Solanyl C2 grades. Solanyl C2 grades are developed for extruded sheet or profile applications.

Transcription

1 PROCESSING GUIDELINE SHEET / PROFILE EXTRUSION are developed for extruded sheet or profile applications. are biodegradable granulates based on reclaimed potato, grain, root or seed flour based resources. Version 01 / Date For general product information, please refer to our technical datasheets. Our technical services department is available to discuss your requirements and advise on the best grade selection for products & (color) masterbatches. WHAT IS SOLANYL? Solanyl is a group of products consisting of a smart series of biobased and biodegradable end compounds, suitable for direct conversion by the various known techniques. The Solanyl portfolio is special tailored for various converting methods and is a renewable alternative for various petroleum-based plastic applications, e.g. PS, PP, PE and PVC. The compounds can be used directly for the production of bioplastic products with most common converting methods with respect to injection molding, sheet and profile extrusion, thermoforming and extrusion film casting or blowing products and processes. APPLICATION: EXTRUDED SHEETS, PLATES OR PROFILES are end compounds suitable for extrusion applications and is specially developed to obtain a complete portfolio of bioplastics with properties like synthetic plastics designed for rigid or flexible products, PS, PVC, PE or PP. can be processed on most conventional extrusion lines suitable for (multi-layer) sheets, plates or profiles, typically with thicknesses in the range of 0,3 mm 5 cm. are competitive alternatives for currently used biodegradable plastics and polyolefins for a wide range of applications. have a natural feel and look. are biodegradable having a high biobased or plant derived material content. Applications in which can be used are: Consumer goods Agriculture products Packaging Agriculture products Thermoform applications Cups, boxes & trays Plates and sheets Groundwork applications like pipes Extruded profiles FIGURE 1 From reclaimed potato starch from the French fries industry to Solanyl bioplastic granulates. FIGURE 2 Typical product examples made with Solanyl extrusion grades.

2 are developed for rigid or flexible applications. offer the opportunity for The data listed have been established on standardized test specimens under standard temperature and humidity conditions. The data and figures should be regarded as guide values only and should not be used in preparing end specifications. The properties given must be regarded for guidance purposes only, since product is based on renewable raw materials with fluctuating properties by nature. Under specific conditions the properties can be influenced to a large extent by the processing conditions applied. Figures Consequently the material has to be processed in accordance with our guidelines. low temperature easy processing. PORTFOLIO The basic portfolio of the consist of several end compounds with properties like PS, PVC, PE or PP. Because Solanyl consist of oxygen based polymers the characteristics are different from synthetic oil based plastic such as polyolefines. As a result will show differences in processing behavior & product features. Dedicated types or specialty grades can be made available as well. New grades our continuously developed, such as grades with higher heat resistant, improved melt flow, impact strength, higher biobased as well as lower costs varieties. OVERVIEW STANDARD C2 GRADES The main standard Solanyl C2 products are shown in the table with indication of main characteristics. The various grades show differences in melting and crystallization behavior, which will be reflected in differences in optimal processing temperature profiles and characteristics such as flow, shrinkage and thickness. In the figures a rough estimation is shown of some mechanical properties. C grade Alternative Attributes MFI & Standard grades C2101# * LDPE High flexibility, soft 2-6 C2201# * PS Rigid 3-7 C2204 PE, PPcopol Flexible, high impact & tearing 3-8 C2001 HIPS, PP like Rigid, improved impact, glossy 2-6 C2002 HIPS, PPcopol, rigid PE Plasticizer free, good impact 2-7 C2003 PS, PP Plasticizer free, enhanced biodegradation 2-6 Special grades SPxxx@ On request Dedicated specific processing & properties # Vinçotte OK Biobased certified. * Vinçotte OK Compost under development. & MFI is indicating function of water content: MFI is measured at T above the processing T and as such are indicating flow & cannot directly be compared with polyolefines. ADDITIONAL INFORMATION This information is intended for use only as a guide for the extrusion of films of the mentioned Solanyl C2 grade polymers. The document contains generalized information for safety, processing guidelines and tooling. If are used in applications other than those mentioned above the choice, processing and use of Solanyl is the sole responsibility of the purchaser. All legal and other regulations must be complied with. Since extruded films covers a broad range of applications and products, an experimental approach at your facility will have to be completed to determine what tooling and mode of operation will work best. Testing of the end products is also recommended in order to make sure it meets customer requirements. PACKAGING Packaging; 25 kg bags, 1000 kg octabins. Identification: Grade name, Lot nr. and production location.

