Croda s Guide to Sustainable Polymers

Transcription

1 Reasons to buy l l l Efficient energy consumption Reduced environmental impact Bio-based additives for use in biopolymer applications Croda s Guide to Sustainable Polymers Innovation you can build on TM

2 Croda s Guide to Sustainable Polymers Environmental trends are moving towards sustainable, renewable products which have minimal impact on the environment. Croda is committed to delivering high performance products that meet the needs of our customers whilst ensuring our activities have minimal environmental impact. This brochure is split into 4 sections and details the following topics: l How our additives can reduce energy consumption l Our range of bio-based materials l Products suitable for use in biopolymers l Our green credentials Process Improvements Many of Croda s Polymer Additive products provide significant process improvements, including: l Increased output l Improved polymer flow l Easier processing l Reduced processing temperatures and pressures l Decreased friction and mold release force l Reduced wear on equipment l Fewer rejects and waste Case St udy Increased Production Efficiency With IncroMold S A customer approached Croda for help to reduce cycle time when injection molding black HIPS TV parts. The part weighed 286 g and involved a 50 second cooling phase. The customer was able to produce 38 parts per hour when using a silicone spray every 3 shots. Croda recommended adding IncroMold TM S at a level of 0.4%. The customer found that they no longer had to use the silicone spray to remove the part from the mold, which allowed for a continuous production process. IncroMold S improved polymer flow, resulting in a reduced cooling time of 45 seconds (a 10% improvement). The overall result was an increase in production to 47 parts per hour or a 23% increase in product efficiency and a cost saving for the customer. All of these benefits result in reduced energy consumption and can often mean a cost saving. Case St udy IncroMax TM 100 functions as a slip additive and processing aid for PET by reducing internal friction. It also provides an increased output of the polymer when processing at lower extruder speeds and temperatures. Such processing improvements result in lower energy required to extrude PET which in turn provides cost savings for your business. Energy Saving For a processor using 10,000 tonnes of PET resin a year, the inclusion of just 0.3% IncroMax 100 can reduce the amount of energy required for extrusion by 40% when processing at 275 ºC. Annual energy for processing PET: 9.9 million MJ Annual energy for processing PET + 0.3% IncroMax 100: 5.9 million MJ Energy saving = 4 million MJ Cost Saving The above energy savings which are the result of adding IncroMax 100 to PET during processing translates to annual cost saving of 20,000.* Processing cost for PET = 495,000 Processing cost of PET + 0.3% IncroMax 100 = 475,000 Annual cost saving = 20,000 *Assuming the cost of electricity to be 0.05/MJ 2

3 Additives from bio-based sources Consumers are becoming increasingly more aware of the nature of the packaging they use and its impact on the environment. For example, global legislation around the use of plastic bags is getting tighter as the population uses over a trillion single-use plastic bags each year. This is leading to fast growth in the use of bio-based and biodegradable plastics. 66.1% of the raw materials used by Croda in 2015 came from natural, renewable sources Trade name Chemical description % Bio-based content Biodegradability Slip & anti-block Crodamide TM ER Erucamide 95 Biodegradable Crodamide VRX Oleamide 94 Expected to be biodegradable Crodamide SRV Stearamide 94 Biodegradable Crodamide BR Behenamide 95 Expected to be biodegradable High Performance products Slip Incroslip TM B Proprietary 95 Expected to be biodegradable Incroslip SL Proprietary 94 Expected to be inherently biodegradable Incroslip C Proprietary 95 Biodegradable Incroslip G Proprietary 95 Biodegradable Incroslip Q Proprietary 95 Expected to be biodegradable Mold release IncroMold F Proprietary 94 Expected to be biodegradable IncroMold S Proprietary 95 Biodegradable IncroMax 100 Proprietary 100 Expected to be biodegradable IncroMax PS Proprietary 95 Biodegradable Anti-static Atmer TM 122 Glycerol ester 100 Expected to be biodegradable Atmer 125 Glycerol ester 100 Biodegradable Atmer 129 Glycerol ester 100 Biodegradable Atmer 1013 Glycerol ester 100 Biodegradable Anti-fog Atmer 100 Sorbitan ester 100 Biodegradable Atmer 103 Sorbitan ester 100 Biodegradable Atmer 1006 Glycerol ester 100 Expected to be biodegradable Atmer 1010 Glycerol ester 99 Expected to be biodegradable Pigment dispersion Atmer 104 Sorbitan ester 100 Expected to be biodegradable WPC lubricants IncroMax 100 Proprietary 100 Expected to be biodegradable *The biodegradability notation denotes 60% biodegradation in OECD 301 series (or equivalent) 28 day test method. The inherently biodegradable notation denotes <60% biodegradation in an OECD 301 series (or equivalent) 28 day test method and the biodegradation curve has not reached a plateau. Where literature or read across methods have been employed the prefix expected has been used **The bio-based content refers to the % of the end product that is derived from renewable resources 3

