STATIC INTERCEPT SHRINKFILM

Transcription

1 4 STATIC INTERCEPT SHRINKFILM...simply better protection FPM Inc is a Michigan based disable Veteran owned small business ISO 9001/2000: ISO 14001

2 Saves Money Re-usable Intercept Technology More effective than conventional foils Can be opened and re-closed easily in the field Reliable protection Can be easily combined with returnable dunnage and containers Save time for closing and sealing

3 Protecting Steel Intercept can be provided as small rolls for high speed coil wrapping Intercept can be provided as bags for wrapping steel coils (as consented by Corus) Intercept can be shrink wrapped Intercept can be provided in various formats for complete protection Stretch / Shrink / Film / Bags

4 Intercept Technology Or Protecting your Investment and Your Product

5 No Oils, Sprays, VCI Paper or VCI Sponges Required with Intercept! Many companies apply light oils, greases, Cosmoline or other protective coatings to protect the metal products while in storage or during shipping. Corrosion Intercept eliminates the need for these coatings, which may require removal by solvents at the customer site. Significant savings in purchasing coatings and the reduced labor requirements may be realized. The customer does not have to spend hours cleaning the equipment and use hazardous solvents, which is a saving to them as well.

6 Sampling of Approvals Corus Steel (Netherlands) Orders beginning in Sept Ford Motor South Africa Cast Iron Engine Block shipments from South Africa to India (6 Sigma Test Study) Outperformed all VCI s in test Has been performing well for 18 months BMW / SAKS / Lemforder Leading German automotive companies and suppliers

7 Some Sampling of Customers Shrink Film Australia Australian military for wrapping tanks and tank parts from Germany Libra Rio Tinto Plc (world s largest mining company) BHP Komatsu Hitachi Singapore Military Airplanes / spare parts Armaments Boxes (mold prevention) US Shrink film Westinghouse Areva Siemens Kop-Flex Cummins

8 Some Sampling of Customers Intercept Bags / Films Lucent Diebold Northrop Raytheon L3 Communications Analogic Texas Instruments Messier Dowty Thiokol General Dynamics Nichols Aircraft Long Term Storage BMW The Defence Science & Technology Organisation (DSTO) and The Royal Australian Air Force SAKS Automotive Lemforder Lucent Boeing Samsung (electronics)

9 60,000 Parts Packed 0 Rejects Static Intercept Bags: Safe, Reliable, Reusable, Cost Effective Static Intercept zipper-style bags solved all the problems. Without the need of heatsealing or packing station equipment and a three-step packaging process, worker safety is no longer at risk and the process is easier ensuring higher levels of productivity. If the gerotor part must be put into storage, requiring corrosion inspection after being picked to ship, the inspection can be performed without violating the integrity of the barrier package. In short, the bag doesn t need to be reheated and resealed.

10 The Defence Science & Technology Organisation (DSTO) and The Royal Australian Air Force Parts stored at facility for up to 15 years in Static Intercept bags And Intercept Shrink Film

11 What is Corrosion? Corrosion can be a chemical reaction between a metal and a reactive or unstable gas or liquid. Corrosion can be caused by an electrical reaction between two different types of metals (galvanization). Corrosion can be a electro-chemical Reaction between dust or fungi and a metal-surface. Corrosive gases not only effect metals, but non-metals as well, such as rubber / fabric / leather / plastic / optics / etc. In Principle; Corrosion is an action which changes the chemical or physical structure of metals.