3 Version 01 / Date Solanyl C2 is developed for extrusion applications. Solanyl C2 is a sustainable alternative for oil based plastics. MELT PROCESSING & START UP CONDITIONS Before starting up production and introducing Solanyl C2, the processing system should be thoroughly cleaned and purged to prevent any polymer cross contamination. Insure that the feeding and blending equipment is properly cleaned and free from contamination and dust and all metal parts have been wiped clean. The following purging procedures are recommended for optimal removal of other polymers, in particular high melting and low MFI polymers such as PA, PP and PET. 1. Purge with a polymer like LDPE or EVA or PS at normal operating temperatures. Purge as necessary, at least minutes. Let system empty as much as possible. Clean out the hoppers completely. 2. Introduce an adequate transition polymer, e.g. a high melt flow, low melt temperature LDPE or EVA or PS (>5 MFI), purge and change to the for the specific grade advised Solanyl operating temperatures (see further-on in this document). If the transition polymer has relatively high viscosity at these temperature settings keep the die temperature at a higher level close to the indicated maximal processing T for the respective Solanyl grade. Purge minutes as long as necessary to clean out the system. Let system empty. Reduce the temperature further to the advised settings. Completely clean all hoppers, elbow, slide gates, dryers, hopper loaders bins, hopper loader, filters and material conveying lines of residual polymers such as PET, PA, HDPE or PP. 3. Solanyl is preferably run without filter systems. Low MFI PE, PA, PET and PP will not flow or melt sufficient at normal processing temperatures for Solanyl and potentially can block the filter as such. 4. Load Solanyl into material handling system. Transition to purge Solanyl and purge with open nozzle until melt is clear of any contamination. Keep the output and torque during transition relatively low. We recommend to change the filter or screen before production when present. Run at relative low output and torque conditions during the transition, too avoid pressure build-up by polyolefin. 5. Immediately after completion of the production run, purge Solanyl from the extrusion system, using a moderate to low melting temperature, low MFI PE. At start-up material can be metered with an open die and if necessary adjustments to screw speed, back pressure and temperature profile can be made to arrive at even feeding. No obvious discoloration compared to pellet color should be observed and the material should exit the barrel as a uniform melt. Discoloration of the material indicates that this combination is incorrect (leading to shear rates being too high). When metering with an open nozzle into free air, small clouds of fume (water vapor), could emerge from the nozzle depending on Solanyl grade (p.e. C2101, C2201, C2204). This is normal behavior for these Solanyl C grades. This is not the case for other types such as C2001 which is vapor free. PRE-TREATMENT AND DRYING Some, i.e. C2101, C2201, C2104 require some moisture (bonded to the thermoplastic starch) to enable melting and to ensure the flow properties during processing. These have been preconditioned during manufacturing to the correct moisture content before packaging. Therefore these specific Solanyl C2 grades are not to be dried for standard applications or uses. Drying will affect processing and properties. Important: do not pre-dry Solanyl C2101, C2201, C2104 before processing! Some, i.e. Solanyl C2001, preferably are run at moisture content below 250 ppm. Moisture content can start hydrolysis! Residual moisture content can result in lower melt stability, bubbles and lower properties during processing. Solanyl C2001 is packaged during manufacturing to keep moisture low. However (off- or in-line) pre-drying will improve properties & is recommended before processing. A moisture content of less than 0,025% (250 ppm) is recommended to prevent hydrolysis and loss of properties. Typical drying conditions are 4-8 h at 45ºC or to a dew point of -35ºC, with an airflow rate greater than 0,5 l/s per kg of resin throughput. Sufficient agitation is needed to prevent blocking during drying. In addition, once the material is dried, it preferably is conveyed to the extruder with dry air to keep the compound from regaining moisture. All the blending and holding hoppers preferably are sealed to keep a dry environment for the compound.

