to acquire the company in a letter to its board on 13 February 2013. Ferros board has rejected the offer, believing that the company should remain independent. The two US-based companies are both major players in the additive and colour masterbatch markets. Schulman is also a supplier of thermoplastic compounds, while Ferros business also encompasses coatings and a wider range of materials, including pharmaceutical ingredients. A. Schulman and Ferro are both recognized leaders in specialty chemicals with value-added product lines, similar business models, complementary competencies, markets and applications, said Joseph Gingo, chairman, president and CEO of Schulman. We believe our combination will deliver superior value to our respective shareholders and offer better value to customers, and we would welcome the opportunity to engage in a mutually beneficial dialogue with Ferros board and management. The day after the bid was made public by Schulman, Ferro issued its Q4 and full year results for 2012. It made a pre-tax loss of $264 million for the 12-month period. The company says that it is restructuring its business with a target of reducing costs by more than $50 million over the next two years. A group of Ferro shareholders, which own a 4.3% stake in the company, has issued a statement that raises concerns about the performance of Ferro board and its quick rejection of the Schulman bid rather than engaging in a negotiation. For live updates on this story, follow us on Twitter: www.twitter.com/plasticsworld.

www.aschulman.com www.ferro.com

ISO-13485 for Teknor Apex UK


Teknor Apex has achieved ISO-13485 certification for the production of Medalist TPEs at its Oldbury plant in the UK. The awarding of the medical manufacturing standard strengthens the companys European supply capabilities for medical elastomers its US Medalist production plant obtained ISO-13485 in 2010. Certified production of Medalist TPEs in the UK helps Teknor Apex to save transit time and shipping costs in supplying the EU market, said Stef Hordijk, strategic market manager for the Thermoplastic Elastomer Division of Teknor Apex.

Masterbatch 2013 conference attracts leading global OEMs


AMI has revealed the programme for its Masterbatch 2013 conference, which takes place on 3-5 June in Frankfurt, Germany. The speaker line-up includes representatives from Coca-Cola, Danone, Nokia and Johnson & Johnson. Vince Voron, head of design and associate vice president at Coca Cola, will discuss the use of design to build brands and engage customers, while Laurent Benoit-Marechal, who is a manager for upstream plastic R&D at Danone, will address the use of additives to enhance products. Kirsten Kuehl, Nokias global head of community and developer innovation will give a presentation on design and innovation in mobile devices. In another presentation, the use of appearance, texture and colour to add value will be covered by Ahmed Habiba, Coca-Colas Vince Voron will be at Masterbatch 2013 to discuss the use of design to build brands regional marketing manager at Johnson & Johnson. The comprehensive conference programme also includes talks on the latest pigment, additive and machinery developments. Market trends and strategic issues facing the masterbatch market will be addressed by a number of presentations including papers from: Andrew Reynolds, research director at AMI Consulting; Heinrich Lingnau, business unit director masterbatch solutions EMEA at A. Schulman; and Jacob Scherf, CEO of Polymer Asia. The conference programme and booking details are at http://bit.ly/Masterbatch2013. Book by 19 April to save E110.

www.teknorapex.com
6

www.amiconferences.com
www.compoundingworld.com

compounding world | March 2013

news

RheTech and Braskem to develop bio-based reinforced polyethylene


US-based RheTech has partnered with Braskem to develop a new line of natural fibre reinforced compounds based on the Brazilian polymer producers bio-based HDPE. The new compounds will augment RheTechs existing range of RheVision PP compounds produced using natural fillers and reinforcements, including wood fibre, flax and coconut shell. A spokesperson for RheTech says that the company plans to offer bio-PE versions of all of its RheVision compounds in the future. It already has a wood fibre reinforced grade undergoing market trials and is in the process of developing a flax fibre compound. The new bio-based RheTech Braskems bio-based HDPE is will be compounded with natural fibres by RheTech products have been developed primarily for injection moulding. The company expects them to appeal to its traditional automotive industry customers as well as industrial and consumer firms looking for a more sustainable material option. RheTech says its supply agreement with Braskem provides for an adequate supply of bio-PE to meet the anticipated demand from customers. Braskem is currently the only source of bio-PE resins.

www.rhetech.com

United Dairy uses aragonite renewable filler in bottles


United Dairy of the US is using milk bottles containing Oshenite, a renewable mineral filler harvested from the sea by US Aragonite. Its new EcoJug one-gallon (3.8-litre) packaging contains Oshenite to United Dairys EcoJug contains 25% Oshenite renewable filler, which is harvested from the sea reduce the HDPE used in the bottle by up to 25%. Oshenite is an oolitic aragonite that is harvested by US Aragonite from the seabed in the Bahama Banks. The high-purity calcium carbonate is formed from microscopic marine materials such as algae and plankton more than 20 million tons are added each year to the more than 1 billion tons that are currently in reserve. This is a localised phenomena caused by the confluence of warm and cold ocean currents in the area around the Bahamas. The material is being compounded by Bayshore Industrial, which is part of A. Schulman and operates a plant in La Porte, Texas. For more details on Oshenite, see the mineral fillers article in the September 2012 edition of Compounding World http://bit.ly/fillers. www.oshenite.com
8 compounding world | March 2013

Germany grows sales of machinery


Germanys exports of plastics and rubber machinery grew by 2.3% in 2012 to reach a new record of E536 million, according to the VDMA association. There were big increases in sales to Canada, up by 32%, and the USA, which added 20%. Sales to the EU countries also grew by 10%, while exports to South America were up 10%. However, sales to East Asia were down by 17% in 2012. Deliveries to China fell by 16%, while German machinery exports to Korea and Taiwan tumbled by more than a third. India was down by the same amount.

www.vdma.org
www.compoundingworld.com

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news

Mondi adds paper pulp to plastics


Mondi, the international paper group, has launched a cellulose reinforced polymer for injection moulding applications. Called Fibromer, the new compound contains loadings of 20-30% kraft pulp fibre in PE, PP or PP copolymers. The resulting material is said to process easily and to offer high strength, stiffness and low-temperature impact strength. It also provides reduced density and low levels of odour. The new compounds also offer better heat distortion temperatures compared to talc-filled alternatives. Requirements for composite materials are changing; converters and manufacturers want polymers that are not only strong and stable but also customisable to a certain degree and preferably from renewable or sustainable resources, says Mondi Kraft Paper chief operating officer Clemens Stockreiter.

PolyOne launches colour forecasts and iPad app


PolyOne has revealed its first Color Inspiration collection of colour palettes that it forecasts will be influential next year. They are aimed at helping product designers and developers select colours and reduce the time to market. Developed with input from design, fashion and global megatrend experts, the six colour palettes are: The Blue Movement, which celebrates the precious role of water in our lives; Solid Foundation, highlighting the desire for stability in a world of constant change; Global Citizen, which borrows from influences found in dynamic, emerging parts of the world; Lay of the Land, conveying a hands-on feel from the use of nature in design; Heightened Sense, which brings to life the wonder of design that blends technology, fantasy and reality; and Well People, inspiring a connection to health and vitality. PolyOne has also launched its new OnColor Portfolio app for the iPad. The free app PolyOnes OnColor Portfolio app for the iPad includes a colour selector and its 2014 forecasts PolyOnes first Color Inspiration collection includes six colour palettes enables iPad users to evaluate colour ideas, request colour samples, submit custom colour requests, and access information about PolyOnes colour and additive technologies. It also include the new 2014 colour forecasts. The OnColor Portfolio app is just the beginning of our ability to leverage mobile technology to generate tools that help streamline our customers product development process, said Fernando Sanchez, global marketing director for PolyOne Color and Additives. The app can be downloaded from http://bit.ly/OnColor. Details of the Color Inspiration collection can be found at http://bit.ly/CI2014.

www.polyone.com

www.mondigroup.com/fibromer

Rockwood takes full control of Sachtleben


Rockwood has acquired Kemiras 39% stake in their Sachtleben titanium dioxide joint venture for E97.5 million. It now has full control of Sachtleben, allowing it to explore divestment options on its own. It was reported that both parties were aiming to sell off Sachtleben last year.
10

Speaking about the acquisition, Rockwoods chairman and CEO Seifi Ghasemi said: Given our prior statements that the titanium dioxide business is non-core, it is our key objective this year to explore and execute on the best strategic option for Rockwood. Attaining 100%

ownership of the joint venture provides us with the flexibility to achieve this goal in the time frame and manner most optimal for maximizing shareholder value. Formed by Rockwood and Kemira in September 2008, Sachtleben produces anatase and rutile grades of titanium

dioxide for a range of markets including the plastics industry. It acquired certain business assets of Crenox from the insolvency administrator in July 2012, taking its total capacity to approximately 340,000 tonnes/year from its three production plants.

www.sachtleben.de
www.compoundingworld.com

compounding world | March 2013

POLYMER SOURCING 2013


New sources, optimising customer relations and maintaining protability

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European polymer distribution | markets feature

AMI has just completed its latest market report on polymer distribution in Europe. The studys author, Karla Vittova reveals some of its key ndings

Moving materials: trends in polymer distribution


Polymer distribution is playing an increasingly strategic role within the polymer industry value chain, providing opportunities for polymer producers to cut costs and improve efciencies and deliver better service and support to the plastics processor. However, in an industry notorious for its slim margins and in a low growth economy, the successful distributor needs to be rigorous in understanding the cost-to-serve and the value gained from its customers in order to ensure future survival and growth. The new fth edition of AMIs Polymer Distribution in the distribution industry still has some way to go to recover volumes lost during the 2008-2009 recession, with 2011 sales still more than 500,000 tonnes lower than in 2007. The overall growth for polymer demand between 2009-2011 was 2.5% per year and the volumes sold through ofcial distribution channels grew in the same period slightly ahead of this at 2.8%. Polymer distributors account for approximately 11% of polymer consumed in Europe (the data in the report includes PE, PP, PS, ABS/SAN, PA 6 & 66, PBT, PC, PMMA and POM). In value terms, polymer distribution accounted for revenues of over 6 billion, with the largest contributors being PP and PA. Although affected by the nancial crisis, distributors have also been able to benet from the downturn as polymer majors have rationalised their customer base and bottom-sliced smaller/less protable accounts, driven by a desire to reduce their credit exposure as
March 2013 | COMPOUNDING WORLD 13

