TECHNOLOGY OF PVC COMPOUNDING AND ITS APPLICATIONS

PVC RESINS MANUFACTURING & PROPERTIES

Introduction
Manufacture of PVCSuspension Polymerization Process
Clean Reactor TechnologyLarge Reactor Technology
VCM Containment
Mass Polymerization Process
Emulsion Polymerization Process
PVC Mass Polymerization
Comparative of PVC Produced using Different Processes
Copolymers, Chemical Modification & Blends/Alloys of PVC
Introduction
Reactivity Rations for VCM Copolymerizations
PVC Copolymers
Vinyl Acetate Copolymers
Recipe for VCM-VAC Copolymerization
Effect of VAC on Properties of PVC Copolymer
Copolymers with Olefins
Effect of Ethylene or Propylene on PVC properties
Copolymer with Vinyldene Chloride
Copolymers with Acrylates
Chemically Modified PVC
Introduction
Syndiotactic PVC
Effect of PVC Polymerization Temperature on Crystallinity
Chlorinated PVC
Comparative Properties of PVC & CPVC
PVC Grafts
Acrylic Graft
Properties of PVC Grafts
EVA grafted PVC
Cross linked PVC
Monomer for X-PVC Preparation

PVC Blends & Alloys

PVC/NBR Blend
Properties of PVC/NBR Blends
Powered NBR
PVC/NBR
Dynamically Vulcanized PVC/NBR
Comparative Properties of PVC/NBR Blends and Thermoplastic Rubbers
Typical Properties of Elvaloy Resins
Comparative Properties of PVC/EVA Blends
PVC/ABS Alloy
Dynamic Thermal Stability of PVC/ABS Alloys
Comparative Properties of PVC Alloys
PVC/Acrylic & Miscellaneous Alloys
Properties of PVC/Acrylic Alloys
Properties of PVC/Gadds Alloys
Heat Deflection under Load for PVC Alloy
Effect of processing Temp. on Rheological properties of PVC/Gadds Alloy
Effect of PVC:Gadds Composition on Torque
PROCESSING OF PVC
PVC Resins
Molecular Weight
Injection Moulding
Extrusion
Additives for Improving Processing
Heat Stabilizers
Processing Aids
Lubricants
Impact Modifiers
Compounding
Low Shear Horizontal Mixers (Ribbon Blenders)
Higher Shear Vertical Nonfluxing Mixers
Dry Blend Properties
Low Shear and High Shear Mixing in Horizontal, Jacketed Cylindrical Blenders
Hot Melt Compounding
Two Stage (Farrel) Continous High Intensity Fluxing Mixers

Compounding Lines-Batch Type

Suggested K-Value of PVC Resins
Influence of Formulations on processing behavious
The Polymer
Relation of Polymer K-Values with Threshold Temperature
Lubricants
Heat Stabilizers
Processing Aids
Impact Modifiers
Plasticized PVC
Extrusion
PVC Compounds-Some Routes and Processing
Calendering
Injection Moulding
Unplasticized PVC
Typical Formulation of Rigid and Flexible PVC Films and Functions of various
components there-in
General Types of Industrial PVC Compounding Operations
Equipments for Compounding of PVC
Calendar Products and their Products
Processing of Rigid PVC
Injection Moulding -Rigid PVC
Injection Blow Moulding (IBM)
A Typical Injection Moulding Screw Design for Rigid PVC Material
Three Station Horizontal Indexing Injection Blow Process
Biaxial Orientation
Conclusions
Typical High-Flow PVC Formulation
Blow Moulded Bottles and Containers
Reheat Stretch Blow
PET Vis-A-Vis PVC Stretched Bottles
PVC Heat Shrinkable Bands
Blow Moulding of PVC Bottles
Injection Blow Moulding
Orientation

