High Heat Performance Ingeo Food Serviceware Introduction: Nicole Whiteman, NatureWorks Case Study: Hsiu Mei Chen, UNIC Technology Corporation

Transcription

1 High Heat Performance Ingeo Food Serviceware Introduction: Nicole Whiteman, NatureWorks Case Study: Hsiu Mei Chen, UNIC Technology Corporation NatureWorks LLC

2 Users Seek Compostable Alternative to PS, PP Lid accompanying compostable coffee cup Cutlery accompanying compostable plate, bowl Drop-in to manufacturing processes NatureWorks LLC

3 Why is Ingeo Different? Stiff like PS at room temperature Ingeo and PS are both stiff when below Tg High melting point like PP Ingeo and PP are both crystallizable Molded Ingeo has two forms as a function of processing Amorphous and stiff when below Tg --without adjusting process Crystallize by innovative processing including warming above Tg NatureWorks LLC

4 High Heat Food Serviceware? Storage Modulus, MPa amorphous 2003D HIPS PP Temperature, C NatureWorks LLC

5 High Heat Food Serviceware? Storage Modulus, MPa Good range amorphous 2003D HIPS PP Temperature, C NatureWorks LLC

6 10000 High Heat Ingeo Food Serviceware: Crystalline not Amorphous Storage Modulus, MPa Good range amorphous 2003D HIPS PP crystalline 3100HP Temperature, C NatureWorks LLC

7 Quiescent Crystal Growth Rate as a function of Temperature for L-PLA* Collected G(T) for PLLA (scaled) G(T)- scaled um/min Data from Runt, DiLorenzo,Miyata, Abe, and Vasanthakumari. All adjusted with Go (only term needed for mol wt) to match Runt ( um/min) at peak. Abe fot T<145C only. Thirteen PLLA samples total. Runt DiLorenzo Miyata-high Miyata-med Miyata-low Fit Vasanthakumari-A-D Abe-A,B,C,D Temp (C) * Kolstad, J., Spherulitic Growth Rate of PLLA : Brief Literature Review, 21 October NatureWorks LLC

8 Optimal Crystallization Processes Stress induced crystallization High speed orientation above Tg Annealing nucleated and fast crystallizing grade above Tg Mold temperature (TF, IM) of ~120 C Quench to room temperature, reheat ~120 C Amorphous injection molded parts crystallized in heat tunnel Amorphous sheet partially crystallized in oven before thermoforming NatureWorks LLC

9 Some Options for Nucleating Agents Old and still reliable Talc, quenching and reheating, also reinforcing filler Ethylene-bis-stearamide, only for reheating New and efficient Takemoto Oil & Fat LAK-300 Nissan Chemical EcoPromote NatureWorks LLC

10 Grades More Commonly Used in Food Serviceware Jan In Development 4032D 2003D 4060D Increasing MW In Development In Development 3001D 3251D 3052D In Development Increasing D-isomer level 4032D and 3001D part of High Heat Ingeo Plastic Food Serviceware NatureWorks LLC

11 Jan Expanded Ingeo Portfolio with High Productivity grades 2500HP 4032D 2003D 4060D Increasing MW 3100HP 3001D 3052D 3260HP 3251D In Development Increasing D-isomer level HP grades with very low D-isomer content will have significant impact on physical properties NatureWorks LLC

12 1E+04 1E+03 Improvements in Heat Resistance Ingeo HP Grades ~ 15 C Higher HDT 3100HP +1% LAK D +1% LAK-301 Stiffness 1E MPa HDT estimate ~15 C HDT improvment HP 1E Temperature, C NatureWorks LLC

13 And, improvements in the cycle time required to get heat resistance Existing Ingeo Grades New High Productivity Ingeo Grades: 3x faster Temperature, C NatureWorks LLC

14 Improved Stiffness for Heat Resistant Ingeo Parts E, MPa Modulus of Crystalline Ingeo for Temperature Range of Hot Foods Temperature, C ~40% increase nucleated 3100HP nucleated 3001D NatureWorks LLC

15 Innovating for Higher Heat Serviceware Adapting manufacturing processes to include annealing Hot mold or heat tunnel New faster crystallizing grades still require additive modification Improve cycle times Improve stiffness and heat distortion temperature Case Study Partner, UNIC Technology Corp Evaluate new HP grades substituting into already commercial Ingeo 4032D formulation NatureWorks LLC