Europe report analyses these changes in detail, examines their impact on polymer producers and distributors, and provides the information required to make strategic decisions in this competitive and fast-changing supply chain. The full 250-page report also includes a spreadsheet with details of the sales volumes of around 250 distribution companies. Over the following four pages, we summarise some of the reports headline ndings. The polymer distribution industry continues to recover from the effects of the nancial crisis in 2008, although there was a marked slowdown in the pace of sales growth for 2011 after a strong pick up in 2010. With continued weak economic growth in Europe during 2012, distribution volumes grew at half the rate compared with the previous two years. Furthermore,
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markets feature | European polymer distribution

well as cutting sales and marketing costs. The emergence of new sources of materials outside Europe, for example from the Middle East and Asia, is also presenting an opportunity for distributors, although most of these volumes tend to enter the European market either on a spot or traded basis, or as ofcial volumes for the polymer majors. However, uctuating prices and stagnant economic growth are still presenting other challenges to the polymer distribution market. While processors may prefer the reliability, guarantee of quality, technical support and personal nature of distribution, when prices go up to the extent that processors are in danger of getting into nancial difculty, they start looking for alternative, cheaper options through traders. This is mainly the case for commodities in non-technical applications where materials are non-specied. When analysed by country/region, polymer distribution sales are a function of the structure of the local processing industry, plus the structure of local polymer production and supply, and historical trading links. For example, polymer distribution networks tend to be more established in Western Europe, compared with Central and Eastern Europe where traders are more prevalent and where customer loyalty is less strong. Polymer distributors also tend to account for a higher proportion of the market in the smaller coun-

tries of Western Europe which have relatively little local production and are adjacent to major supply countries. For example, the Portuguese market is often supplied from a distributors Spanish ofce, while Ireland is frequently supplied from the UK, and Switzerland from Germany. Germany and Benelux both have lower than average sales via distributors, which reects the size and strength of the local polymer companies and, probably more importantly, the relative size of the local processing industry. The Benelux region in particular is home to many large-scale processing companies in pipe, bre and lm, which will typically be direct buyers. Although engineering polymers bring higher margin to distributors due to the technical aspect of the processing and services needed, it is commodities which drive the sales volumes, accounting for threequarters of sales by distributors. However, engineering plastics will undoubtedly drive the future value of polymer distribution and will record much stronger growth than standard polymers.

A changing industry structure


Suppliers looking to optimise their distribution networks are more likely to appoint international/ pan-European distributors and reduce the number of local players per country. Together with consolidation among distribution companies, this will result in a declining number of distribution companies in Europe in the long term. Similarly, distributors are making thorough assessments of their customer base, targeting specic services to their customers needs and even terminating cooperation with customers which generate unsatisfactory margins. The effect of ongoing consolidation among the industry plus the increasing importance of pan-European groups has resulted in a relatively high level of concentration in European distribution. This is reected in the fact that the 10 largest distribution groups account for more than half of all polymer volumes distributed. Major recent M&A highlights include: G The sale of Ashlands global distribution business to Nexeo Solutions (April 2011) G The acquisition of Azeliss polymer distribution business by Gazechim Plastiques from the 3i private equity group (June 2012) G Omyas acquisitions of Spanish distributor Unasa

POLYMER DISTRIBUTION SALES IN EUROPE BY COUNTRY (IN TONNES) 2011

(2011) and Central European distributor Plastochem with ofces in the Czech Republic, Hungary and

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COMPOUNDING WORLD | March 2013

www.compoundingworld.com

markets feature | European polymer distribution

POLYMER DISTRIBUTION SALES IN EUROPE BY POLYMER 2011

set out to grow via a buy and build strategy. It concluded its rst acquisition in April 2012, purchasing Atlantic Polymers from Neochimiki. Europes leading polymer distributors include A. Schulman, Albis, Biesterfeld, Chemieuro, Febo, Nexeo Solutions, Resinex and Ultrapolymers, although there are a number of other players which have the potential to emerge as new pan-European groups such as KD Feddersen, Ter Hell, Hromatka, Gazechim Plastiques and Omya.

Source: AMI 2012

The changing role of the distributor


There are different levels of cooperation existing in the Poland (over 2009-2011) G The expansion of Spains Guzman Group into Italy by an acquisition of Sabics distributor Tecno in summer 2012. A number of companies have left the distribution business altogether either due to bankruptcy, divestment, giving up distribution as a non-core business or due to a loss of the only distribution mandate which was not replaced by any other contract. Bankrupt companies include Dipe (Spain), E&B Polymers (Benelux) and Kerins & Morrissey (Ireland). In spring 2012, Neochimiki in Greece divested a number of its subsidiaries, namely Atlantic Polymers with ofces in Germany and Poland and Interallis Chemicals with ofces in Romania, Bulgaria, Serbia and Croatia. European market today. Ranging from a strategic partnership, when a principal and its distributor work very closely together with precisely dened territories and customers, through to much looser types of cooperation. These can even involve direct competition between a distributor and the principals own salesforce in the same market. The relationship between suppliers and their distributors has changed signicantly in recent years in terms of both the role the distributor plays for the supplier and the nature of the cooperation agreement between them. A distributor increasingly is no longer regarded as just a local merchant which takes care of smaller customers that are not important or valuable enough for the supplier to serve directly. Instead, there is a growing trend to develop strategic distribution networks, a process which has been accelerating in the face of slower economic growth as suppliers look to achieve faster cash generation, lower inventories, shorter supply chains and reduced payment terms. The size of a customer, although still important, is no longer a sole determinant of whether it will be served directly or via a distributor. Accelerated by the economic downturn, there has been a trend towards specialisation, with suppliers focussing on strategic core business. Therefore, focusing simply on the

Polymer distributors have increased opportunities to represent overseas suppliers, particularly from the Middle East and Asia

On the other hand, some new ofces have been established by existing European players. KD Feddersen set up new ofces in the UK in 2009 and in Austria in summer 2012. During 2011, Ultrapolymers established ofces in Poland and the Baltic States, while Plastoplan and Sirmax also opened ofces in Poland, and Gazechim set up in Spain. During 2012, a new Hungarian ofce was set up by Central European distributor Radka and Polymix opened a new ofce in Belgium. A new player entered the market in 2009 in the shape of Allandis. It established an Ireland ofce and

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COMPOUNDING WORLD | March 2013

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markets feature | European polymer distribution

their customer bases to focus on the larger, strategically important customers and passing smaller, nancially unsound or non-strategic customers onto distributors. Distribution is going to grow most strongly in value-added and technical applications for polyolens, plus technical compounds, particularly in injection moulding (automotive, white goods, electrical sectors). The strongest growth will be seen in Poland and other markets of Central and Eastern Europe, where distribution networks are still growing and where there is the opportunity to export to markets further east, such as Russia, Ukraine and other CIS states.

More information
For more information about AMIs report on Polymer Distribution in Europe and to gain access to details on Moving up a gear: polymer distribution is expected to grow at double the rate of polymer demand in the next ve years polymer purchasing thresholds is much less relevant in an assessment of the polymer distribution market. The factors affecting a principals decision whether or not certain customers will be passed on to a distributor include: their strategic t with suppliers business, growth potential, cost to serve (for example, credit and payment history) and where the customer will be better cared for. There is also a tendency for distributors to be more selective about their customers and it is no longer a priority for distributors to serve all customers with equal care. Distributors not only focus on customers in high growth segments (for example from the cosmetics, medical or technical sectors) but also offer services for certain customers and reduce the service where it is not needed or required for others. sales volumes of some 250 distribution companies, please contact Karla Vittova, kv@amiplastics.com, +44 117 924 9442. The 9th edition of AMIs Polymer Sourcing conference will take place on 14-16 May 2013 in Vienna, Austria. This forum is specically created for companies involved at every stage of the polymer supply chain. The programme features market analysis presentations from Andrew Reynolds and Karla Vittova of AMI Consulting, plus papers from leading distributors, including Biesterfeld, Distrupol, Febo, Nexeo, Plastribution, Poliversal, Radka and Ter Hell. There
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POLYMER SO 2013
New sources, optim ising customer

URCING
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What will the future bring?


Despite challenges the industry faces, polymer distribution is expected to grow at double the rate of polymer demand in the next ve years. This will be driven by suppliers rationalising their sales teams and

will also be talks from polymer producers and purchasers, including Styrolution, Ineos and Innovia Films. For more information visit http://bit.ly/PSconf or contact Maud Lassara, ml@amiplastics.com.

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COMPOUNDING & PROCESSING 2013


International industry conference on the protable use of bioplastics

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Natural bres | additives feature

Bio-based bres are putting down roots in applications where eco-awareness counts. Pat Toensmeier reports

Exploring the natural options for reinforcing plastics


Compounders are harvesting a range of production and marketing benets from natural bres. The materials, which are typically derived from wood, regenerated cellulose, kenaf, hemp, sisal, ax or jute, can offer advantages over inorganic bres such as glass in terms of sustainability, recyclability, low density and low cost. Natural bres cant match inorganic bres in overall mechanical properties, but they can provide higher specic strength and stiffness than glass and deliver some performance benets. In addition, when they are paired with a bioplastic like polylactic acid (PLA), natural bres contribute to a fully biodegradable polymer. The use of natural bres in products is largely driven by environmental concerns and price. Consumer product manufacturers especially tap the eco-friendly image of such materials as a selling point and a way of differentiating themselves and their products from competitors that do not use natural bres. Some rms go so far as to make bres visible in products so that consumers can see them. Major applications include outdoor decking, panelling, wall separators, furniture, kitchenware and household goods, large and small appliances, and automotive components. The automotive sector is a major target both for the high volume of parts involved and for the design and
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engineering credibility that such applications can bring. Natural bres provide a number of benets for car makers, notably vibration damping and sound absorption. However, their ability to reduce part weight thanks to their low density compared with glass bre about 45% lower on average - is a major factor in vehicle use, especially with fuel efciency targets rising in Europe and North America. The overall weight reduction in nished parts is generally 6-10%, experts say, though this depends on the design. Most automotive OEMs have programmes to make natural bres part of component design. Among them are: General Motors, which has applications in door substrates in the Cadillac ATF and the rear window tray in the Buick Lacrosse; Mercedes Benz with rear quarter panels in the M-Class SUV; Fiat, which is using natural bres in the rear load oor of the Fiat 500 electric vehicle; and Ford, which is using such materials in door bolsters and armrests in the 2013 Escape. Ford has been a pioneering player in the application of natural bre reinforced plastics in car components. For example, it the rst automotive OEM to use wheat/ straw bre reinforcements in a vehicle part, with the third-row door storage bin in the 2010 Flex model. The PP-based compound was developed and tested by the

Aimplas is developing natural bre composites for more demanding applications

March 2013 | COMPOUNDING WORLD

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additives feature | Natural bres

The Ford Flex was the rst vehicle to use plastic parts reinforced with wheat/straw

Ontario BioCar Initiative, a consortium of Canadian universities and industry, and then produced by A. Schulman in the US. Ford says that the part has high dimensional stability and provides a 10% weight savings over a glass breor talc-reinforced PP compound.