Cushioned Vinyl Flooring

Wide Choice of Different Substrates
Streen Coating System
Way ahead in Flexibility
Versatility in Coating
One Pass Production
Unique Process Improvements
Principle of Operation
Embossing problems a thing of the past
Double sided Coating of Openweave Fabrics
Single screen coating process
Screen to screen coating process
Principle of application
Recycling
Description of the Process
Compounding Internal Mixers
Internal Mixers
Schematic View of Compounding Operations
Unit Operations to Produce Glass Filled Polymers
Post Compounding Operations
Schematic of Banbury Mixer
Schematic of a Grnulator
Schematic of a strand pelletizer
ADDITIVES FOR PVC
Introduction
Plasticizers
Plasticizer usage for PVC Compound
Typical Properties of Plasticizer
Physical Properties of Phthalate Plasticizers
Physical Properties of less common Phthalates
Properties of Specially Plasticizers
Physical Properties of Miscellaneous Plasticizers
Plasticizer Efficiency and Properties of Flexible PVC
Plasticizer Efficiency

Dry Blending Time for Plasticizers

Effect of Plasticizers on Plastisol Gelation Temperature
Effect of Structure of Plasticizer on PVC Properties
Properties of Flexible PVC compounds at 50 PHR Phthalate Plasticizer Level
Physical Properties of Flexible PVC using specially plasticizers
Requirements for PVC Plasticizers
General Relationships between the structure of Plasticizers and their behaviour in PVC
Characteristics of the Major Types of Plasticizer
Polymeric Modifiers for PVC
Modifiers for Flow Improvement
Flow Promoter for PVC
Haake Rheogram for Rigid PVC Pipe Compound
Standard PVC Pipe Compound 2 PHR Modifier
Effect of Level of Flow Promoters on UPVC Rheological Properties
Effect of Low Molecular Weight Polymers
Typical Properties of Flow Promoters
Modifiers for Impact Enhancement
Mechanism of Impact Resistance
Effect of Modifier Quantity
Effect of EVA
Effect of Processing Time on Impact Strength
Systems with Honeycomb Network
Effect of Processing Conditions
Effect of Processing Conditions of UPVC
Effect of MBS/Acrylic Quantity on UPVC Impact Strength
Effect of Composition on Impact Resistance
Effect of Temperature of UPVC
Impact
Applications for Impact Modifiers
Heat Stabilizers for PVC
HCI Absorption
Elimination of Labile chlorine
Prevention of Autoxidation
Addition to polyene secuence
Carbenium ion elimination

Lead Stabilizers
Structure of Lead Stabilizers
Tin Based Stabilizers
Structure of Tin stabilizers
Barium Cadmium Stabilizers
Stabilization by Barium and Cadmium Stabilizers
Calcium-Zinc Stabilizers
Non Metallic Stabilizers
Epoxy Based Stabilizers
Effect of Epoxy and Phosphite on PVC Static Thermal Stability
Organic Phosphites
Polyhydric Alcohols
Antioxidants
Light Stabilizers
Lubricants
Appearance and Melting Point of Lubricants
Calcium Carbonate
Physical Properties of CaCO3 Fillers
Clay & Talc
Silicas & Glass Fibres
Properties of Glass Fibre Reinforced PVC
Flame Retardant Agents
LOI for Various Plastics
Chlorinated Flame Retardants
Brominated Compounds Metal Oxides
Chemicals and Additives-A Review of Future Outlook
Colourants
Blowing Agents
Heat Stabilizers
Plasticizers
UV Stabilizers
Antimicrobials
Flame Retardants
Phosphate Ester Flame
Retardants/Plasticizers for Polyvinyl Chloride (PVC)

Effect of Various Flame Retardants in Plasticized

Polyvinyl Chloride
Plasticized PVC with High Oxygen Index Use of Brominated Phosphate
Typical High emperature Wire Cable Polyvinyl Chloride Flame Retardant
COMPOUNDING
Introduction
Mixing Theory
Limitations of Mixing Theory
Mixing Evaluation
Fillers
Common Fillers and their uses
Plasticizers
Colorants
Heat Stabilisers
Antioxidants
Ultraviolet Light Absorbers
Antistatic Agents
Flame Retardants
Blowing Agents
Lubricants
Methods of Compounding
Intensive Dry Mixers
Internal Intensive Batch Mixers
Continous Mixer
Two Roll Mills and Pelletisers
Underwater Pelletiser
Single Screw Extruders
Compounder Extruder
Twin Screw Extruder
Compounding Lines
COMPOUNDING OF PVC
Selection & Characterization of PVC
Major Types of PVC Resins
Processing & Applications of PVC

