Improving the sustainability of thermoformed polyolefin food packaging through UPES interpolymer modification

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Laurence Cornelius Harris
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1 Improving the sustainability of thermoformed polyolefin food packaging through UPES interpolymer modification Presenter: Dr. Eric Vignola ASTM Committee D10 Workshop on Packaging October 12, 2010 San Antonio, TX

2 Outline Sustainability concepts Introduction to QINNEX technology & UPES interpolymer resin UPES resin modification of polyolefins HDPE PP LDPE Summary Acknowledgements

3 NOVA Chemicals and Sustainability We believe a sustainable business is a profitable and socially responsible business Our approach to managing health, safety, security, environmental protection and sustainability is implemented primarily through the principles of Responsible Care

4 Sustainability Development We support the United Nations definition of Sustainable Development meeting the needs of the present without compromising the ability of future generations to meet their own needs NOVA Chemicals is committed to the Triple Bottom Line approach to sustainability: Environmental, Social, Economic Environmental Sustainability Economic Social

5 Sustainable concepts The 3 R s Reduce Re-use Recycle Plus Renewable resources Recycle content End of life Lightweight Lower Carbon Footprint Reduced Volume Increased Durability

6 A product of The technology behind UPES resin delivers enhanced compatibility with various polymers systems and broadens the processing window of most polyolefins. An interpolymer made from Polystyrene (PS) and Polyethylene (PE), UPES resin offers the following: Variable ratio of the two polymers Different types of polyolefins can be used Can add different co-monomers Ability to vary of amount of cross-linking Where the two phases are compatibilized in situ

7 Polyolefin pellets Polyethylene Micro-pellets Suspension Polymerization extrusion Opaque / white beads 55 to 60 pellets per gram

8 UPES resin Interpolymer Morphology PE/PS Melt Blend PE/PS Interpenetrating Network

9 UPES resin Interpolymer Properties Properties (1) ASTM (2) UPES-090-EXP resin Tensile Strain at Break (%) UPES-170-EXP resin (1) Properties were determined on injection-molding specimens following the protocols of ASTM D4549 Standard Specification for Polystyrene Molding and Extrusion Materials unless otherwise specified. (2) The product properties designated in this standard have been determined in accordance with the current issues of the specified testing methods. Methods of the American Society for Testing and Materials (ASTM) are used wherever applicable. (3) Melt flow index at 230 C/2.16kg (446 F/4.76lb). a) UPES-090-EXP : Notched Izod specimen displayed partial break, un-notched specimen displayed torque and flex upon impact, but no break b) UPES-170-EXP: Notched Izod specimen displayed hinged break, un-notched specimen displayed indentation, but no break c) UPES-315: Notched Izod specimen displayed break, un-notched specimen displayed break UPES-315 resin D Flexural Modulus (psi) D Notched Izod (ft-lb/in) a,b,c D Un-notched Izod (ft-lb/in) Melt Flow Index (3) (g/10 min) D D Properties of UPES resin are tailorable

10 Shear Viscosity (Pa-s) Rheological Properties of UPES resin C PS1600 FP120-A UPES-315 resin Frequency (rad/s) Resin (Supplier) Melt Index (g/10 C/5 kg Melt Index (g/10 C/2.16 kg PS 1600 (INEOS-NOVA) FP-120-A (NOVA Chemicals) UPES-315 resin (NOVA Chemicals) UPES -315 resin offers: Improved processability Shear thinning properties

11 Collaboration throughout the Value Chain NOVA Chemicals :: resin PRIMEX :: sheet Tray-Pak :: thermoformed parts

12 Situation Polyolefin Thermoforming Challenges Warpage Increased sheet gauge required to deliver desired performance properties Poor material distribution Inefficient processing Difficulty achieving sustainable output rates

13 What is Thermoforming?

14 Deep Draw Produce Tray UPES resin/hdpe 50 mils HDPE Part 60 mils Increase in melt strength offered by UPES resin provides: 50 mils = mm 60 mils = mm Reduced gauge Better material distribution

15 HDPE/UPES resin 50 mils HDPE Property Modification HDPE 60 mils 0 s 15 s 30 s 45 s 60 s 75 s 90 s 105 s 120 s

Crush strength (psi) HDPE Property Modification 120 100 HDPE 60 mils HDPE/UPES 50 mils 103 80 60 40 44 140% increase 20 0

16 Crush strength (psi) HDPE Property Modification HDPE 60 mils HDPE/UPES 50 mils % increase 20 0 Increase in melt strength offered by UPES resin provides: Increased thermoforming throughput Improved part performance ASTM D 2659

17 UPES resin/hdpe blends vs. HDPE 20% source reduction 33% faster forming rates and shorter start-ups Increased machine time availability > 100% increase in mechanical properties Enhanced part definition Reduced scrap rates Recyclable

Flexural modulus (psi) Shallow Draw Institutional Tray 400 350 300 250 200 150 100 50 0 HDPE 25 mils HDPE/UPES

18 Flexural modulus (psi) Shallow Draw Institutional Tray HDPE 25 mils HDPE/UPES 20 mils 30 % 20% source reduction 30% increase in flexural properties 40% increase in throughput rates ASTM D 790

compared to HIPS & similar mechanical properties than HIPS PP/UPES resin

19 Polypropylene-UPES resin Lidstock HIPS is the incumbent Achieved 11 mil parts, previously unattainable with 100% PP Enhanced ESCR properties compared to HIPS & similar mechanical properties than HIPS PP/UPES resin parts weigh less than HIPS or filled PP parts at the same gauge Processability similar to HIPS

Density Tensile strength Tear strength Puncture Compression deflection Elongation Property % of Voltek Foam foam 1 UPES resin in LDPE based x-linked foams Voltek Foam 1 foam Youngbo Foam 2 foam

20 Density Tensile strength Tear strength Puncture Compression deflection Elongation Property % of Voltek Foam foam 1 UPES resin in LDPE based x-linked foams Voltek Foam 1 foam Youngbo Foam 2 foam Cellect Foam w/upes foam resin w/ IP-73-U (30%) Foam 1: 4.4 pcf (70 kg/m 3 ) Foam 2: 4.9 pcf (78 kg/m 3 ) Foam w/ UPES resin: 2.5 pcf (40 kg/m 3 ) UPES modified LDPE resin produces lower density foams with superior properties

21 Summary UPES resin is a tailorable product that can offer increased rheological properties, melt strength, compatibility and functionality Documented sustainability benefits: Lightweight Lower carbon footprint Reduced volume Increased durability Opinion letters available for food contact applications

Questions? Acknowledgments: Joseph B. Paolucci Shelly A. Martel Daniel C. Purpura Christine B. Hetzer H. T. Kemp For more information visit: www.upesresin.

22 Questions? Acknowledgments: Joseph B. Paolucci Shelly A. Martel Daniel C. Purpura Christine B. Hetzer H. T. Kemp For more information visit: UPES, QINNEX and their logos are trademarks of NOVA Brands, Ltd.; authorized use/utilisation autorisée. The information contained herein is provided for general reference purposes only. By providing the information contained herein, NOVA Chemicals Inc. makes no guaranty or warranty and does not assume any liability, with respect to the accuracy or completeness of such information, or product results in any specific instance, and hereby expressly disclaims any implied warranties of merchantability or fitness for a particular purpose or any other warranties or representations whatsoever, expressed or implied. Nothing contained herein shall be constructed as a license to use the products of NOVA Chemicals Inc. in any manner that would infringe any patent. Nothing herein shall be copied, reproduced, distributed or otherwise used without the express written permission of NOVA Chemicals.

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