Overcoming limitations
Natural bres typically come with a number of trade-offs, which can include moisture absorption, poor dispersion, limited polymer compatibility and low process temperatures (usually 180-200C) that restrict their use to polyolens and PVC. However, work is underway to overcome these limitations and improve performance. Major developments include techniques to disperse natural bres in compounds more efciently and to enhance their polymer compatibility. The latter is difcult since the bres are polar and most polymers that they are used with are non-polar, with the exception of bioplastics and PVC. For dispersion and resin compatibility, progress is being made in the surface modication of bres by chemical treatments, which can be a relatively costly process, or by the addition of additives such as coupling agents based on maleic anhydride, silanes and titanates among other chemistries. Since most natural-bre compounding is in Weyerhaeuser is aiming its Thrive cellulose and PP composites at automotive applications such as armrests and battery holders twin-screw extruders, work is also being undertaken to develop new screw and barrel congurations to improve the control of process temperatures and shear levels so that they do not degrade bres. Some researchers and compounders also report that they are achieving good results by pre-drying natural bres before use, which reduces moisture content from around 10% on average to less than 1%. Another approach is to compound bres without pre-drying and reduce moisture content with high-vacuum pumps and venting during processing. Another focus of research is combining cellulose nanomaterials with polymers to increase resin strength. Alan Rudie, a supervisory research chemist at the Forest Products Laboratory of the US Forest Service in Madison, Wisconsin, says that 300% gains in strength have been achieved in some resins. As a result of such developments, natural bres might nd their way into new markets they previously could not enter, says Vanessa Gutierrez Aragones, materials engineer at Aimplas, Spains plastics technology institute. These markets include aerospace, electrical/electronic, sporting goods and medical test devices, as well as broader applications in automotive parts. Aimplas works with different types of natural bres in synthetic thermoplastics and in biopolymers. The institute has recently been analysing chemically modied bres, notably regenerated cellulose, which has high purity, less odour generation and reduced discoloration during processing, combined with high batch-to-batch consistency. Such properties are hard to achieve with conventional natural bres, says Aragones. She sees regenerated cellulose bres as prime candidates for demanding applications in automotive, aerospace (primarily panels) and in high-value building products. The institute has also had success in developing a re-resistant wood-polymer composite (WPC) compound for panelling and decking, in which additives are metered to the thermoplastic matrix during processing. Aimplas and other research organizations coordinate their work with industry. Their developments in
22 COMPOUNDING WORLD | March 2013 www.compoundingworld.com

additives feature | Natural fibres

The Pacific Northwest National Laboratory is working on novel methods to reduce the moisture content of natural fibres

formulations, compounding technology and homogeneous properties are crucial to the reliable and efficient use of natural fibres in different markets.

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Compounders and suppliers also come up with developments in natural fibres and formulations. Although many markets make use of composites with natural fibre reinforcements, the prime target for compounders and suppliers remains automotive. Among the suppliers targeting this market is Weyerhaeuser. The US forest-products giant recently commercialized a PP-based composite using cellulose fibres called Thrive, which is available as either a masterbatch, with 70% cellulose loading, or in pellet form, where loadings are 10-40%. Thrive composites are used in office furniture and household goods, but Weyerhaeusers market development manager Jorge Cortes says that automotive is key to the products success. If the company gets its material specified by an OEM or Tier One supplier, it will generate momentum for many applications, automotive and otherwise. Weyerhaeuser will soon announce an undisclosed interior part for a Ford vehicle, Cortes adds, and it expects to supply Thrive grades this year that can be moulded with Class-A finishes. The composite currently fibre-reinforced parts are not heated as much as glass-reinforced parts and can thus be demoulded faster. And because they hold less heat, thick parts are demoulded more rapidly than with glass-fibre reinforcements. The low density of the composite compared with glass will be an important way for automakers to meet US government CAFE (Corporate Average Fuel Economy) standards, which are set to rise from their current 27.5 mpg to 37.8 mpg in 2016, and to 54.5 mpg by 2025. As the paradigm shifts in car design owing to the need for more weight savings, natural fibres will be here to stay, Cortes says. Natural fibres are also on average one-quarter to one-third the cost of glass fibres, another important point for automakers. Ford and other OEMs will never agree to substitute natural fibres for glass if they make parts more expensive, Cortes remarks. Finally, there are the green marketing benefits: natural fibres are recyclable, sustainable and less energy-intensive to produce than glass fibres. In most of our plants, we put energy back into the grid, says Cortes. With a 3.6 billion lb (1.6 million tonnes) annual supply of cellulose, Weyerhaeuser has no shortage of fibres. The company plans to expand the Thrive line later this year with a high-density polyethylene (HDPE) grade and possibly a biopolymer. The US government is also investigating the impact of natural fibres on automotive fuel efficiency, energy use and part cost. The Pacific Northwest National Laboratory in Richland, Washington, works with kenaf compounds for the Department of Energys vehicle technology office, says Leonard Fifield, senior research scientist. One area of work involves reducing the moisture content of fibres, which is an ongoing concern. The lab has developed a proprietary process that removes most of the moisture from the hydroxyl groups in fibres and, with the use of additives, improves fibre dispersion

Kenaf fibres applications are being developed by a number of organisations, including the Pacific Northwest National Laboratory

produces a Class-B finish in parts. Cortes says that interiors are a focus of the companys automotive work. Targets include trunk-area parts and undisclosed applications under-the-hood. Weyerhaeuser has figured out how to engineer the fibres, feed them for compounding, and prevent fogging and odour issues in finished parts. As with other suppliers, Cortes cites process and marketing benefits for natural fibres. Thrive composites reduce injection moulding cycles by 30-42%, he says, depending on part design. This is because natural

24

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additives feature | Natural bres

lead to the use of natural bres in semi-structural and exterior parts. A company that has installed signicant natural-bre capacity is Polymera. Its plant was opened in central Ohio, USA, in 2011 and it has a nameplate capacity of 60 million lb/year (27,000 tonnes/year). It supplies WPC in its Merablend PVC, HDPE and PP grades for injection moulding and extrusion applications. PVC compounds come in three standard grades based on particle size: 40 mesh, 60 mesh and 80 mesh. Standard bre loadings are 40, 45 and 50%, though custom orders have as little as 15% loadings. Fibre loadings for HDPE are 30-75%, GeoPellet is developing applications for pulp cellulose such as this PVC foam siding with 30% bre content throughout a resin matrix. The lab is also looking at hybrid reinforcements, in which natural bres are compounded with glass or carbon bres to improve mechanical properties. Such a compound could provide some savings in weight and cost, while expanding automotive applications for natural bres. Natural bre reinforced automotive parts are now typically restricted to interiors where there is no exposure to moisture, such as headliners, rear window trays, door panels and consoles. Field believes that eliminating moisture and using bre hybrids will and 30-60% for PP. The companys vice president and general manager, Herb Hutchison says that the bres line up randomly in composites, which improves resin strength. An example he cites is an unreinforced PVC grade that typically has a 450,000-psi modulus of elasticity. With 40% bre loading, this increases to 830,000 psi. Polymera also extrudes Merawood custom WPC proles for indoor and outdoor use, and supplies turn-key extrusion lines through its Meraplast product unit. The equipment is available without license fees or

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Natural bres | additives feature

royalties, if a compounder or producer commits to using Merablend materials. The companys main markets are outdoor furniture, railings and siding, spas, and extruded proles for consumer and industrial applications. Hutchison says demand for WPC is growing, with keen interest from custom product makers that want to use the compounds in moulded and extruded parts.

weight, Schut remarks. In tests, a 100% rigid PVC masterbatch had exural strength of 1,212 psi and exural modulus of 374,893 psi. A 50:50 blend of PVC and pulp cellulose increased exural strength to 9,998 psi and exural modulus to 992,000 psi. A 60:40 PVC/ oak wood blend (40 mesh), in contrast, yielded lower results in both areas: exural strength of 6,805 psi and exural modulus of 593,584 psi. The company is pelletizing blends of PVC, PLA and polystyrene that are reinforced with the reclaimed stock bres. GeoPellet has also experimented with a bio-based material called polytrimethylene terephthalate, or PTT, which comes in the form of a textile bre from DuPont called Sorona. The polyester-like biopolymer is composed of 37% renewable plant-based ingredients (basically glucose fermented from corn starch), DuPont reports. Schut believed its bio-based composition would work well with the pulp cellulose bres he was using, and it did. Both materials are polar and thus compatible, which improves bre wet-out and increases strength. Since PTT is available in bre form, GeoPellet took the bre from DuPont, chopped it and blended it

Pulp faction
GeoPellet of Rock Hall, Maryland, USA, has developed process technology to exploit an innovative source of natural bres. The company uses pulp cellulose bres from recycled newspaper and magazine stock in its formulations. The benets, says company president Edward Schut, are the materials low density, high tensile strength, uniformity and low cost. The reinforcements also lack most of the organic volatiles found in natural bres, as they were originally removed during the printed-stock manufacturing process. GeoPellet processes reclaimed stock into bres that are 3,000 microns long and 1-2 microns thick. The bres provide incredible tensile strength for their

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additives feature | Natural fibres

This pulp mill operated by the US Forest Service generates natural fibres for polymer testing.

with the fibres. GeoPellet says that PVC reinforced with pulp cellulose could be used in internal reinforcement bars for window and doorframes. The material, which would replace aluminium and steel, is non-corroding, lightweight, easily machined and welded, and in the case of windows would increase R-value.