4 are developed for rigid or flexible applications. offer the opportunity for The data listed have been established on standardized test specimens under standard temperature and humidity conditions. The data and figures should be regarded as guide values only and should not be used in preparing end specifications. The properties given must be regarded for guidance purposes only, since product is based on renewable raw materials with fluctuating properties by nature. Under specific conditions the properties can be influenced to a large extent by the processing conditions applied. Figures Consequently the material has to be processed in accordance with our guidelines. low temperature easy processing. DEGRADATION (HYDROLYSIS) Please note that several have a degradation temperature of C depending on type. The possibility of degradation of the natural components in Solanyl C exists during prolonged exposure to elevated temperatures. When the machine is idle and Solanyl C is present in the barrel, idle times should not exceed 5-10 minutes. Prolonged idle times, even at the proposed temperature profile, can lead to a significant decrease of product quality. When longer idle times are foreseen, we strongly suggest purging the barrel to prevent loss of dosing properties and overall material quality. Symptoms of degradation are: Chewing gum effect in the first phase, then increase of brittleness and increased discolouration or beige/brownish burning spots will occur. Preferably the feed zone is not to be overfed and cleaned out and cooled during prolonged idle times to avoid degradation and blocking of the feed zone. EXTRUSION MACHINE RECOMMENDATIONS Solanyl C2 extrusion grades cab be processed on most conventional single-screw extrusion lines with standard screw settings but there could be some torque limitations if the screw design has a high compression ratio. Compression ratios of 2-3 are in general considered to be adequate for. Preferred screw design is a PS or PE type. Processing on double-screw PVC lines is possible as well in most cases. However processing will deviate from standard conditions and specific conditions should be discussed with our technical service department. Products can be processed with barrier elements like with a Maddock element and filter screens, although high shear conditions are not needed and preferably avoided. Standard screen pack configurations can help to protect melt pumps and dies from incidental contamination that may occur during material handling. Screen mesh sizes of mesh are generally sufficient. Finer filtration leads to excessive shear & heating and should be avoided. process well on mono and co-ex lines. Temperature profiles during extrusion are typically lower than conventional polymers, providing energy savings for the converter. The residence time of Solanyl material in the barrel at temperatures over 170 should be kept low. It requires to rule out the remain material in the barrel in order to avoid discoloration, decomposition, charring and plugging the die head. FIGURE 3 A comparison of mechanical properties of some Solanyl extrusion grades. FIGURE 4 Viscosity profile of Solanyl extrusion grade C2201 at 160ºC. Please note that more grades with a variety of properties are available.

5 Version 01 / Date Solanyl C2 is developed for extrusion applications. Solanyl C2 is a sustainable alternative for oil based plastics. PRE-TRIAL QUESTIONNAIRE Before doing your trials we would like to ask you to fill-in a pre-trial questionnaire as shown below. With this questionnaire we are able to give a customized processing advise and to address possible difficulties for processing Solanyl. Please ask for a Microsoft version of this questionnaire. MATERIAL SAFETY DATA SHEETS Material Safety Data Sheets (MSDS) for are available for all grades of resin products which Rodenburg Biopolymers produces. Material Safety Data Sheets are provided to help customers satisfy their own handling, safety and disposal needs, and those that may be required by locally applicable health and safety regulations, such as OSHA (U.S.A), MAK (Germany), or WHMIS (Canada). CHEMICAL CONTROL LAW COMPLIANCE Across the globe regulations exist for local environmental authorities to evaluate materials to assure the protection of human health and the environment from any unreasonable risks associated with chemical substances. Components used in Rodenburg Biopolymers resins as supplied from the factory gate comply with the European Union (EINECS)/REACH chemical inventory. TRANSPORT, STORAGE AND SHELFLIFE must be stored in closed packaging in a cool dry (no condense sensitive) place, out of direct sunlight and protected against humidity. Changes in moisture content (either loss or gain depending on atmospheric conditions) should be avoided during longer term storage. During production, open bags or silo s must be avoided during production and storage (reseal bags). In the case of outside storage, if the product is supplied in boxes or other nonbulk containers, the unopened container should be brought into the extrusion production area and allowed to equilibrate for a minimum of 4 hours before opening to prevent excessive condensation. Storage time should not exceed 1 year after date of production of the granulate.