12 Corrosion Cycle Energy Energy Energy

13 Rust Chemistry Rusting of iron consists of the formation of hydrated oxide, Fe(OH) 3, FeO(OH), or even Fe 2 O 3.H 2 O. It is an electrochemical process which requires the presence of water, oxygen and an electrolyte. In the absence of any one of these rusting does not occur to any significant extent. In air, a relative humidity of over 50% provides the necessary amount of water and at 80% or above corrosion of bare steel is worse. When a droplet of water containing a little dissolved oxygen falls on an steel pipe, the solid iron or Fe(s) under the droplet oxidizes: Fe(s) --> Fe 2+ (aq) + 2e - The electrons are quickly consumed by hydrogen ions from water (H 2 O) and dissolved oxygen or O 2 (aq) at the edge of the droplet to produce water: 4e - + 4H + (aq) + O 2 (aq) --> 2H 2 O(l) More acidic water increases corrosion. If the ph is very low the hydrogen ions will consume the electrons anyway, making hydrogen gas instead of water: 2H + (aq) + 2e - --> H 2 (g)

14 Corrosion Reviewing the various information it is possible to see that Iron rusts in Acidic environments, but not necessarily quickly in neutral ph water. This is why testing for corrosion has to include gases or materials that are present in normal environments, these include atmospheric corrosive gases. These gases tend to be acidic in nature, hence producing an environment rich in corrosion potential These reasons also have a lot to do with the test regiment that Rolls Royce Plc looks at salt fog (which can seed the surface of a metal with corrosive gases) followed by high humidity which promotes rapid rust

15 How to Protect Against It? You need to eliminate one or more of the causes you need to remove the fuel. Three areas to combat: Metal + corrosive gases (pollution) + moisture => rust Moisture minimize temperature changes minimize trapped air - block out new moisture - Metal - passivate or cover it up (paint or oils) - Gases - eliminate them, take them out of the equation Intercept does this - Gloves need to be worn

16 Methods of Corrosion Protection Dry Method attack the moisture Germans found that Ferrous metals will not corrode if kept below 38% RH, hence the use of foils and desiccants However with Non-Ferrous metals, such as Silver, Moisture has little or no impact on their corrosion rates. Foils are expensive, cumbersome, need to be hermetically sealed and should be evacuated Foil is not recyclable or re-usable, so it is an issue with European packaging regulations

17 Methods of Corrosion Protection Work on the metal coatings / paints: Volatile Corrosion Inhibitors (VCI s) generally work on this part of the equation. VCI s utilize chemicals that are modified to outgas at temperatures between 65oF and 85oF ideally, they will outgas faster at elevated temperatures. The VCI oils outgas from the packaging, leaving a thin layer of VCI oils on the metal surface. Care must be taken to ensure compliance with TRGS 615 in Europe, and that no interactions are caused with other metals or plastics.

18 Methods of Corrosion Protection Remove the Corrosive Gases Only the Intercept Technology works on this part of the equation Intercept was developed by Bell Labs, who discovered how to radically increase the active surface area of pure Copper, then chemically bond or graft it into a polymer structure. The resulting plastic acts as a plastic, but also as an extremely highly reactive Copper sheet Intercept also has low MVTR rates, so it is effective as a replacement for foils for the dry method

19 Some Intercept Product Testing Rolls Royce Plc Testing 1000 Hours Salt Fog then 1000 Hours High Humidity Protected in an Intercept Bag No rust / No corrosion English MOD tested and approved for their standard: Def Stan Part 2, methods 1 and 1C Def Stan Part 1A and 11

20 Types of corrosive gases Nitrous Oxides (NOx) --- exhaust from gas powered forklift trucks / auto exhaust / un-vented heaters Ozone (O3) - reactive oxygen (smog, etc.) Hydrogen Sulfide (H 2 S) and Sulfur Dioxides (SO2) Exhaust from cars, outgassing from corrugate. Etc. Carbonyl Sulfide (COS) -- very prominent on oceans, Hydrogen Chloride (HCl)

21 US Army TACOM (Tank Command) EVALUATION OF INTERCEPT BARRIER MATERIAL FOR MILITARY PACKAGING SALT-FOG Test Data Comparison <<<<< Days of protection against corrosion >>>>>>> Intercept VCI MIL-PRF-131 Metal coupon Poly Poly Foil / Poly 4-mil 4-mil 5-mil Steel Aluminum Brass Zinc

22 Independent Lab ASTM B117 Testing Results 4 weeks (672 Hours) in Salt Fog Testing Intercept Technology VCI Protection Pink Poly Anti-Static Aluminized Polyester Testing Courtesy of American Competitiveness Institute (ACI)

23 STATIC INTERCEPT Is the new generation of corrosion protection which provides an active protection for all materials. The principle technology was developed and patented by Lucent Technologies and Bell Laboratories (USA).