Nano news
In the future, compounders may use nanomaterials to improve the performance of natural fibres in formulations. The US Forest Service is working with different techniques to create cellulose nanocrystals (CNC) and cellulose nanofibrils (CNF) that are light, have relatively uniform dimensions, and will significantly increase polymer strength. CNCs that have been produced in the lab are calculated to be stronger than aramid fibre, yet based on molecular modelling would have a density of only 1.5 grams/cm3. This is a theoretical value, since no one has yet been able to assemble a sample and physically test it. The technology is complex and needs to be scaled up before it can be commercially viable. Nevertheless, it demonstrates the potential for desirable properties in a fibre-polymer compound. One technique for making CNC involves hydrolyzing wood pulp with sulphuric acid, leaving the crystalline portion of the cellulose polymers untouched. The native state is a fibril that is about 6 nanometres (nm) in diameter and with a length measured in microns, Cellulose nanocrystals produced by the US Forest Service are uniform, lightweight and strong explains Rudie of the US Forest Services Forest Products Laboratory. The salt remaining from the sulphuric acid treatment is removed from the resulting crystalline structure with a process that includes membrane filtration. This creates a viscous suspension that is 5-10% water. To eliminate water, the lab has fine-tuned a freeze-dry process that leaves an aero-solid a low-density, sponge-like cellulose nanomaterial, with crystals averaging 10 nm in diameter and 50-200 nm long. This nanomaterial would be interlaced by resin, yielding a composite with theoretical strength in the range of an aramid fibre-reinforced compound. The potential benefits of this approach include lower loadings of reinforcement and high mechanical properties. Rudie believes that the labs work with nanomaterials could yield commercial products in the near future. Among these might be a disposable medical sensing device for blood work and other uses. The device could degrade in landfills or can be incinerated with no toxic by-products. Longer-term, nanomaterials could be used to make flexible substrates for printed circuitry. The performance and potential of nanomaterials assures them of a major role in the ongoing development of natural-fibre compounds. Their reach could eventually extend to mainstream applications and help advance the benefits and performance of bio-based materials. Click on the links for more information:

www.ford.com http://bit.ly/BioCar www.aschulman.com www.fpl.fs.fed.us www.aimplas.es www.weyerhaeuser.com www.pnnl.gov www.polymera.com


28 compounding world | March 2013 www.compoundingworld.com

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PET additives | additives feature

Peter Mapleston examines the latest additives designed to boost the performance of PET in wide range of applications including packaging, textiles and technical parts

Promoting PET performance


PET is widely used in packaging applications because of its ability to produce lightweight containers that are clear and strong. But it is not a perfect polymer, and the inclusion of additives is often necessary to enable resin producers and processors to create premium products. As material suppliers and their customers seek out more challenging applications, the inclusion of speciality additives is virtually essential to enhance the polymers physical properties and give it an edge over the competition. The global PET additives market has never been more focussed on cost-efciency, exibility, ease of use and sustainability, says Bjoern Klaas, director of product development and operations at additives supplier ColorMatrix. Reducing container weight continues to be a major trend in the packaging industry, where PET already controls a signicant segment of the market nearly half of the worlds soft drinks are packaged in PET bottles today. But the potential for growth in the market still remains enormous. Klaas says improvements in barrier technologies are allowing brand owners to move further from glass to PET. lighter weight, highly exible material and maintaining packaging clarity, says Klaas. ColorMatrixs Amosorb SolO2 is a combination of an active oxygen scavenger and a passive barrier to oxygen and carbon dioxide, making it very suitable for carbonated and non-carbonated beverages. It can be used with any grade of PET for mono- and multi-layer applications. Amosorb technology, which is based on polyester copolymer chemistry, was originally developed by Amoco Chemicals, but ColorMatrix now owns the technology. Oxygen scavenger technology has also been developed by PET bottle producer Constar. Its original MonOxbar technology was complemented several years ago by DiamondClear, which it describes as the industrys most advanced oxygen scavenging technology available for PET containers. DiamondClear offers food and beverage products many advantages, including barrier protection for up to 24 months, and the clarity and gloss of glass, Constar says. Constar licenses or sells its oxygen scavenger technologies to converters and brand owners. Its MonOxbar Single Sack Oxygen Scavenger Resin Blend, for direct addition into the injection moulding machine or extruder, is available from compounding company Americhem. Engineered clays serve as the basis for another line of development in oxygen scavengers. Nanotechnology
March 2013 | COMPOUNDING WORLD 31

Building barriers
Effective barrier technologies help brand owners and converters to overcome market challenges such as extending shelf life, reducing total cost in use by using a
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additives feature | PET additives

to disperse the active ingredient directly into the polymer during production. It says its technology provides greater versatility and efciency than competitive oxygen scavenging systems, noting that the effective dispersion maximizes the access to the active system, which ensures minimum reaction time and a very uniform protection of the packaged goods. The material is immediately active after being added to the packaging system, notes the company. These characteristics present signicant advantages over systems where additional activation equipment is required. Typical addition levels are up to 0.25% for catalyst based engineered clays. O2Block can be supplied as a micronized powder or masterbatch. Scavenging NanoBioMatters comparison of the oxygen depletion of various oxygen scavengers (according to ASTM F2714-08, immersion in water at 20C) capacity is directly linked to the amount of active ingredient available in the system, and this can be adjusted either by changing the addition level of any one masterbatch or by altering the active clay content within the additive. It is suitable for use with various packaging materials apart from PET, including PE, PP and PLA.

Radiation absorbers
NanoBioMatters chief technology ofcer Pedro Vazquez points out an extra advantage for O2Block: it is a very effective absorber of ultraviolet (UV) radiation. Tests indicate that at an addition level of 0.25%, transmission of electromagnetic radiation up to just below 400 nm, which is where the visible spectrum begins, is zero. After this point, transmission levels increase rapidly (see graph). In food and beverages, exposure to UV light can promote oxidation and changes to the taste, odour and rheology of products, affecting shelf life, product quality and aesthetics. Adeka cites a recent case study in Japan, in which its NanoBioMatters comparison of the light blocking properties of various PET additives specialist NanoBioMatters recently introduced O2Block for various applications. For use in PET, a modied phyllosilicate clay is functionalized with a catalyst. For other applications, iron can be used instead of the catalyst, but this affects transparency. NanoBioMatters says that the use of active engineered clays to produce active materials has advantages such as raw material availability and low cost, plus relatively simple processability and dispersion. Also, the incorporation of active engineered clays into polymers could additionally improve the passive barrier due to the alteration of the diffusion path imposed by the clay platelets in the polymer matrix, it notes. The company claims that the key to the effectiveness of the system is its use of a puried and layered clay-based carrier, surface modied to make it possible
32 COMPOUNDING WORLD | March 2013

ADK STAB LA-31 additives was used in green tea bottle packaging. The addition of the UV absorber in the PET bottle screened the contents from the UV light that deteriorates the taste and appearance of green tea contributing to extended shelf life, the company notes. ColorMatrixs Ultimate UV light barrier technology offers protection up to 600 nm without affecting PET container transparency. Bjoern Klaas says this is currently the only UV barrier additive for PET recognised by the Association of Postconsumer Plastics Recyclers (APR) and the European PET Bottle Platform (EPBP) for having no negative impact on the recycling stream. ColorMatrix also has its eye on the other end of the visible spectrum, noting that for PET preforms, an effective reheat agent can improve processing economics and part quality. Its Joule RHB is a liquid dispersion reheat agent that improves the absorption of infra-red radiation of the preform when it is reheated prior to blowing moulding into the nal container. This reheat
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additives feature | PET additives

ColorMatrixs Joule RHB improves the infra-red energy absorption of preforms during the blowing process

capability is retained over repeated processing, which delivers further energy gains in the recycling stream, according to the company. It adds that Joule RHB is able to enhance polymer clarity because it is based on inorganic material, which means it can naturally withstand higher temperatures and is less likely to yellow. Inherent, natural blue toning properties further reduce the appearance of yellowing, even after long-term recycling. UV and IR absorbers are also available from ColorChem under the Uvaplast and Amaplast banners. ColorChem says its Uvaplast absorbers, which are understood to contain oxazolone and/or azine functional groups, are three to ve times stronger than benzotriazole, depending on the grade of Uvaplast and the wavelength. It has three grades, which are also distinguished by different melting temperatures, which range from 165 to over 300C. ColorChem says they can provide UV blockage up to 400 nm without imparting colour to the substrate. Amaplast IR 1000 and IR 1050 are high-molecularweight IR-absorbing dyes that the company says are suitable for applications requiring strong IR absorption,

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PET additives | additives feature

low haze, and high clarity that include laser marking and masterbatch identification, as well as preform reheating.

PET by intensive compounding but may coalesce downstream in the compounder, Scheirs says. Functionalized elastomers such as Arkemas Lotader AX8900 [a random terpolymer of ethylene, methyl acrylate and glycidyl methacrylate, GMA] are excellent toughening agents for PET as they improve interfacial adhesion and importantly, reduce interfacial tension, thus allowing the formation of smaller rubber particles. Functionalized impact modifiers are available from various other polymer producers, including DuPont (Elvaloy ethylene copolymers), Ningbo Nengzhiguang New Materials Technology (Imact ethylene copolymers), ExxonMobil (Exact plastomers), Asahi Kasei Tuftec (SEBS), and Kraton (SEBS). MBS (methyl methacrylatebutadiene-styrene) core-shell graft copolymers such as Dows Paraloid are among the most efficient non-reactive impact modiers for PET, particularly recyclate, according to Scheirs. Speed of crystallization, as well as the uniformity of the crystal size, can be improved using nucleating agents. Crystallinity is often desirable in moulded parts for technical applications, since it increases heat resistance and mechanical stability (it does of course

Making PET more mouldable


Unmodied PET is generally not useful as an injection moulding resin in technical applications because of its slow crystallization rate and the tendency to embrittle upon crystallization. PET also suffers from a low glass transition temperature and relatively low impact strength. Various additives can be used to turn PET into an engineering-grade thermoplastic. An effective way to enhance the impact strength and to induce a brittle/ductile transition of the fracture mode is by the dispersion of a rubber phase within the PET matrix, says John Scheirs, principal consultant at Australian testing outfit ExcelPlas Testing Services. Reactive compatibilization has been found to be a good way of obtaining a nely sized dispersed phase in the PET matrix. Functionalized reactive impact modiers are preferred over non-reactive elastomers because they form a stable dispersed phase by grafting to the PET matrix. Non-reactive elastomers can be dispersed into

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additives feature | PET additives

Adekas ADK STAB NA-05 improves the gloss of injection moulded articles. Glasslled PET is shown without nucleating agent (left) and containing ADK STAB NA-05 (right)

also make PET opaque consider heat-set PET bottles, with their clear amorphous bodies and white crystalline necks). PET can be nucleated using heterogeneous particulates such as talc or by chemical modication of the polymer itself. PET grades for injection moulding are usually chemically nucleated using sodium salts such as sodium stearate. Adekas recently launched nucleating agent for PET, ADK STAB NA-05, was granted full EU food contact approval in polyesters at the end of last year and is currently under customer testing in several different applications including bottle preforms, lms and injection moulding applications. Adeka describes the product as an organic salt, without going into more detail. In injection moulding for both glass lled and unlled articles, the use of ADK STAB NA-05 in very low concentrations has shown a remarkable increase in gloss as well as a reduction in cycle time, according to the supplier. The output of preforms has been shown to be more than double in the case of hot-ll containers due to the increased rate of neck crystallization speed, while in lm applications, barrier properties (CO2 and water vapour) are improved. In polyester alloys for automotive, mechanical properties could signicantly be boosted, Adeka says. The exural modulus and gloss properties of PET both rise sharply with low additions of Adekas ADK STAB NA-05 nucleating agent