6 are developed for rigid or flexible applications. offer the opportunity for The data listed have been established on standardized test specimens under standard temperature and humidity conditions. The data and figures should be regarded as guide values only and should not be used in preparing end specifications. The properties given must be regarded for guidance purposes only, since product is based on renewable raw materials with fluctuating properties by nature. Under specific conditions the properties can be influenced to a large extent by the processing conditions applied. Figures Consequently the material has to be processed in accordance with our guidelines. low temperature easy processing. RE-USE & COMPATIBILITY The leftover materials can be reclaimed and reprocessed if they are free from dust and contamination. Recyclability: clean waste can be shredded or re-granulated (typically up to 5-15%) and used with virgin material. However, the leftover materials should be collected, shredded and sealed quickly in order to avoid humidity absorption. Addition levels should be controlled within a reasonable and constant addition range. It is strongly recommended that the reclaiming materials will be reprocessed to grains in good time. Pre-drying to appropriate moisture levels before reprocessing would be needed if the reclaiming materials have been stored without sealing. The leftover materials should be stored sealed in a dry cold environment. The are compatible and can be mixed and can as such be used as combinations. TEMPERATURE PROFILE AND PROCESSING Typical extrusion conditions are described in the next sections below. Products made with Solanyl C2101, C2201, C2002, C2003 & C2204 result in a nontransparent, opaque or yellowish or beige product with a natural soft feel. Products made with Solanyl C2001 result in a glossy more ivory or translucent (depending on thickness and process) product appearance. Properties may depend on water content, humidity, processing and thickness. Prospective clients should evaluate in their own laboratories to establish optimal conditions for use in their processes and applications. Solanyl can be colored with biodegradable masterbatches. Solanyl C2101, C2201, C2002, C2002 & C2204 are printable without any pre-treatment. Solanyl C2001 needs similar handling as PLA (polylactide acid) type products. Overheating of products should be avoided. Before production, make sure that all temperatures zones work correctly. Do not allow material to remain hot inside the extruder for extended periods as the material can degrade. Therefore, do not heat products over indicated maximal process temperatures for long times and not over 160 C when machine is not running. FIGURE 5 Typical product examples made with Solanyl C2 extrusion grades.

7 Version 01 / Date Solanyl C2 is developed for extrusion applications. Solanyl C2 is a sustainable alternative for oil based plastics. The suggested regular temperature profile (from inlet, feed to melt zones to the die) consists in most cases of a gradually increasing temperature to higher temperatures at the die. However, the profile may depend on extruder type & design, die type & design and also on type of product made. Therefore always communicate with our technical department details and use our pre-trial questionnaire. Most of the are rather soft or low Tglass granulates and too avoid sticking in the inlet it advised to cool the inlet. The inlet should be kept cold, below 35 C for the C2101, C2002, C2003, C2102 and C2204 grades. Inlet of the C2001 grade is preferably done at C. The optimal temperature is depending on the screw design features of the inlet zone. It is advised to avoid overfeeding the inlet zone. This is in particular important during start-up. In the table the suggested profiles for a screw with various heated zones are tabulated for the various grades. The suggested profile is intended as a starting point. If flow and processing is good it is possible to reduce the temperature settings. If the flow of the material needs to be improved or gel particles or die lines appear with a particular product, there is the possibility to increase the temperature. We strongly recommend you to apply the decrease or increase to zones 3 and 4 first with steps of 5 C and evaluate the result. Depending on C-grade type of product it advised not to exceed the maximal processing temperature. Typical processing conditions are tabulated below. Data presented was generated using various standard laboratory and industrial equipment. Using different machineries with differences in screw, output, smaller dies and die design can lead to differences in optimal conditions. Differences in die gap will creates changes in orientation in the machine direction. Thus: Processing can vary with type of equipment used. Data are as such indicating conditions for processing. During production excessive shear induced material heating should be avoided as much as possible. When during continuous production, an emergency stop occurs, it is advised to reduce the extruder barrel T to about ºC to avoid degradation of Solanyl C. During restart temperatures can be increased and further processing can be started with open die first to clean screw. ADDITIONAL EQUIPMENT INFORMATION Materials described in the tables below were all run on a laboratory Collin ZK 50 single screw extruder (30 mm diameter, L/D=25 with 6 heating zones, water cooled). The system has no degassing, melt pump or filter. Motor power 4,4 kw. PE screw with Banbury dispersion barrier element. The line has a sheet die and a water-cooled 3-roll calander. 30 rpm (0-120 max.) Die gap mm Die width range 8-10 or cm 2-15 kg/h output. C2 grades have been run on other industrial scale equipment as well including melt-pump, degassing and filter systems. The data shown are indicative for various machineries. Several commercial lines have extruder screws optimized to run polyolefins at the maximum output for the screw diameter. Due to the different rheology Solanyl, they do not shear thin as readily and therefore could require additional power input from the drive. This additional power input could manifests itself as an excessive increase in melt temperature, which could limit screw speed limited to be able to avoid excessive increase in melt temperature.