PVC Resins Properties

Relation of PVC K-Value, Viscosity & Mole Wt.
Effect of Polymerization Temp on % Crystallinity
Syndiotactic Structure
PVC Morphology and PVC Characteristics
Effect of PVC Morphology on Extruder Output
Rheological Properties of PVC Dry Blends
Effect of PVC Resin Bulk Density on Rheological Properties
Effect on Processing RPM on Rheological Properties
Effect of Processing Temp. on Rheological Properties
Effect of Bulk Density on DOP Absorption
Introduction
Elements of Compounding
Methods of Compounding
Intensive Dry Mixers
Internal Intensive Batch Mixers
Contionuous Mixer
Two Roll Mills
Single Screw Extruders
Compounder Extruder
Twin Screw Extruder
What are some of them ?
Custom Compounding for Special Properties
General Guidelines for PVC Formulations for Common Product
Formulating Rigid PVC Compounds
PVC Pipe Formulations
PVC Conduit Pipe Formulations
Window Profile Formulations
Interior PVC Profile Formulations
PVC Siding Formulations
Cellular PVC Profile Formulations
Extruded PVC Sheet and Film (Single -Screw)
Calendered PVC Sheet and Film Formulations-Second Alternative
PVC Injection Moulded Pipe Fitting Formulations
High Flow PVC Injection Moulding Formulations

Extrusion Blow Moulding Rigid PVC Containers

Crystal Clear Food Contact Bottles
Clear Bottles good on taint and odour
Blow Moulded Bottle Formulations
Blow Moulded PVC Bottle Formulations
CA-ZN Formulation (Mineral Water)
CA-ZN Epoxy Recipe for 1 Litre Bottle
PVC Bottle for Shampoo
Shoe Soles
Tests for Compound
Floor Coverings/Wall Coverings
Typical Light Stable Formulation
Carbon Black Properties
Comparison -Titanium Dioxide and Zinc Oxide
Portable Water Pipe (Extruded from Dry Blend)
General Purpose Vinyl Film by Calendering
Sheeting for Outdoor Upholstry
COMPOUNDING OF PVC PASTES
Plastisols
Compounding Ingredients of Plastisols
PVC Polymers
Plasticisers
Stabilisers
Fillers
Colourants
Thickeners
Other Additives
Organosols
Compounding Ingredients
Preparation of Pastes
Gelation
Applications of PVC Pastes
Rotational Casting Formulation for Dolls and Play Balls
Compounding of PVC Latices
Latex Property Modifiers

Latex Stabilisers
Surface active agent
Defoaming Agents
Thickeners
pH Modifiers and Buffers
Polymer End Properties Modifiers
Heat Stabilisers
Plasticisers
Fillers
Pigments
Antiblocking Agents
Coalescing Aids (Volatiles)
Handling and Processing
Mixing
Dipping
Coating
Spraying
Compounding of PVC Solution & Adhesives
Plasticizers
Stabilisers
Fillers
Pigments
Lubricants
Methods of Application of Solutions
Applications of Solutions Adhesives
TESTING OF RESINS AND COMPOUNDS
Testing of PVC Resin
K-Value
Bulk Density
Plasticizer Absorption
Particle Size Distribution
Electrical Conductivity of Water Extract
Powder Flow
Sulfated Ash Content

Fish Eye Count

Testing of PVC Compounds
Bulk Density
Shore Hardness
Tensile Strength/Elongation
Static heat Stability
Dynamic Heat Stability
Brabender/Haake Gelation & Degradation Time
Electrical Volume Resistivity
Volatile Loss
Ageing Test
Cold Bend Temp. Test
Testing of PVC End Products
Films/Sheets/Profiles
Tensile Stress at Yield
Test for Dimentional Change at 120o C
Rigid PVC Pipes for Potable Water Supplies
Dimensions of Pipes
Visual Appearance
Opacity
Short Term Hydraulic Test
Long Term Hydraulic Test
Reversion Test
Impact Strength at oC
Methylene Dichloride Test
Flexural Strength
Wires and Cables
Thermal Stability Test
Determination of PVC Cable insulation Degradation
Comparison of Techniques to Assess FVC Degradation
Problem Solving in PVC Compounding and Processing
Resin
Lubricants
The Role of Lubricant
In PVC Compounding