Nanoclay particles by virtue of their particulate nature are emerging as effective heterogeneous nucleating agents for polyesters. The nanoclay particles in PET/ montmorillonite nanocomposites impart to PET a higher crystallization rate without the need for expensive nucleating agents. AClyn 285 ethylene-acrylic acid sodium ionomers resin from Honeywell has also proven to be a highly efcient nucleating agent for PET, according to Scheirs, who also cites DuPonts Surlyn 8920 (ethylene-methacrylic acid sodium ionomers) resin. Adeka has other additives dedicated to polyesters (as well as other engineering plastics), such as high performance heat stabilizers and catalyst deactivators. It says the use of ADK STAB PEP-36 as a high performance heat stabilizer has helped customers to overcome resin degradation during processing. Some of these negative aspects could be related to certain catalyst residues, says Richard Green, area sales manager with Adeka Palmarole, the European afliate of Adeka. The introduction of a catalyst deactivator such as ADK STAB AX-71 can efciently help scavenging these catalyst residues and prevent any drop in intrinsic viscosity (IV) and discoloration of PET. ADK STAB AX-71 could be added at the post condensation stage to facilitate IV increase and production of high molecular

36

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additives feature | PET additives

Croda says that IncroMax 100 additive makes no visible difference to the colour and haze of pure PET. Photo compares PET mouldings containing IncroMax 100 (left) and a rival product (right)

weight polyesters. Croda too has a range of additives and modiers to help improve the processing and/or performance of PET. One of them, IncroMax 100, tackles issues relating to slip. PET naturally exhibits very high surface friction, especially immediately after processing, the company notes. This can lead to production issues such as poor mould release, problems with line ow during lling, increased tendency to scratch and mark, difculties with winding lm rolls, as well as reduced packing density of parts in boxes. Slip additives can be used to overcome these difcult and costly problems. Echoing Adeka, Croda says it used technical know-how built up from years of experience in the slip additive market for polyolens to develop IncroMax 100. This additive can help reduce surface friction by up to 60% without impacting the colour and clarity. IncroMax 100 is also available in concentrate form (10% in a PET carrier) as Atmer 7510. Croda says Atmer 7510 has been found to give other benets such as allowing easier processing of PET which results in energy cost savings and an increased scratch and scuff resistance to help maintain the part appearance.

Progress in ame retardants


Stabilization Technologies in Charlotte, North Carolina, which specializes in analytical services and additives solutions, says it has recently introduced several key products for PET. Director Joe Webster points to a successful resolution to the complex story of ame retardancy for PET bres. He says it has proven difcult to nd a suitable ame retardant that passes vertical burn tests with no drip. The nature of PET chemistry limits the use of various additives to provide solutions to problem due to their [acidity] properties or limitations in volatility, he says. Molecular weight is key to overall physical properties of textile bres so maintaining intrinsic viscosity is important for both prime and especially the use of more recycled materials. We have found a solution to this problem and the problem of cross-over contamination by other plastics in recycled PET that destroys molecular weight. The need for consistent and reproducible ameretardant polyesters has never been more urgent, Webster says. He claims that the new ame-retardant system can be used at less than 3% in relation to total weight in the polyester bre and that passes both FAA

Bar charts compare the kinetic coefcient of friction of pure PET with that of a PET containing 3% of Crodas Atmer 7510 slip additive and also a rival product (according to ASTM D1894)

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additives feature | PET additives

Sukano has added highly effective black masterbatches for PET

and NFPA-701 vertical burn tests, including instantaneous flame out, no smoke and no drip criteria. The product has no adverse effects on short- or long-term physical properties, or on UV durability; causes no discoloration or antagonism with colorants used in polyesters; and has no restrictions on use for the majority of applications for a flame-retardant polyester today in a global market. The price and economics and costbenefit performance is higher and more consistent than any flame retardant system in use today, Webster claims. The product is offered by Phoenix Plastics, Conroe, Texas, and sold under the trade name Cel-Span 789. Webster says he is working on numerous other developments in the field of PET fibre and film technologies, including: a broad UV and IR absorber from 200 to 800 nm and mid- and far-IR absorber, providing permanent long-term protection to PET; molecular modifiers for PET to retain IV and molecular weight; pigment and dye extenders to reduce the need for colorants; and stabilizers to maintain the shade of colorants exposed to UV radiation. Still on the subject of colour, Swiss company Sukano says its white masterbatches for PET applications have become the gold standard in container applications for their high quality and opacity, their excellent dispersion, brightness and gloss. Now it plans to repeat the feat in black. It offers Sukano black masterbatches based on PET and PLA, available with carbon black or dyestuff. It Click on the links for more information: says they enable a luxurious piano black colour and a shiny hi-tech appearance. Products made with masterbatches without carbon black are transparent to infrared radiation and are extremely glossy.

www.adk.co.jp/en (Adeka) www.americhem.com www.akelastomer.com (Asahi Kasei) www.colorchem.com www.colormatrix.com www.constar.net www.croda.com www.dow.com www.dupont.com www.excelplas.com www.exxonmobil.com www.honeywell-additives.com www.nanobiomatters.com www.materchem.com/en (Ningbo NZG) www.phoenixplastics.com www.stabilization-technologies.com www.sukano.com

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CO-ROTATING TWIN-SCREW EXTRUDERS: FUNDAMENTALS, TECHNOLOGY, AND APPLICATIONS


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Twin-screw extruders | processing feature

Suppliers of twin-screw extruders are racing to develop machines that meet the changing needs of compounders and masterbatch makers. Mikell Knights nds out about the latest developments from 10 leading manufacturers

Whats next in twin-screw extruders?


Twin-screw extruder manufacturers are developing new machines that meet the evolving demands of the global compounding and masterbatch industries. These requirements include: higher throughputs; increased additive loading levels; improved handling of difcult and sensitive materials; faster changeover times; reduced energy consumption; simplied machine operation; and more effective processing of bioplastics, natural bres and recycled materials. Over the following pages we speak with 10 leading twin-screw extruder suppliers from around the world to nd out about their most recent and forthcoming developments. They include Coperion, Entek, Feddem, ICMA San Giorgio, KraussMaffei Berstorff, Leistritz, Maris, Sino-Alloy Machinery, Steer and Technovel. Mc18 model has an optimised Do/Di ratio of 1.55 and its torque has been increased by 30%, allowing for more material in the screw ights and greater output. The more material you are able to put into the screws, the lower the average shear that is put into the product. This means that at constant screw speed the melt temperature is decreased by 10C or more. But more importantly, the available torque helps increase output by up to 75% for certain products, says Peter von Hoffman, head of Coperions compounding machines business unit. Coperion has also developed a special venting unit that helps to process mineral llers, ne powders and other low bulk density materials. The second generation of its Feed Enhancement Technology (FET) incorporates a lter to suck out air between the low bulk density particles and increases the friction before pushing the material into the melt ow with the screws. The unit is essentially a porous barrel with a vacuum
March 2013 | COMPOUNDING WORLD 43

Above: Coperions latest ZSK Mc18 model offers 30% more torque

Left: Coperions feeders are now offered with FET to improve the handling of low bulk density materials

Coperion ups the torque


Coperion has developed new solutions for power-limited and feed-limited processes, based on its well established ZSK line parallel co-rotating twin-screw extruders. Its latest ZSK
www.compoundingworld.com

processing feature | Twin-screw extruders

Entek is developing new designs that can shave time off screw changes

connected to it , says von Hoffman. It is available as a modification to the side feeder or for open barrels of the main extruder. The porous material is downstream of the feed inlet, positioned at the top and/or bottom of the side feeder unit. The productivity enhancements can be dramatic; lab tests using certain mineral fillers (PP/talc), yielded a 250% increase in product, says von Hoffman. Meanwhile, experience in the field has shown that these increases can be maintained constantly over a period of years. Coperion has also introduced a new STS Masterbatch die-head for its mid-tier STS machines which are assembled in China to German designs. The new die-head is designed to be opened easily and cleaned rapidly. Flow geometry inside the unit has also been improved for uniform melt flow across the entire die-head to ensure that the individual strands are produced at the same rate. The new die is at work on two Coperion STS 35 compounders installed at FBW, a Germany-based plastics compounder of pigment and additive masterbatches. The company generally produces additive masterbatches containing lubricants, toughening agents, antioxidants and UV stabilizers, as well as pigment masterbatches for metallic and translucent effects in batch sizes from 25 to 300 kg. It also offers a special service where customers can order customcompounded masterbatches in batch sizes upwards of just 1 kg for new developments and pigmentation trials. of the downtime experienced by all of the process machinery on a plant floor, says Dean Elliott, Enteks laboratory manager. Productivity gains are the reward if the downtime for colour changeovers can be minimized and they can hit their colour specifications quickly. Entek is developing new designs for the screw couplings and the die that can shave time off screw changes, and it is also looking at better ways to clean up vents. And for colour houses that prefer to purge their machine rather than pull the screws, Elliott has developed a recommended purging procedure for Enteks twin-screw machines that is getting a good reaction from customers. It address the best purge procedure, how to get the machine cleaned quickly, or how to execute a screw change. The optimised machine designs and purging procedures are being developed and proven in lab tests. Entek is also looking at a processing enhancement that provides a means for mixing two materials that have dissimilar melting points. It is hard to combine two different materials because as you start to melt one polymer the second one may degrade, says Elliott. One solution is to feed a hot melt from a separate extruder into the twin-screw extruder. At present, development in hot melt compounding is ongoing, but the goal is the development of new material formulations.

www.coperion.com

Entek accelerates changeovers


Entek has been focusing on new ways to speed up product changeovers on its compounding lines. It highlights the continuing trend by colour houses towards smaller batch runs, with up to 12 different batches run per machine each day. The move away from week-long production runs featuring a single colour has placed an emphasis on trimming the changeover time between batches. Colour houses are squeezed for time and that further increases the pressure to quickly attain a colour standard after each production run, explains John Effmann, Enteks director of sales and marketing. If the machine is not cleaned effectively the new batch of colour could end up off-spec. Colour formulators either rely on purging compounds or a screw change to facilitate the change, but can face difficulties. It is becoming more evident that inefficient changeover or cleaning can claim up to 40%
44 compounding world | March 2013

www.entek-mfg.com

Feddem provides new options


Feddem has introduced several new options for its Multi-Task Standard (MTS) line of co-rotating twinscrew extruders. Its new FSV side degassing (stuffer) unit is designed for the small- or medium-sized compounder with occasional applications that required degassing. The companys managing director Dieter Gross says: We
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100 %