8 are developed for rigid or flexible applications. offer the opportunity for The data listed have been established on standardized test specimens under standard temperature and humidity conditions. The data and figures should be regarded as guide values only and should not be used in preparing end specifications. The properties given must be regarded for guidance purposes only, since product is based on renewable raw materials with fluctuating properties by nature. Under specific conditions the properties can be influenced to a large extent by the processing conditions applied. Figures Consequently the material has to be processed in accordance with our guidelines. low temperature easy processing. C grade Temperature in ºC Standard Inlet section Feed Zone 1 Melting Zone 2 Metering Zone 3 Die head Maximal process T ideal T melt or material C C C C C C Special grades SPxxx@ Data on Under development: data are provisional subject to optimization. Please note that Solanyl C has a degradation T lower than for typical polyolefins. Prolonged idle times, even at the proposed temperature profile, can lead to a significant decrease of product quality. Monitor melt temperature continually. One should use sufficient cooling for extruder and forming equipment (calander, thermoform etc..). Reducing the output in combination with screw speed could help in keeping melt T under control. The melt is softer than most polyolefins when emerging from the die. The products need some time to get their final properties. Some property changes can occur after production due to for instance recrystallize or changes in water content due to changes in humidity. C2 grades have higher die swell and lower shrinking then polyolefins which could make further downstream converting different. To increase the surface quality of the product it may be needed to use low cooling temperatures during shaping products such as sheets or plates with low calander temperatures. Because of the limited shrinkage it can lead to different size of formed products such as tubes compared to polyolefin based products such as PP and PE. The tension control through the web path has to be controlled well and all driven rolls must be maintained in top working condition. If the product is edge trimmed or slit, sharp knives or rotary shear trimming wheels are preferred to prevent breaks. MELT-PUMP For single-screw extrusion systems, melt pumps can in most cases be used for sheet or shape profile consistency. When using a melt or gear pump system, the suggested T at the melt pump is C depending on C2 grade. Again, as with the suggested temperature profile, these temperatures are intended as starting point. Low viscosity grades such as C1201, or with some grades where no degassing can be applied, are preferably run without a melt-pump because these materials have a very low viscosity the tresh-hold pressure control setting should be adjusted. FILTERS Standard screen or filter pack configurations can be used to protect melt pumps and dies from incidental contamination that may occur during material handling. Screen mesh sizes of are generally sufficient. Finer filtration leads to excessive shearheating with Solanyl and should be avoided. Because of the viscous nature of Solanyl some pressure build can be reduced by having a 0-10ºC higher temperature at the filter compared to the mass temperature.

