Le polypropylène clarifié au Millad NX 8000 comme source de gain en productivité/énergie et une solution de remplacement au PS et PET

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Arline Roberts
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1 Le polypropylène clarifié au Millad NX 8000 comme source de gain en productivité/énergie et une solution de remplacement au PS et PET MichelGeorges Roussel, Key Account Manager POLYOLEFINES & ADDITIFS 1er juillet 2014 Dijon

2 Milliken & Company Founded in Headquartered in Spartanburg, SC, USA 7,000+ associates Global presence 45 facilities around the world H Technical Innovation Community of innovators More than patents Segments served Specialty Chemicals Floor Covering & Interiors Protective & Performance textiles Industrial Products H Headquarter Technical center 2

Milliken & Company Performance Materials Customengineered textiles for a variety of industrial markets including automotive (hoses, airbags, interlinings, tires) Apparel & Specialty Fabrics Fabrics

3 Milliken & Company Performance Materials Customengineered textiles for a variety of industrial markets including automotive (hoses, airbags, interlinings, tires) Apparel & Specialty Fabrics Fabrics for industrial applications such as healthcare, hospitality, table linens, office interiors, labels, and much more Floor Covering Beautifying offices, hotels, airports, homes, and commercial environments around the world Performance Solutions Assisting organizations to become safer and more competitive in the marketplace 3

4 Milliken & Company Chemical Division Chemical Producing innovative chemical additives & colorants that help create value for customers by improving performance, appearance, productivity & costs 4

5 Millad NX 8000 clarified PP Innovative clarifier technology Transparency Low temp processing Around 15% energy savings Around 10 % reduction in CO 2 emissions Opportunities to replace other clear materials 5

6 Innovative clarifier technology PP often described as Milky or Translucent PP clarified with Millad NX 8000 An innovative clarifying technology from 6

7 Innovative clarifier technology PP often described as Milky or Translucent PP clarified with Millad NX 8000 An innovative clarifying technology from 7

Innovative clarifier technology Millad NX 8000 allows the ability to tune clarity as needed Millad NX 8000 Ultimate Clarity Other Clear Material Substitution Millad NX 8000

8 Innovative clarifier technology Millad NX 8000 allows the ability to tune clarity as needed Millad NX 8000 Ultimate Clarity Other Clear Material Substitution Millad NX 8000 Enhanced Quality Improved Aesthetics Improved Quality and consistency Cost reduction from Cycle time reduction Energy Savings Reduced CO 2 emmissions DMDBS Millad NX

9 Productivity improvement Millad NX 8000 allows for low temperature processing DMDBS 240 C Haze 21 % DMDBS 200 C Haze 43 % Millad NX C Haze 20 % Millad NX C Haze 21 % 9

10 Productivity improvement Millad NX 8000 allows for low temperature processing Lower Process Temperature Lower Energy Shorter Cooling Time DMDBS Millad NX 8000 Energy Savings & Higher Productivity 10

11 Millad NX 8000 Energy savings and improved productivity Part Machine Shot Weight Deca TPS Hydraulic 118,2 g/part Traditional clarifier Resin 45 MFR crcp Millad NX 8000 EQ Resin 48 MFR RCP EQ Parameter Energy Cost Machine Cost Labour Cost Sustainability Assumptions 0.11/kWh 25/hour 5/hour (1 person per 4 machines) kg CO 2 /kwh Cycle Time (s) 6,6 6,0 Millad NX 8000 resin kwh/kg kwh/kg Traditional clarifier resin 190 IM Temperature ( o C)

12 Millad NX 8000 Savings achieved by processing PP with Millad NX 8000 versus traditional clarifiers Savings /1000mT PP expressed as 9,1 % cycle time 1410 hours saved in manufacturing ,7 % CO 2 emissions 0,83 cars running per year 0,53 domestic power [houses] per year 0,90 acres of forest 12

13 Energy savings and improved productivity Case study Part Machine Shot Weight DMDBS Resin Millad NX 8000 Resin 5L TWIM Bucket Hydraulic 132 g/part ; 1 cavity mould MFR RCP 60 MFR RCP Assumptions Energy Cost Machine Cost Labour Cost Sustainability Avg of EU Top 10 Countries 0.11/kWh 25/hour 5/hour (1 person per 4 machines) kg CO 2 /kwh Cycle Time (Sec) Millad NX 8000 resin kwh/kg kwh/kg DMDBS resin 200 o C IM Temperature 240 o C 13