MADE IN ITALY

processing feature | Twin-screw extruders

Feddems new FSV side degassing unit allows the line to run at higher rates

have designed the FSV with dimensions and mounting points similar to Feddems side feeder. The side degasser can be installed onto the same side ports as the feeder, and a user can reconfigure from a side degasser to a side feeder in just 20 minutes. It is suited to compounding processes involving thermoplastic materials like reinforced polyesters or nylons, plus materials that are filled to a certain extent. Gross says that an advantage of degassing from a side port rather than a top port without stuffer is the ability to apply a high vacuum that does not draw much more than the off-gases out. If you apply conventional vacuum on the top of the machine, it can be that in addition to the gas, fillers or polymer material are also pulled up, eventually accumulating and closing up the opening of the portal. This minimizes vacuum power and increases the potential of off-spec material pulled out of the process initially falling back into the melt stream. To avoid this, users typically reduce their throughput rates, says Gross. With side degassing, the operating forces of the

involving materials or masterbatches that are highly filled with powders. It is positioned opposite but slightly upstream of the feeder and vents any off-gases to atmosphere. Air can come out but no powder can come out, says Gross. Feddem has also developed a new Curved Strand Die Plate as a solution for compounders where the productivity bottle neck is in the number of strands. The new patent pending design improves throughput up to 25%, and is already in commercial use. Usually a die plate has a row of so many holes with a certain diameter and at a certain distance from each. Output has to do with the diameter of the hole, the number of holes, and the pulling speed of the pelletizer, explains Gross. In order to pull a strand of similar diameter but increase throughput, processors may add holes in one row or add a second row of holes to the die plate. Just adding holes in one row, or adding a second row brings a number of potential pitfalls, adds Gross. These include melt flow issues, where the die holes at the edges may be at a different flow distance from the holes at the centre of the die plate. Strands produced from a more central hole in the die plate may vary in diameter from strands coming from an outermost hole since the melt experiences different flow conditions. Adding multiple rows in holes can make cutting tricky. If you have a strand cut from the upper row, it easily can cause an imperfect or accidental cut of the lower row. This is a main reason why many avoid a two-row stand die-head, says Gross. Feddems Curved Die Plate allows 25% more holes in one row over a similar width of the die plate, with the same hole dimensions and equal flow lengths from hole to hole. The compounder uses the same strand pull speed with a higher extruder rate to attain higher throughput with a more stable strand pull, resulting in better pellet quality, Gross claims.

ICMA demonstrated recycling lines at its recent open house combining its extruders with Filtec pelletizers and Ettlinger screen changers

twin-screw work against the materials to keep them in the melt stream. The FSV allows the user to run at higher rates while ensuring the portal for degassing remains open. The unit is said to deliver 20-30% higher throughput than a conventional side degassing unit, along with the fast changeover capability. Another new option from Feddem is its FSE side venting unit, which was launched last year. It mounts to opposing side ports and also allows for fast and no-fuss installation or removal from the twin-screw extruder. The FSE is suited to compounding applications

www.feddem.com

ICMA adds value to recyclate


ICMA San Giorgio recently demonstrated the capabilities of it twin-screw extruders for processing recycled materials at an open house held at its facility near Milan last month. The firm, which offers co-rotating twin-screw compounding machinery, partnered with Filtec, an Italy-based supplier of pelletizers for recycled materi46 compounding world | March 2013 www.compoundingworld.com

processing feature | Twin-screw extruders

screw extruder, which is designed for processing highly filled compounds, along with several new technology developments. According to Ralf Dahl, Berstorffs vice president for twin-screw extruders, this is the companys first turnkey system to incorporate its deep-flighted high torque ZE-UT-R unit, and its first system to process undried wood flour with up to 12% moisture in-line. The pre-mounted module will produce a special wood-plastic compound with up to 60% wood flour, and will run at rates up to 2 tonnes/hour. Taking existing and proven technology and processes and recombining them creates an opportunity to enter new markets with new applications, says Dahl. Other companies may have installed higher capacity lines, but those systems use pre-dried material, and they dont go Pinuform is using KraussMaffei Berstorff twin-screw extruders to produce WPC pellets and profiles als, and Ettlinger, a Germany-based manufacturer of screen changers and filtration systems, to demonstrate advanced recycling and pelletizing of mixed waste plastics. Two processing lines were used to show how combinations of equipment from the three companies could be used to create a value-added product from waste materials by delivering a high degree of compounding, degassing and extraction of volatile substances. The first demonstration involved the processing of mixed-waste packaging containing polyolefins, barrier films, metalized films and printed films. A second line converted ground un-washed PP car bumpers into a product modified with thermoplastic rubber and mineral fillers to improve elastic modulus and boost sturdiness, respectively. beyond a 40% loading of wood flour, he adds. The wood flour is fed wet into the machine with direct degassing in-line, then is sent through an underwater pelletizer, but in the end the product is quite dry, with less than 0.5% of remaining moisture in the pellet. It is bagged and will feed decentralized profile extrusion lines, says Dahl. One company that is making use of KraussMaffei Berstorff systems for WPC compounds and profiles is Pinuform of Germany. It has recently installed one of the companys twin-screw co-rotating extruders for the compounding of wood flour and PP pellets at its Ammelshain plant near Leipzig. It has also invested in three Berstorff twin-screw counter-rotating extruders for the production of decking profiles using the WPC pellets.

www.icmasg.it

www.kraussmaffei.com

Berstorff boosts WPCs


KraussMaffei Berstorff has developed a new highthroughput system for producing highly-filled WPC compounds based on undried wood. The company used its experience in building complete turn-key systems to develop the WPC line using its ZE-UT-R series twinLeistritz is offering a second control panel to simplify the operation of strand pelletizing lines

Leistritz simplifies operation


Leistritz says that it has introduced several simple enhancements that are bringing big benefits to users of its ZSE Maxx series of machines. Its new double control panel for strand pelletizing lines is designed to improve process efficiency by

48

compounding world | March 2013

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Twin-screw extruders | processing feature

eliminating the operators need to make process changes from the primary control panel on the extruder. Adding a secondary control panel downstream at the pelletizer allows the user to make changes to the line from either end. Often an operator has to run from the pelletizer back to the extruder to make a process change, then back to the strand pelletizer for an adjustment, and back and forth like this continuously, says Michael Thummert, head of marketing at Leistritz. Now the user can control the line from either end of the process, which allows for a quicker response to process changes. The secondary touch-screen panel features an industrial control system that is not an expensive add-on and it ties in to the process control. A double control panel is in use on two Leistritz lines at a colour masterbatch producer in Sweden that compounds top quality materials, but with many formulations and at fantastic throughputs, says Thummert. The Swedish producer is using double control panels on its ZSE 18 Maxx and ZSE 27 Maxx machines. Leistritz also extended its feed barrel designs with a new size featuring a 50% larger opening. Introduced at the end of 2012, the new Leistritz E barrel is designed for volume-limited applications. The larger openings are available for the main feeders and the side feeders, and they help to eliminate potential problems in feeding low-bulk density materials, says Thummert. Leistritz also developed a new masterbatch die-head that is easy to open, clean and access the die plates. The special LSA masterbatch head is designed to reduce changeover times. The company also introduced updated versions of insulating barrel jackets which help to reduce machine energy consumption. The twin-screw process is continuous, whereas conventional devulcanizing methods using chemicals is a batch process. The Maris method with twin-screws is not subject to formulation mistakes or downtime for cleanout or changeovers, and it does not require side feeders on the unit, since nothing is added to the process. The approach can help to pull more scrap rubber out of the waste stream while providing compoundable material for injection moulding or compression moulding applications, says the company. Deactivating the cross polymeric chains of the rubber by means of a co-rotating twin-screw extruder is something that has never been achieved commercially before. This is state-of-the-art technology from the perspective of a co-rotating twin-screw, says Revelli. Maris developed special screw elements as well as heating profiles for the extruder to create the thermalmechanical reaction. The design and composition of the kneading elements, mixing elements, and conveying elements, and their configuration on the screw, in combination with a certain temperature setting for the rubber, along with the length of the machine and the screw speed, all collectively create the effect of cutting close to 100% of the cross polymeric chains, says Revelli. Maris says the unit can devulcanize a wide variety of rubber types, including EPDM, SBR, FKM, and even mixes between SBR and natural rubber. The scrap rubber only needs to be devoid of any textile or metal, and it can be devulcanized. Each rubber behaves at a different temperature setting within the extruder, so the throughput amounts may shift depending on the quality and kind of rubber. The devulcanized rubber is extruded from the Maris process in bands. After being cooled in a water tank and dried by air knife, the rubber can be vulcanized later using machinery equipment from other manufacturers, once curing agents and other chemicals have been compounded with the devulcanized rubber. Maris has commercial installations of devulcanizing lines in Europe and the Americas producing, operating
March 2013 | compounding world 51

Maris is using its twin-screw extruders to devulcanize rubber

www.leistritz-extrusion.com

Maris devulcanizes rubber


Maris supplies co-rotating twin-screw extruders for a range of technical plastics compounding applications. However, in the last four years it has developed a process that takes its machines into a completely new arena: devulcanizing scrap rubber with a twin-screw unit. There are several technologies that devulcanize rubber, but these approaches rely on chemicals or other agents and additives to cut the cross-links between the material. Maris developed a process that creates a thermal-mechanical reaction within the twin-screw extruder that devulcanizes the material without the use of any chemicals or agents, says Alberto Stephano Revelli, sales & marketing specialist with the company.
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processing feature | Twin-screw extruders

a rates from 10 to 1,000 kg/hour and beyond. It claims that users of the technology have realized an ROI in less than two years. The company supports product testing and trials at its 1,100 m technical centre,
2

as it does with its co-rotating extruder models. Sino-Alloy has also launched the third generation of its PSQ underwater pelletizer, enhancing the control of the cutting blades and redesigning the die plate for improved interchangeability. A linear motor now controls the position of the cutting knives, instead of the pneumatic system used by the previous model. Users now can adjust the cutting blade position either against the die plate or off of it when it is not necessary. The pneumatic design kept the blades against the die face at all times. Being able to adjust blade position extends the life of the blades and die plate. Not having constant pressure against the die face allows for the use of a smaller, more energy efcient motor, says Stephens. The die plate has been redesigned as an interchangeable insert, allowing processors to change from one die hole size to another quickly. The die plates with hole sizes ranging from 0.8 to 3.2 mm are offered. Sino-Alloy says it also improved the thermal insulation and the heat circulation of the die plate, which helps to prevent die hole freezing while also generating a more stable and consistent pellet.

which has four extruders installed, and it has a presentation video about the process on its website.

