Omyacarb : The way forward for enhanced sustainable production.

Transcription

1 Omyacarb : The way forward for enhanced sustainable production. Gil Morieras Director Marketing Asia Pacific Group Marketing Plastics Oftringen, Switzerland 23 May, 2015

2 Table of Contents Omya : A group at your service Calcium carbonate : Some information Product portfolio Advancements in : Thermoforming sheets Blow Molding Non Woven Raffia 2

3 CaCO 3 -Powder: most important properties Aspect Ratio = Shape Fineness Specific Surface Area Top Cut = Coarsest Particles Impurities Chemical composition Surface Energy = Surface Tension Hardness Color Refractive index Thermal properties Surface Treatment

4 Why Fine Treated Calcium Carbonates are you best choice?

5 Output Increase

6 Reduced Extruder Pressure and Torque

7 Product Portfolio 7

8 Filipinos Product Portfolio Fine treated CaCO3 Omyacarb 2T DC Omyacarb 2 - DC Omyacarb 1T DC Omyacarb 1 DC Special applications : Hydrocarb 95 T KU & Omyafilm CU Anti Blocking Masterbatches for Films Injection Molding Raffia Thermoforming Sheets Blow Molding Anti Blocking Masterbatches for Films Raffia 8

9 Advantages of GCC in Thermoforming Polypropylene thermoforming Sheets 9

10 Why use CaCO 3 for PP Sheet Extrusion? - Improved thermal conductivity - Faster melting in extruder - More homogenous melt - Faster sheet-cooling on calender rolls Faster Extrusion Line Speed - Low coefficient of expansion - Lower melt volume - Lower friction to barrel surface - Lower torque and die pressure Increased Extruder Output Rate (by volume) 10

11 CaCO3 in Thermoforming Sheets cycles per min Productivity improvements Thermoforming: cavities yoghurt beakers Cycle Time Reduction Thermal diffusivity in mm²/sec no sheet preheating with sheet preheating 12% & 35% more cycles (with & w/o pre-heating) Heat Transport HIPS virgin PP PP 30% CaCO3 PP 60% CaCO HIPS PPH 30% CaCO3

12 CaCO3 in Thermoforming Sheets Performance improvements Stiffness: CaCO 3 Enhancing PPH Stiffness E-Modulus in N/mm² E-Modulus Increase in CD & MD => 15% & 30% 0 30 % carbonate CD MD 12

13 CaCO3 in Thermoforming Sheets Performance improvements Impact Resistance: Weight in g Dart Drop Impact Resistance Improvements virgin PPH DDI Increase 250% (at same weight or at same gauge) 30% CaCO3 same thickness 30% CaCO3 same weight 13

14 CaCO3 in Thermoforming Sheets Post-Shrinkage / Orientation 30% CaCO 3 Virgin PPH 14 Thermoformed yoghurt cups after 30 min at 140 C

15 CaCO3 in Thermoforming Sheets Improved economics!!! Cost Saving with CaCO 3 in thermoformed PPH overhead & labour mould depreciation machine production & depreciation sheet cost Cost in % PPH 20% CaCO3 30% CaCO3 40% CaCO3 HIPS 15

16 Blow Molding The higher thermal conductivity and lower specific heat of calcium carbonate are key advantages in molding applications. Blow Molding Calcium carbonate is used in blow molding applications to produce bottles or containers by offering substantial benefits such as: Increased flexural modulus Sustained top load and drop impact Improved ESCR (Stress Cracking Resistance) Reduced cycle time Lower melt temperature Reduced titanium dioxide amount Improved printability Cycle time improvement 16

17 GCC in blow molding mechanical properties: top load 17

18 GCC in blow molding mechanical properties: Drop test Minimum Requirement 18

19 GCC in blow molding properties: ESCR 19

20 Nonwoven 20

21 Spunbonding nonwoven with mineral additive Wide range of application options for existing and new markets Hygiene Baby and adult diapers Female hygiene Medical Protective clothing Technical products Architectural nonwovens Coating substrates Agrotextiles & Geotextiles Filtration Disk covers Wipes 21

22 Spunbonding nonwoven with mineral additive Product Masterbatch spunbonding grade 70% Omyafiber, ultra fine special treated calcium carbonate Let down 2-5 % wt. as a mineral additive 7-18 % wt. as extender properties Cost & Benefit ratio Antiblocking Soft touch Cooling Elongation E-Modulus Antistatic Tenacity Dimensional stability Weldability Wind up speed Line Efficiency Productivity and formulation costs 22

23 Trials on Multifilament Lab Line Collin Multifilament Lab Line CMF 100 PP Moplen HP 561R (LyondellBasell), MFR = 25 Spinneret 115 mm with 100 filaments 0.35 mm No GCC 5 % GCC 15 % GCC 23

24 PP multifilament fibers containing CaCO 3 2 % GCC masterbatch 10 % GCC masterbatch 40 % GCC masterbatch Scanning electron micrographs (SEM) Fiber surface (top) & fiber cross section (bottom) 24

25 CaCO3 in PP Woven Tapes Calcium carbonate is conventionally used in PE or PP woven bags, weaving tapes or bands to offer antisplitting and anti-fibrillation effects. Polyolefin masterbatches based on appropriate calcium carbonate offer: Reduced splitting propensity of oriented polypropylene Increased stiffness Reduced amount of titanium dioxide Reduced raw material consumption Conventional calcium carbonate loadings are in a range of 2% to 30% in final articles. 25

26 CaCO3 in PP Woven tapes Advantages of using Omyacarb 2T in PP woven tapes : Achieve high filler loading in Masterbatches Optimized mineral dispersion (Low FPV) Prevent using waxes and lubricants which reduces WCO and Die build up Low humidity level in masterbatches Reduce WCO Increase life time for knives and increased screen pack change over time 26 Reduces dust accumulation (spinning and knitting)

27 CaCO3 in PP Woven tapes : Higher requirements For high speed line or high demanding applications, Omyacarb 1 T is the optimum solution Appropriate surface treatment to avoid Die build up during processing and dust accumulation Lower WCO : Speed could be increased Increased break compare to coarser grades. Improves post-weaving operation and production efficiency. Improve knitting process less yarn breakage Increase tensile strength thus enabling higher filler loading Higher tape surface smoothness 27

28 Cost Savings g/d % Dosage 15% Dosage 22% Dosage 30% Dosage Omyacarb 1T Omyacarb 2T Coarse Competitive 28 A finer product allows you to increase the CaCO 3 addition level maintaining mechanical properties (+3%)

29 Cost Savings Omyacarb 1 T Omyacarb 2 T Compounding Costs 50 Formulation PE 2000 Omyacarb 1T USD + 30 / Ton Omyacarb 2T 80% OM 2T % OM 1T Tapes with 22 % Omyacarb 2T 28% 1614 Tapes with 25 % Omyacarb 1T 32% 1559

30 Thank You 30