9 Version 01 / Date Solanyl C2 is developed for extrusion applications. Solanyl C2 is a sustainable alternative for oil based plastics. DEGASSING The use of degassing can help in optimisation the processing and properties of. In particular in the case of open product forming techniques water vapor will be reduced (for instance in cast sheet or thermoforming). For the C2201 atmospheric degassing is advised, due to the relative low melt viscosity the product can be pushed out when using vacuum. The other grades preferably use vacuum degassing. GENERAL CHARACTERISTICS & OTHER INFORMATION Solanyl compounds are compatible with most bio-masterbatches containing chain extenders, such as Joncryl (BASF), impact modifiers and various color master batches, in particular those designed for PLA or starch containing products. To enhance processing and product features, typically anti-block and anti-slip master batches can be used based on biopolyesters and designed for starch or biopolyester based products such as Basf Ecoflex SL1 and AB1. Solanyl compounds are not compatible with synthetic or oil based master batches. It is not necessary to have a Corona treatment before printing or lasering for the C2101, C2204, C2002 and C2201 grades. The C2001 grade can be printed similar as advised for PLA. Sheets show good sealability & welding. STORAGE FINISHED PRODUCTS Storage conditions: Sheets on rolls and other finished products best are stored dry and cold or room temperature. It is recommended to seal goods in black PE films to protect them against moisture and UV radiation. In any case we recommend to use products as soon as possible and not to store them for long time periods (> 6-12 months). Storage time depends on processing parameters and on climate conditions in the respective area. Because of these essential and complex interacting parameters, Rodenburg Biopolymers cannot give any shelf life guarantees for finished goods. The conditions mentioned relate to our customers experiences. Each customer should execute individual storage tests according to product specifications and storage requirements. DISCLAIMER This information and technical advice is whether verbal, in writing or by way of trials offered solely for your consideration and verification and should not be interpreted as a guarantee of representation for which Rodenburg Biopolymers assumes legal liability, except to the extent that such liability is imposed by legislation and cannot be excluded. This also applies where proprietary rights of third parties are involved. This advice does not discharge customers from the obligation to undertake their own determination of the product s suitability and completeness for their intended processes and use and to check its validity and to test Solanyl products. In using Solanyl products you must establish yourself the most suitable formulation, production method and control tests to ensure that the uniformity and quality of your product complies with all applicable laws. The application, use and processing of the products and the products manufactured by you on the basis of this technical advice are beyond Rodenburg Biopolymers control and are therefore entirely your own responsibility. Rodenburg Biopolymers reserves the right to make improvements or amendments to the composition or any grade or product without alteration of the product code. Rodenburg Biopolymers products are sold in accordance with our General Conditions of Sale & Delivery.

10 are developed for rigid or flexible applications. offer the opportunity for The data listed have been established on standardized test specimens under standard temperature and humidity conditions. The data and figures should be regarded as guide values only and should not be used in preparing end specifications. The properties given must be regarded for guidance purposes only, since product is based on renewable raw materials with fluctuating properties by nature. Under specific conditions the properties can be influenced to a large extent by the processing conditions applied. Figures Consequently the material has to be processed in accordance with our guidelines. low temperature easy processing. CERTIFICATION Presuming appropriate processing, the composition of comply with EC Plastics Regulation 10/2011 and as such has potential to be used in the EC countries for materials or articles according to article 3 of Regulation EC No 1935/2004 on materials and articles intended to come into contact with food and repealing Directives 80/590/EEC & 89/109/EEC and FDA food contact standards codes of federal regulations CFR 21. Compliance with the provisions of these regulations, especially the suitability of the articles for the given application, the effect on smell and taste of the food, and observance of any given limitations, must be ensured by the person who introduces the articles into circulation. The specific restrictions mentioned in EC Plastics Regulation No 10/2011 and amendments have to be ensured. Migration should be measured on finished articles placed into contact with the foodstuff or appropriate food simulants for a period and at a temperature which are chosen by reference to the contact conditions in actual use. All Solanyl C2 grade comply with EN13432 (industrial composting). Solanyl C2101 and C2201 are certified according to Vinçotte OK Compost and Vinçotte OK Biobased. For more information and product specifications please contact: Rodenburg Biopolymers WARRANTY Solanyl is a registered trademark. The info contained in this publication is true & accurate, to the best of our knowledge, but any recommendations or suggestions which may be made do not constitute a guarantee, since the conditions of use are beyond our control. Furthermore, nothing contained herein shall be construed as a recommendation to use any product in conflict with existing patents covering any material or its use. The info refers to the laws, regulations & products at the date of issue. However, Rodenburg Biopolymers makes no express or implied representations or warranties with respect to the information contained herein. It is the responsibility of our customers to determine that their product is safe, lawful & technically suitable for their applications. Because of possible changes in the laws & regulations, we cannot guarantee that the status of the products will remain unchanged. Denariusstraat RC Oosterhout PO Box CB Oosterhout The Netherlands T +31 (0) F +31 (0) Rodenburg Biopolymers is a trade name of RB Biobased Institute B.V.