S www.mariscorp.com

Sino-Alloy protects the sensitive


Sino-Alloy has introduced counter-rotating, non-intermeshing lines for sensitive materials such as PVC Sino-Alloy Machinery, a supplier of fully intermeshing co-rotating twin-screws, ventures into new territory with its rst counter-rotating, non-intermeshing unit. The new PSMC targets heat- and shear-sensitive materials such as PVC or PET, where intermeshing screws can generate too much shear, says Donald Stephens, international marketing sales manager at the company. The parallel screws also feature a segmented design that allows for different screw congurations. The non-intermeshing and counter-rotating aspect delivers higher distributive mixing and less dispersive mixing along with lower shear, while the segmented design broadens the number of potential applications by changing the conguration of the elements, says Stephens. Sino-Alloy has turned away numerous potential customers who have looked to them for such a machine. We wanted to go into a market that is completely new for us, and this is a growing market niche we can pick-up by offering new equipment that challenges competitive models on throughput, says Stephens. The rst unit built is a PSMC 65, featuring 65 mm diameter screws with 1.57 Do/Di, a machine length of 38:1 L/D, and screw speeds up to 300 rpm. The PLC-based control and motor size is similar to those used with the companys co-rotating series. Steers innovative Shovel screw element is designed to overcome limitations in feeding material
52

S www.sinoalloy.com/en

Steer offers natural benets


Steers research into the use of natural bres in the compounding of biocomposites has led to the development of several screw elements that allow for high production throughputs without degrading these shear-sensitive materials. When updating the design of its OmegaLab co-rotating twin-screw extruder for the processing of natural materials such as jute bre, grass, and poultry feathers, the company exploited the fact that shearing isnt the only force present or able to compound these materials. The kneading blocks bring shearing forces, elongation, kneading, and stirring actions, as well as compression and laminar mixing, says Robert Roden, Steers head of global compounding technology. In addition, having larger gaps between the screws and the barrel, and between the screws in the intermeshing zone can lead to non-uniform shearing through the process, and shear peaks between the screws, Roden adds. Steers Omega series extruders eliminates these shear peaks by maintaining very tight tolerances in these regions. Steer has developed several screw element technologies designed to separate as much as
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Stephens says the new model will deliver throughput rates somewhat close to the rate of its PSM 72 co-rotating model, from 20 to 600 kg/hr depending on material. Sino-Alloy will consider offering the PSMC in higher rpm versions (600 and 900 rpm)

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processing feature | Twin-screw extruders

A quad-screw version of Technovels WDR extruder is being used for R&D at UMass Lowell

shear-sensitive biocomposites with no penalty on production or quality, says Roden. Twin-screw units incorporating the updated component designs are active in several commercial projects using natural fibres. A US compounder has commissioned a line that will use undried poultry feather fibres with 5-15% moisture content. A large biocomposite processing line in Ontario, Canada, set to launch this month (March) will produce compounds reinforced with miscanthus grass that will be converted into plant pots for sale by several major home improvement stores, says Padmanabhan. Applications to load 40% Jute fibre reinforcements in PP are in development. Steer says the updated equipment for these tasks starts with a

possible the different types of forces while minimizing shear. Having the correct type of element in the correct place puts the right amount of energy into the material at the right place and right time, which improves processing, says Dr Babu Padmanabhan, founder of Steer. This also allows for shear-sensitive materials to be processed at much higher production rates and speeds, he adds. The new elements were derived following the evaluation of other mixing equipment, including roll mills, a roller compactor, counter-rotating twin-screws, dispersive kneaders or Banbury mixers, a Buss co-kneader as well as existing co-rotating screws. The developments include: Shovel elements that overcome limitations in feeding material; Fractional Kneading Blocks (FKB) that bring enhanced melting and mixing along with the stretching, folding and squeezing action of a kneader at low shear; Fractional Lobed Mixing Elements (FME) which avoid the effects of pressure and shear peaks while imparting a high degree of elongational mixing in a constrained space; and novel mixing elements called DSEs that impart a dynamic stirring action in an unconstrained, open environment. Incorporation of the elements, along with close attention to process settings, has allowed for high production rates of filled materials. Steer said it produced a 40% talc-filled PP at 900 kg/hr with a screw speed of 1500 rpm, torque of 497 Nm, power of 120 KW, a material residence time of four seconds and 0.12 KW/h/Kg specific mechanical energy using a 40mm Omega H class extruder. In another test, using a standard Omega 40 mm extruder in its lab, Steer achieved production rates to 540 kg/hr running shear-sensitive biomass filled PP. This compares with a typical rate in the region of 100 kg/hr when a conventional machine of similar size is used. We can run our compounders at full rpm, full torque, full screw speeds and at full rates running
54 compounding world | March 2013

pre-wetting (stirring) step before kneading, shearing and elongational mixing. Steer adds that it is now offering a version of its side feeders with its novel Shovel elements as a way to improve the conveying capability of hard-to-handle materials. The elements are said to improve rates by 40-50% when a biomaterial is used. It has been successfully deployed in programs using biomass reinforcements, ceramics and calcium carbonate.

www.steerworld.com

Technovel turns up the rpm


Technovels WDR series high-rpm twin-screw compounding extruder, which is capable of speeds up to 4,400 rpm, is helping to push material dispersion to new levels. Such a unit is being used to process a range of materials at the University of Massachusetts Lowells new Emerging Technologies and Innovation Center (see Compound-

ing World, Jan 2013, p10 - http://bit.ly/Technovel). Robert Whitehouse, associate professor at UMass Lowell, has 40 years of experience in plastics compounding and many decades focused on dispersion. He says that these rpm speeds are at least four times higher than conventional twin-screw speeds, and they break new ground in the arena of dispersion. It is not an incremental improvement; this is a factor of two or three times better dispersion. I would say that the Technovel WDR twin-screw is providing a totally new platform in mixing energy. Whitehouse says that typical twin-screw extruder designs tend to degrade polymers when screw speeds edge above 500 rpm, which has prompted many manufacturers to develop higher torque models instead. When I first saw the Technovel twin-screw model, I did not think that using the high speed offered would be an advantage. No one has really done it because polymer degradation tends to occur at higher screw speeds, says Whitehouse, who has now
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processing feature | Twin-screw extruders

masterbatch into EVOH. Low rpm did not alter viscosity or dispersion, but at a higher rpm the EVOH showed a viscosity drop and some drop in molecular weight. When a nanoclay was added it compensated for the slight loss in molecular weight to the EVOH and viscosity actually increased two-fold. This indicated better exfoliation of the clay far better than had ever been done in a masterbatch before at a lower speed, says Whitehouse. He found that the EVOH bound itself strongly with the clay particles, producing a bound rubber layer type technology. Together with several students at UMass Lowell, Whitehouse also looked at incorporating nanoclay into PP. PP is purely a hydrocarbon, so one would not expect results similar to the EVOH trial. However, at higher screw speeds, the PP did create a bound rubber layer with the clay, showing high and uniform dispersion. Keep in mind that we are processing at 4,000 rpm UMass Lowell graduate student Melissa Egan runs trials using Technovels high-speed twin-screw extruder conducted several experiments with the unit and has come away with a new view. The first experiment processed a straight PP above 500 rpm. Whitehouse said thermal degradation did occur, however that allowed for the material to be converted from a low melt index PP into a MI 200 PP, which is more of a fibre grade. If we can achieve this melt grade without the use of peroxide, then a processor has a new, clean way of depolymerizing PP. Essentially you can run it in an inline fibre extrusion process. When peroxide is used there is a strong residual, sickly odour from the alcohol release which can take several days inside a hopper drier to eliminate the smell on the product. With the Technovel model running at higher speeds, the material did have thermal degradation but with no odour. When processed through the unit at 4,000 rpm, it raised the melt index from 1 up to 200. We were also able to repeat the results predictability, as we found a correlation with the screw rpm and feed rate, says Whitehouse. Whitehouse then ran a program of a nanoclay with the same screw, same L/D and same geometries; just changing the motor speed. Whitehouse is now using Technovels twin-screw to test high-rpm processing of reactive processes. He says that if the machinery and process can generate that much thermal mechanical energy perhaps there is a chance to generate radical sites on the polymer itself which will allow for drafting between two polymer blends. An idea I am interested in is taking a mixed polymer blend from the waste recycling stream and determining if it can be compatibilized back into commercially viable compounds from waste by generating radicals to get some grafting or branching, or to put in some compatibilizer to enhance the linkage, says Whitehouse. Technovel offers the WDR extruder in twin-screw and quad-screw formats, and it has installed both models at the Emerging Technologies and Innovation Center. Both machines use 15 mm extruders and have a choice of 45:1 or 60:1 L/D says Diane Fukuda, US agent for Technovel.

www.technovel.co.jp/en

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2013 Pipes in I n f r a s t r u c t u re
Market trends, new products and technical developments in plastic pipes for infrastructure applications

Images courtesy of: Wavin GmbH and HOBAS Rohre GmbH

CLICK HERE FOR DETAILS

9-11 April 2013


Hotel Nikko, Dsseldorf Germany
* + 19% German VAT

FINAL REMINDER BOOK NOW


Organised by: Applied Market Information Ltd. Sponsored by: Media supporter:

Giulia Esposito Conference Organiser ge@amiplastics.com Tel: +44(0)117 924 9442 Fax: +44(0)117 311 1534

Download the programmes for these forthcoming conferences


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

Green Polymer Chemistry


GREEN POLYMER CHEMISTRY 2013
International conference on manufacturing conventional plastics from sustainable sources

Stretch & Shrink Film


STRETCH & SHRINK FILM 2013
The business conference & exhibition for the stretch & shrink film industry

The second international conference on manufacturing conventional plastics from sustainable sources is being held on 19-21 March in Cologne, Germany. This brochure has all the details.

ANNIVERSARY CONFERENCE

10

th

The 10th anniversary conference will be a celebration of the success of the stretch & shrink film industry over the past ten years

AMIs 10th international conference on Stretch & Shrink Film will take place in Berlin, Germany, on 16-18 April 2013. The programme includes detailed market analyses, plus the latest materials, processing and application developments.