Stabilizers
Additives
Material Characteristics and its effect of processing resins
Development of an Optimum Formulation
New Do's and Don'ts
Plasticizer Migration
High Purity Non-Stain Plasticizers for Floor and wall Coverings
Testing
Sample Preparation
Cure
Stain Specimen Conditioning
Stain
TGATensile Properties
Hardness
Results
Chemical Resistance
Rigid
Chemical Resistance of Vinyl Compounds: Percent Change in Weight
SPECIALITY PLASTIC COMPOUNDS & MASTERBATCHES
Introduction
Product
Coloured Masterbatches
Additive Masterbatch/Speciality Compounds
Market
Suggested Capacity
Land & Building
Raw Materials
Utilities
Manufacturing Process
Plant & Machinery
Personnels
Estimated Cost of the Project
Suggested Means of Financing
PVC COMPOUNDS
Introduction

Product
Market
Suggest Capacity
Land & Building
Raw Materials
Utilities
Manufacturing Process
For Rigid Pipes
For Bottle Blowing
For Blown Film
For Flexible Hose Pipes
For Mineral Water Bottle
Plant & Machinery
Personnels
Estimated Cost of the Project
Suggested Means of Financing
XLPE CABLE COMPOUND, JELLY FILLED TELECOMMUNICATION CABLE COMPOUND
& SHEATING COMPOUND
Introduction
Product
XLPE Compound
MDPE Compound
FRLS Compounds
Land & Building
Raw Materials
Utilities
Manufacturing Process
XLPE Compound
MDPE Compound FRLS & Low Halogen
Compounds
Plant & Machinery
Personnels
Estimated cost of Project
Suggested Means of Financing

PLASTIC GRANULES FROM FRESH RESIN

Manufacturing process of LDPE Granules from LDPE Resin
Plastic Filler Granules (PP)
PVC Granules
Process of Manufacture
Plant Economics
Fixed Capital
Raw Materials
Total Working Capital
Total Capital Investment
Turn Over/Annum
PLASTIC GRANULES
Process of Manufacture
Concentration of Blending
Removal of Colour to obtain Transparent Granules by Activated Carbon Treatment
Filteration
Distillation
Cooling and Dehumidifying
Granulation
Weighing, Filling and Packing
Plant Economics
Fixed Capital
Raw Materials
Total Working Capital
Total Capital Investment
Turn Over/Annum
APPLICATIONS OF PVC
Review of Major Applications
Rigid PVC Pipes
Advantages of Rigid PVC Pipes
Graphical Sketch of a Twin Screw Extruder
Applications
Chemical Resistance
Resistance of PVC Pipes to Common Chemicals under use Conditions

Composition Energy Saving of PVC Pipes

Weathering
Summary of the Testing Results
Flow through Rigid PVC Pipes
Flow or Friction Losses
Surge and Water Hammer
Economics of Rigid PVC Pipes
Water Flow Velocity
Start up
Schematic of a large tube die
some Common Problems and Solutions of Pipe Extrusion
Industrial Profiles
Various Forms
Major Applications
Cellular PVC Profiles, Boards and Pipes
Introduction
Technology of Structural Foam extrusion
Foaming
Foaming Processors
Free Foaming Process
Inward Foaming Process
Machine and Die Technology
Extruders
Dies
Chemical Blowing agents
Processing aids
PVC grades
Properties of Cellular UPVC Pipes
Physical Properties of Cellular UPVC Pipe
Physical Properties of Cellular UPVC Board and Profile
Manufacturing of PVC Sheets
Calendering
Extrusion of PVC Sheets
Extrusion Blowing of PVC Sheets
Calandrette Process

Further Processing of Sheets by Forming

Requirements of PVC Sheets
Roller Film Calender
Calenders
Blister Packaging
Vacuum Formed Products
Skin Packaging
Problems and Suggested Remedies in Sheet Extrusion
Calendered Film-Typical Problems
Thickness Variation
Film Curling or Side Bending
Flatness Defects
Blister Packaging
Calendering of Rigid PVC Compounds
Advantages of Calendering Process
Blister Packaging Components
Heat Seal Coatings
Selection of Paperboard
Blister Packing Vs Skin Packaging
Blister Packaging Machinery
Advantages of Blister Packs
Blister Packaging Constraints
Blister Packaging in Pharmaceutical Industry
some Typical Applications of PVC Sheets
Typical Blister Packaging Applications
End Use Applications Chart
Non Packaging Applications
Tropicalised Blister Pack-ANew Concept
Rigid PVC Free Foam Boards
Areas of Application Overseas
Advertising
Building Sector
Electrical Industry
Miscellaneous
Typical Values of PVC