4 Additives for bio-polymers Biopolymers are polymers that are made from bio-based materials (consisting of renewable carbon) such as cellulose, starch, protein and DNA. The biopolymer market is growing rapidly and attracting much interest, however, there are still some questions and concerns around performance and processability. In order to compete with conventional plastics, biopolymers require additives to improve these issues. Problems With Biopolymers Biopolymers can exhibit a number of problems including: l High friction / adhesion l Limited impact strength and heat resistance l Can require enhancements in melt strength, thermal stability and lubrication Key Benefits Of Our Additives Croda offer a range of additives that are suitable for use in bio-based polymers that can help overcome a number of these issues, including: l Slip & anti-block l Mold release l Torque release l Anti-static l Anti-fog l UV absorption Renewable base Starch-based polymers Polyhydroxyalkanoates Polylactic acid Green polyethylene Blends Application Films, molding, extrusion Molding, films Films, molding, fibres Films, injection molding Films, extrusion, molding Example Slip In Polyester Based Biopolymers Croda s slip additives for polyester based bio-polymers can improve overall processability in PLA film and sheet manufacturing and during injection molding by: l Decreasing friction by up to 50% l Improving mold release l Improving packaging density of molded parts l Increasing scratch and scuff resistance l Improving surface quality l Improved pigment dispersion and melt flow during processing These additives have minimal impact on colour, clarity and physical properties of the biopolymer. PLA biopolymer (no slip control) 0.5% IncroMax % Crodamide ER/BR (7:3) Figure 1: Kinetic CoF of Crodamide ER/BR and IncroMax 100 in PLA 4

5 Product selection Our range of additives can be added directly to the polymer at the processing stage, pre-compounded or included via a masterbatch. Typical addition levels are around 0.1 1% depending on the polymer type and effect required. Trade name Recommendation Application Speciality plasticisers Syncroflex TM range Flexible packaging and molding, flow improver, flexibility improver UV absorbers Solasorb UV-200F* Food contact applications Slip & anti-block Crodamide ER Slip Crodamide VRX Slip Crodamide SRV Anti-block Crodamide BR Anti-block Crodamide 203 Controlled slip Crodamide 212 Controlled slip Crodamide EBSV Anti-block and dispersion aid Crodamide EBO Slip, anti-block and anti-tack High performance products Slip Incroslip B Torque release Incroslip SL Friction reduction where high oxidative stability is required Incroslip C Torque release Incroslip G Friction reduction where high oxidative stability is required Incroslip Q Torque release Mold release IncroMold F Internal mold release IncroMold S Internal mold release IncroMold K Anti-scratch IncroMold T Internal mold release IncroMax 100 Friction reduction and mold release in PET IncroMax 300 Friction reduction and mold release in PC IncroMax PS Friction reduction and mold release in styrenics Anti-static Atmer 110 Atmer 129 Atmer 190 Atmer 1013 Anti-static in particular PET Anti-static in polyolefins and flexible PVC Anti-static in HIPS, ABS, non-transparent rigid PVC Anti-static in polyolefins, EPEs and flexible PVC Anti-fog Atmer 100 Anti-fog in PE and EVA food wrap Atmer 103 Anti-fog for agricultural films in LDPE and PVC Atmer 185 Anti-fog for agricultural films, especially EVA Atmer 688 Anti-fog in laminated PE film Atmer 1010 Anti-fog in food wrap Atmer 1440 Anti-fog in polyolefin food wrap Pigment dispersion Atmer 104 * FDA food contact approval Only available for supply in USA Highly recommended for use in biopolymers Recommended for use in some biopolymer applications Better dispersion in PE and PVC 5