19-21 March 2013


Maritim Hotel, Cologne, Germany
Image courtesy of: Shutterstock
* + 19% German VAT

16-18 April 2013


InterContinental Hotel, Berlin, Germany
* + 19% German VAT

SPECIAL OFFER: Save 140* if you register before 15th February 2013
Organised by: Applied Market Information Ltd. Sponsored by: Media supporters:

SpECIAL OFFER: Save 150* if you register before 8th March 2013

o +44 (0)117 311 1534

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Organised by: Applied Market Information Ltd.

Sponsored by:

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Polymers in Photovoltaics
POLYMERS
in

Middle East Strategy Seminars


P LASTICS P ROCESSING I N T HE GCC S EMINAR 2013
A review of challenges and opportunities in the GCC

Photovoltaics 2013

International industry conference on polymer components in photovoltaic systems

Images courtesy of: Ray Colby of Sundial Solar and SBM Solar Inc. USA

AMIs international conference on polymer components in photovoltaic systems is taking place in Cologne, Germany, on 16-18 April. Check out the programme that covers new developments in this exciting market.

16-18 April 2013


Maritim Hotel, Cologne, Germany
* + 19% German VAT

7th May 2013 Dubai 11th May 2013 Jeddah 12th May 2013 Riyadh 13th May 2013 Dammam

AMI is running strategy seminars on Plastics Processing in the GCC during May 2013 with dates set for Dubai, Jeddah, Riyadh and Dammam. They will be led by Leslie McCune, an expert on the regions chemicals and plastics markets.

SPECIAL OFFER: Save 140* if you register before 8th March 2013
Organised by: Applied Market Information Ltd. Sponsored by: Media supporters:

Updated information on 2012 market developments

o +44 (0)117 311 1534

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Organised by: Applied Market Information Ltd.

Click here to download

Thin Wall Packaging USA


THIN WALL PACKAGING 2013
International conference on lightweight plastic tubs, trays, jars, containers and cups for food packaging

BOPP Film

Images courtesy of: Danone and Printing Company Verstraete

Images courtesy of: Brckner Maschinenbau Gmbh & co. KG

HEADLINE SPONSOR

The American version of AMIs Thin Wall Packaging conference returns to Chicago on 18-19 June. This brochure has the full programme which covers the latest developments in thermoformed and injection moulded packaging.

BOPP FILM 2013


The international conference and exhibition for the bi-oriented polypropylene film industry

platinUM sponsor

AMIs global conference for the BOPP lm industry will be taking place in Singapore this year on 25-27 June. Download the programme which covers the latest market trends, materials developments and processing technologies.

June 18-19, 2013


The Westin Chicago North Shore, Chicago, Illinois, USA

25-27 June 2013


Marina Bay Sands Hotel, Singapore

SPECIAL OFFER: Save $200 if you register before May 10, 2013
Organized by: Applied Market Information LLC Sponsored by: Media supporters:

special offer: Save US$375 if you register before 15th May 2013

Click here to download

Organised by: Applied Market Information Ltd.

Also sponsored by:

Media supporter:

fax back to +44 (0)117 311 1534

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To see our full line-up of more than 25 plastics industry events over the next 12 months, please visit www.amiconferences.com

This months free brochure downloads


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

ICMA: compounding systems


This 20-page brochure from ICMA San Giorgio covers the companys advanced compounding and extrusion systems. These include special lines for recycling, direct extrusion, reactive compounding, and processing natural bres.

C.A. Picard: extruder technology


EXTRUDER TECHNOLOGY

ONE CO-ROTATING HEART IS BEATING IN OUR SYSTEMS

CO-ROTATING TWIN SCREW EXTRUDERS

COMPOUNDING

ADVANCED RECYCLING

NATURAL FIBERS

DIRECT EXTRUSION

LAB SYSTEM

OUR PEOPLE MAKE THE DIFFERENCE

This 12-page brochure from C.A. Picard International covers its high-quality replacement parts for extruders, mixers and kneading machines. These include screw elements, kneaders, screw shafts, barrels, cylinders and bafes.

www.icmasg.it

Click here to download

Click here to download

Reduction Engineering: pelletizers


This brochure covers Reduction Engineerings Bullet Series of strand pelletizers. Aimed at both laboratory and production users, these pelletizers have been developed to be easier and faster to clean and service.
Bullet Series Strand Pelletizer Granulador de Hebra Serie Bullet

Entek: WPC lines


Extrusion Solutions for Wood-Plastic Composites

This brochure covers Enteks complete turn-key extrusion lines for the production of wood-plastic composite (WPC) decking. The lines are built around the companys E-MAX twin-screw extruders.

Click here to download

Click here to download

Steer: EPZ screw elements


This 20-page brochure from Steer Engineering features its wide range of screw elements including many innovative designs developed by the company. It also covers replacement barrels and shafts.

PlasMec: PVC mixing/cooling


This brochure covers PlasMecs HEC High Efciency Horizontal Cooler for the production of rigid or plasticized PVC dry-blend. Available in sizes up to 8,000 litres, it delivers high levels of efciency, throughput and quality.

Click here to download

Click here to download

If you would like your brochure to be included on this page, please contact Claire Bishop. claire@amimagazines.com. Tel: +44 (0)20 8686 8139

compounder of the month

Bada
Head ofce location: Date founded: CEO: Ownership: No. of employees: Sales 2012: Plant locations: Production 2012: Prole: Bhl, Germany 1997 Andreas Schettler Privately owned Approximately 120 Approximately 70 million Bhl, Germany, and Huesca, Spain 24,000 tonnes Bada is a customer-focused specialties compounder based in Bhl, BadenWrttemberg, Germany. In addition to this site, it has another compounding plant in Huesca, Spain. New production lines are being added at both facilities this year, increasing annual capacity by around 4,000 tonnes. The companys technical thermoplastics and thermoplastic elastomers (TPEs) are exported to more than 70 countries in Europe, Asia, America and Africa. Bada offers a range of engineering plastic and TPE compounds including Badamid (PA), Badadur (PBT), Badaex (TPE-S), Badalac (ABS), Badaprene (TPV), and Badatron (PPS). Bada supplies materials to a wide range of industries, including the automotive, electrical/electronic, sports/leisure, construction, furniture, medical technology and household goods sectors. Bada sees itself as an innovative compounding specialist, providing exibility, quality and reliability. Its highly qualied team and sophisticated technology enable it to meet a wide range of customer requirements.

Product line:

Product strengths:

Forthcoming features
The next issues of Compounding World magazine will have special reports on the following subjects: April 50th issue celebration special Anti-oxidants Wire and cable applications May Anti-stats and conductive additives Clariers, nucleating agents & processing aids Chinaplas 2013 show preview

Editorial submissions should be sent to Andy Beevers: abe@amiplastics.com For information on advertising in these issues, please contact Claire Bishop: claire@amimagazines.com Tel: +44 (0)20 8686 8139

Catch up on our recent issues for FREE


Simply click on the cover to see the full magazine, or download the issue in the relevant Apple or Android app
Compounding World Feb Compounding Worlds February issue is packed full of features on thermallyconductive compounds, additives for polyolens, materials handling systems, changes to EU patent legislation, plus costmanagement for plastics processors. Click here to view Compounding World Jan The January edition of Compounding World covers developments in foaming additives and the formulation of polyolen foams. It also takes a look at coupling agent innovations and pelletizing technology. Click here to view

Injection World Jan/Feb This edition of Injection World covers automotive composites, IML developments, reinforcing bres and additive manufacturing, plus it has three practical features on cost management, developing multi-shot products and understanding moulding variables. Click here to view

Wind Turbine Blades 2013 The rst edition of Wind Turbine Blade Manufacturing magazine looks at trends in the wind energy market, reviews developments in reinforcing bres and core materials, and reports on the worlds longest blade. Click here to view
WIND ENERGY MARKET UPDATE

2013

BLADE REINFORCEMENT TRENDS ANALYSING CORE PROPERTIES JEC 2013 EXHIBITION PREVIEW

Pipe and Prole Jan/Feb The January/February issue of Pipe and Prole Extrusion contains articles on additives and colorants, screenchangers, PVC stabilizers, corrugated pipes, and the use of composites and engineering plastics in high-performance pipes and proles. Click here to view

Film and Sheet Feb This edition of Film and Sheet Extrusion looks at developments in medical applications, analyses trends in pallet lms, reviews mineral llers from renewable sources, and examines the latest news in thermoforming. Click here to view

Take out your own FREE subscriptions to any of the magazines. Click on the logos below to simply register on-line.

dates for your diary

Global exhibition guide


3-5 April 3-6 April 10-11 April 10-12 April 7-10 May 14-16 May 20-23 May 20-24 May 6-8 June 18-19 June 18-20 June 19-22 June 20-23 June 3-6 September 5-7 September 16-23 October Plastex Uzbekistan, Tashkent, Uzbekistan Tiprex, Bangkok, Thailand PlastTeknik, Malmo, Sweden Plastic Japan, Tokyo, Japan PlastPol, Kielce, Poland Plast-Ex, Toronto, Canada Chinaplas, Guangzhou, China Feiplastic, Sao Paolo, Brazil Plastics Printing Packaging Tanzania PDM, Telford, UK Plastec East, Philadelphia, USA PlastExpo, Casablanca, Morocco InterPlas Thailand, Bangkok Applas, Shanghai, China Plasti & Pack, Lahore, Pakistan K 2013, Dsseldorf, Germany www.plastex.ite-uzbekistan.uz www.tiprex.com www.easyfairs.com www.plas.jp/en www.plastpol.com www.plast-ex.org www.chinaplasonline.com www.feiplastic.com.br www.pppexpo.expogr.com www.pdmevent.com www.plasteceast.com www.plast-expo.com www.interplasthailand.com www.applas.com www.pk-plastipack.com www.k-online.de

AMI conferences
18-20 March 19-21 March 7-8 May 14-15 May 14-16 May 3-5 June 4-5 June 4-6 June 13-14 June Masterbatch Asia, Singapore Green Polymer Chemistry, Cologne, Germany Bioplastics Compounding & Processing, Miami, FL, USA Polymers in Cables, Miami, FL, USA Polymer Sourcing, Vienna, Austria Masterbatch, Frankfurt, Germany Profiles, Philadelphia, PA, USA End of Life Plastics, Cologne, Germany Fire Retardants in Plastics, Denver, CO, USA Polyolefin Additives Medical Grade Polymers Fire Resistance in Plastics, Cologne, Germany Polymer Foam, Hamburg, Germany

For information on all these events and other conferences on film, sheet, pipe and packaging applications, see

10-12 September 17-18 September 12-14 November 19-21 November

www.amiplastics.com

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