14 Energy savings and improved productivity Savings achieved by processing 1000 mt PP with Millad NX 8000 versus DMDBS Savings expressed as 10 % cycle time hours saved in manufacturing ,4 % CO 2 emission 6,92 cars running per year 2,60 domestic power [houses] per year 7,5 acres of forest 14

15 Millad NX 8000 Energy savings and improved productivity Part Machine Shot Weight Flip top cap Hydraulic 5,2 g/part ; 62,2 g/12 cavity mould Traditional clarifier Resin 35 MFR crcp Millad NX 8000 EQ Resin 45 MFR RCP EQ Parameter Energy Cost Machine Cost Labour Cost Sustainability Assumptions 0.11/kWh 25/hour 1/hour (1 person per 4 machines) kg CO 2 /kwh Cycle Time (s) 15,1 14,4 Millad NX 8000 resin kwh/kg kwh/kg Traditional clarifier resin 200 IM Temperature ( o C)

16 Millad NX 8000 Savings achieved by processing PP with Millad NX 8000 versus traditional clarifiers Savings /1000mT PP expressed as 4,6 % cycle time 3126 hours saved in manufacturing ,3 % CO 2 emissions 8,1 cars running per year 5,15 domestic power [houses] per year 8,81 acres of forest 16

17 Millad NX 8000 Savings Calculator App for ipad, iphone or website to calculate energy & production savings 17

18 PP InterMaterial replacement The Value of Clarity in Disposable Food Packaging Application Disposable Food Packaging Process Thermoforming Region Material Replaced Asia Polystyrene (PS) Food Packages Drivers for material replacement: Excellent transparency Boost impact resistance & avoid breakage Economics Microwaveable

19 PP InterMaterial replacement The Value of Clarity in Appliances Application Larges Appliances refrigerator vegetable tray Process Injection Molding Region Material Replaced India GPPS Refrigerator vegetables tray Drivers for material replacement: Transparency customers desire Improved impact resistance for better durability Polypropylene provides the beautiful appearence customers seek, combined with practical performance in everyday use.

20 PP InterMaterial replacement The Value of Clarity in Housewares Application Cutlery Tray Process Injection Molding Region Europe Material Replaced Styrene Acrylonitrile (SAN) Guzzini Tray Drivers for material replacement: Health & safety concerns of BPA Provides cost savings compared to PC with clarity & environmental friendliness Exceptional impact resistance

21 PP InterMaterial replacement The Value of Clarity in Housewares Application Water Pitchers Process Injection Molding Region Latin America Material Replaced Drivers for material replacement: PC replacement Premium quality marketing strategy Design refresh in combination with excellent transparency Objective of capturing higher value in the market place Cost savings Imusa Water Pitcher

22 PP InterMaterial replacement The Value of Clarity in Blow Molded Food Containers Application Food Containers Process Multilayer Extrusion Blow Molding Region Material Replaced Europe Glass Replacement Food Packaging Drivers for material replacement: Light weight material Hot fill application Design refresh in combination with excellent transparency Market share growth initiative

23 PP InterMaterial replacement The Value of Clarity in Drink Cups & Lids Application Disposable cups & lids Process Thermoforming Region USA Material Replaced PET Drivers for material replacement: Premium quality marketing strategy Sustainability and density advantages of PP Ultimate clarity with Millad NX8000 Cups

24 Millad NX 8000 clarified PP Innovative clarifier technology Transparency Low temp processing Around 15% energy savings Around 10 % reduction in CO 2 emissions Opportunities to replace other clear materials 24

25 Questions? Clarity in polypropylene never looked so good MichelGeorges ROUSSEL Key Account Manager MichelGeorges.Roussel@Milliken.com 25

NX UltraClear. Polypropylene. Clarity in polypropylene never looked so good

NX UltraClear. Polypropylene. Clarity in polypropylene never looked so good NX UltraClear Polypropylene Clarity in polypropylene never looked so good NX UltraClear Polypropylene for Transparency Light weight Hot fill Microwavability Sustainability Recyclability Easy to empty The