6 Our green credentials Croda s Sustainability Policy For Croda, sustainability means doing business the right way; environmentally, socially and financially. All of our employees around the world contribute to sustainability on a daily basis and we are fully committed to: l Using renewable raw materials and environmentally sensitive and safe processes l Producing innovative, high quality products with sustainable benefits in use l Supporting our people and communities in which we operate Sustainability is fundamental to who we are and what we do. It touches every area of our business: from the way we design our products and run our manufacturing sites, to the way we work with our suppliers and engage with our communities. Steve Foots, Group Chief Executive Raw Material Sourcing Croda is committed to consistently sourcing and using a high level of natural, renewable raw materials to make our products. This continues to differentiate us from our competition and makes a significant contribution to our sustainability program. For example, the rape seed oil that is used in the manufacture of our Crodamide range fixes CO 2 from the atmosphere during the growing stage, helping to reduce global warming. Minimising Global Environmental Impact To maintain safe levels of carbon emissions, it is estimated that by 2040 the world needs to reduce its emissions by 50%. Croda is committed to do its bit and continually strive to use natural, renewable raw materials. Responsibly Sourced and Supported HERO We are users of both low and high erucic rapeseed oil based on multiple sourcing options in Europe and other regions. The oil we use is extracted from rapeseed in a process where nothing is wasted. The vast majority of the rapeseed we use is grown by a network of growers located in the best temperate climates. Long standing and good relationships with many of these growers, help us both to understand the value of transparency, quality and sustainability. We also agree contracts for crops well in advance of planting, giving farmers a degree of financial security, and in return ensuring that our customers have a reliable, high quality, consistent supply of HERO. Croda works hard to minimise the environmental impact of our operations by reducing volatile organic compounds (VOC) and greenhouse gas (GHG) emissions, reducing waste to landfill and reducing water consumption. This is partly achieved by an increased use in non-fossil fuel energy sources. Here are some highlights of our global initiatives to reduce the impact of our operations 48.9% reduction in VOC emissions since % reduction in waste to landfill since % energy from non-fossil fuels 5.5% reduction in water consumption since % reduction in GHG emissions since

7 Reducing Environmental Impact at our Hull Site Our manufacturing site in Hull, UK is an important site for Polymer Additives and is where a large proportion of our products are manufactured. The site has managed to reduce its carbon emissions by around 55% since 2000 partly due to the installation of a 2MW wind turbine. Since the turbine was installed the site s imported electricity demand has also reduced and the turbine now supplies around 40% of the site s electricity requirements. At full output the wind turbine will exceed the site s requirements and electricity is exported to the national grid. Figure 2: Carbon emissions from our manufacturing facility in Hull Figure 3: Energy consumption per tonne production Since 2000, energy and water consumption at Croda s manufacturing facility in Hull has reduced by around 50% per unit of production Sustainable Transport Choices Croda also minimises its environmental impact through transport of raw materials. Rape seed oil is delivered to the manufacturing site by boat, displacing approximately 1000 trips by road tanker and avoiding subsequent traffic congestion and fuel consumption. The boat minimises its fuel use by timing trips up and down the river according to tidal flow. We have also worked closely with rapeseed growers, optimising controls to reduce seed haulage through transferring seed directly to our crushing facilities, rather than from the farm to a seed store and then on to the crush. This has saved approximately 600 lorry movements annually. Figure 4: Water consumption per tonne production 7

8 Further information Croda sales and distribution are coordinated through an extensive worldwide network of associates and agents. For details of your local representative please contact your nearest Croda regional office. Visit our global website at Europe, Africa, Middle East Croda Europe Ltd Tel +44 (0) North America Croda Inc, USA Tel Asia Pacific Croda Singapore Tel Latin America Croda do Brasil Ltda Tel Non-warranty: The information in this publication is believed to be accurate and is given in good faith, but no representation or warranty as to its completeness or accuracy is made. Suggestions for uses or applications are only opinions. Users are responsible for determining the suitability of these products for their own particular purpose. No representation or warranty, expressed or implied, is made with respect to information or products including, without limitation, warranties of merchantability, fitness for a particular purpose, non-infringement of any third party patent or other intellectual property rights including, without limit, copyright, trademark and designs. Any trademarks identified herein are trademarks of the Croda group of companies Croda Europe Ltd 03/17 BP007/1