16 HP grade Performance in CPLA Heat Resistance Demand Pooling Feb, 2013 UNIC TECHNOLOGY CORP.

17 Agenda Company Introduction CPLA Formula comparison Conclusion Demand Pooling

18 Group highlight Founded 1976 Revenue US$260M/2012 Headquarter Taipei, Taiwan Public in OTC May, 2000 Factory Taipei, China SH & DG, Malaysia, Thailand Products Plastics, Optical material Demand Pooling Employee 700 Capacity Resin Coloring 7,000mts/M Compounding 3,000mts/M

19 Demand Pooling Milestone 1976 Founded in Taiwan 1990 Started ABS Business cooperation with Cheil Industries Inc. (CII) 1993 Started business with Philips Monitor BU 1994 ISO 9002 Certified 1995 Started business with Compaq, IBM 1996 Set up coloring factory in Malaysia 1997 Started business with HP, Dell 1998 UNIC Thailand set up 1999 UNIC Suzhou (SZ) set up 2000 UNIC DongGuan (DG) set up 2000 Listed company at OTC 2002 ISO 9001: 2000 certification for Cheil Taiwan, UNIC Suzhou, UNIC Dongguan and U-Bon Malaysia, Thailand 2002 Cooperate with Hyundai Engineering Plastic Co., Ltd. for Automotive Business in China 2002 Cooperate with Mitsubishi Engineering Plastic Corp. for N/B business 2003 New compounding factory in Suzhou, China 2005 UNIC being NatureWorks authorized distributor 2006 Set up JV company ( Cheil Advanced Materials ) with Samsung Cheil for China biz 2010 Expanded to Optical/Touch panel market film and adhesive 2010 Established U.S. Biopolymers for PLA food ware selling

20 Group highlight Founded 1976 Revenue US$250M/2008 Headquarter Taipei, Taiwan Public in OTC May, 2000 Factory Taipei, China SH & DG, Malaysia, Thailand Products Plastics agent & production Demand Pooling Employee 700 Capacity Coloring 7,000mts/M Compounding 3,000mts/M

21 Asian Sales & Logistics Support Asian Presence Compounding Factories Tainjing Suzhou Wuhan Fuzhou Taipei Taiwan Seremban Chonbury Suzhou Dongguan 1,500MT/M 1,500MT/M 1,000MT/M 4,000MT/M 1,000MT/M Demand Pooling After expansion Taiwan Seremban Chonbury Suzhou Dongguan 2,000MT/M 2,000MT/M 2,000MT/M 8,000MT/M 2,000MT/M DongGuan Chonbury Seremban Offices Taiwan Seremban Chonbury Suzhou Dongguan Fuzhou Tainjing Wuhan Cross-Region Support

22 Company Vision Focusing on General Plastics Market Expanding Bioplastics Market Developing Worldwide Market for General Plastics and Bioplastics Demand Pooling

23 Major Market for Bioplastics Material Demand Pooling Foodware Industry Paper Coating Thermoforming Consumer Electronic Parts and Accessories

24 CPLA Formulation Comparison UNIC offers a proprietary CPLA composition based on 4032D Evaluated 2500HP and 3100HP in this proprietary CPLA composition Demand Pooling Composition of additives and injection molding conditions were previously optimized for the 4032D formulation

25 Dry Formulations Provide Consistent Quality Demand Pooling All compounds compared were well dried 4032D formulation 2500HP formulation 3100HP formulation ppm Moisture

26 Standard Conditions Optimal for 4032D Formulation Standard molding conditions include 125 C mold temperature 35 second cooling time 54 second cycle time Demand Pooling New formulations can be molded the same as the standard base Good parts produced using same molding conditions For 4032D, 2500HP, and 3100HP formulations

27 Optimization of molding conditions maintaining 125 C mold temperature cooling time, s cycle time, s Demand Pooling D standard 2500HP optimized 3100HP optimized

28 For HP Grades, effect of 10 C mold temperature reduction cooling time, s cycle time, s 20 Demand Pooling D, 125 C 2500HP, 115 C 3100HP, 115 C

29 Maintaining 125 C mold temperature, effect of 10% regrind cooling time, s cycle time, s Demand Pooling HP no regrind 2500HP 10% regrind 3100HP no regrind 3100HP 10% regrind

30 In Conclusion: Demand Pooling - In the same injection condition Total cycle time remains the same - In the optimized condition Total cycle time decreases for both 2500Hp and 3100HP. 3100HP has a major decrease - In the 10C Lower Mold Temp Total cycle time decrease for both 2500HP and 3100HP - With 10% regrind Total cycle times remain the same

31 Major Improvement: Original CPLA formulation is 4032D plus some additives including mold release. Demand Pooling BUT can use 3100HP formula without mold release, which means a Cost Reduction!

32 Demand Pooling Thank You!