Integral Foam Sheets

PVC Integral Foam Sheets Applications
Characteristics
Advantages
Fabrication
Major Applications
Expanded PVC for Replacement of Wood
Free Foaming
Surface Treatment
Fabrication of PVC Sheets
Matchining
Rigid
Flexible
Cutting
Rigid
Flexible
Drilling
Punching and Blanking
Planning
Routing and Milling
Screwing and Tapping
Grinding and Sanding
Engraving
Adhesive Bonding
PVC to Other Materials
PVC to itself
Printing and Metallising
Laminating and Plastification of Printed Master
Welding
Ultrasonic Welding
High Frequency and Radio Frequency Welding
Shaping of PVC
Cold
Hot
Three Dimensional Shaping

Simple Forming
Injection Moulding-Rigid PVC
Injection Blow Moulding (IBM)
Biaxial Orientation
High Flow Injection Moulding Applications
Conclusions
Typical High Flow PVC Formulation
Blow Moulded Bottles and Containers
Reheat Stretch Blow
Pet vis-a-vis PVC Stretched Bottles
PVC Heat Shrinkable Bands
Blow Moulding of PVC Bottles
Injection Blow Moulding
Orientation
Cushioned Vinyl Flooring
Wide Choice of Different Substrates
Prodution of Cushio Vinyl Flooring Using glass fibre
Production using asbestos mat
Rotary screen printing system for cushion vinyl flooring
Screen Coating System
Way ahead in FlexibilityVersatility in coating
The screen coating system: Advantages
One Pass Production
Unique Process Improvements
Principle of Operation
Embossing problems a thing of the past
Double sided Coating of Open weave Fabrics
Single Screen Coating process
Screen to screen coating process
Principle of application
PVC in Medical Applications
Typical Medical Grade PVC Compound for Extrusion
Moulding of PVC Footwear
Compounding
Moulding

Machines
Moulds
PVC Uppers
Processing
Coatings
Sectional View of a coating Machine
Various types of spreader
Rotational casting and slush moulding
Dipping
Injection Moulding
Extrusion
Graphical Sketch of a twin screw extruder
Screw Temperature Control
Application Principle
Friction free Applications
Clear, simple operation
Two sided coating of openweaving fabrics
Tarpaulin Coating Line
PVC Coated Tarpaulines
Properties of Vinylidene Chloride Copolymer Films
Properties of VDC copolymer Films made
From Aqueous Latices and from Solutions
Lamination Methods
Direct lamination in cleander of two PVC Sheets
Lamination in calender of several sheets
Independent Lamination and Embossing
Laminating and Embssing Plant
Lamination and embossing of three PVC or PVC/ABS sheets
Embossing of wall paper coated with vinyl film
Roller Melt Process
Description of the Process
Application Carrier Materials
The Roller Melt Process is suitable for Recycling
Processable Raw Materials
Advantages of the Process

Process of Plasticised PVC

Processing of PVC Pastes
Dipping Process
Slush or Rotational Moulding
Blown Films
Moulding of PVC Footwear
Moulding
Flexible (Soft Plasticized) PVC Film
RECYCLING OF PVC
Plastics Waste Management Hierarchy
Coding as an aid to separation
Recycling of Short Life PVC Products
Bottles
Separation by Hydrocyclones
New Products from Recycled PVC Bottles
Prospects for Chemical Recycling of PVC
Tecoplast Bottle Plant
Service Life of PVC Products
Recyclable Vinyl
PVC Bottles, Jars and Containers
Design Considerations
Physical Properties
Marketing Consideration
Safe and Recycleable
Lower Mold Costs
SUPPLIERS OF RAW MATERIALS
PRESENT MANUFACTURERS
SUPPLIERS OF PLANT & MACHINERIES
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