24 STATIC INTERCEPT (SI) SI is being used by a number of renowned companies. The advantages of the material are: Environmentally-friendly (no migration of particles and elements) No sloughing (NASA approved for Space Flight) High effective Temperature Range ( from 35 C to +80 C) Humidity independent, permanent ESD protection (true permanence) Long durability ( > 10 Years corrosion protection) Protects Ferrous & Non-Ferrous metals, electronics, optics & plastics. Universally usable and cost effective Cost-effective

25 How Intercept Works

26 H2S Neutralization Bell Labs Testing Corrosion Intercept 10 Year Exposure at 7 ppb

27 S/Cu Ratio Test Using SEM-EDX (Scanning Electro-Microscope) Intercept - Sulfur Penetration H2S 10 Equiv. Years Exposure to 7ppb H2S 58 um Penetration Depth (um) 12 um

28 Neutralization of Chlorine 2 mil Film (50 Micron) DuPont Chlorine Test Years to Breakthrough Time Chlorine Takes to Move Through the Plastic Intercept Polyethylene 0 Intercept - 35 Years Polyethylene - 7 Days 1 Part Per Million Chlorine -.002" Thick Film

29 CORROSION INTERCEPT Intercept is being used by a number of renowned companies. The advantages of the material are: Environmentally-friendly (no migration of particles / reusable / recyclable) High effective range (cold to hot from 35 C to +80 C) Long durability ( > 10 Years) Protects all Ferrous- and Non-Ferrous metals, electronics, optics and plastics (1 product, not a variety of different products). Universally usable Cost-effective

30 Function Intercept Products consist of special high surface area Copper particles which are reacted into the polymermatrix to create a new class of product, a new polymer: Several protective functions are combined in one product: Neutralization of corrosive gases present in the bag and gases that are attempting to migrate (permeate) into the bag Protection as an Anode for electro-chemical Processes Natural function against Bio-Corrosion (Copper is a passive mildewcide)

31 Worker s safety & Environment - Intercept is not a VCI - There is no outgassing and there are no VOC issues related to Intercept - There are no restrictions for Intercept in regards to: - TRGS 615 Intercept is compliant - RoHS - Intercept meets RoHS initiative in Europe - Fully reusable and recyclable in Europe CORROSION INTERCEPT was tested by NASA for contamination certified for space-flight conditions

32 Spare Parts Storage / Shipment (Supply Chain) Shipment of goods world-wide. Partially opening by customs. or from Dramatic climatic changes. Preserves Solderability

33 Automobile Applications Comparison (Supply Chain & CKD) Problem: Partially long storage periods before or After Shipment under climatically difficult circumstances. Application:STATIC INTERCEPT and CORROSION INTERCEPT Films as alternative (replacement) to Foil, VCI and wax-paper. All components are protected equally well. Test have been performed by leading companies under realistic conditions for the complete period of time required. Intercept always outperformed the VCI films. Further: Intercept Products are recyclable and no further protection (Oil, Wax, etc.) is needed besides sufficient amount of desiccants (16 Units/m³). We recommend Desi Pack Desiccants. Only one material in stock no need for VCI emitters, various VCI formulations for different materials, VCI paper and plastic, etc.

34 Tested by US Army Tank Command Picatinny Arsenal Easy Handling High Protection Cost Savings A replacement for Mil 131J Foil (TACOM)

35 Metals and Assemblies Bags / Stretch / Shrink

36 Applications Cast Iron Engine Blocks Bare No Oils / No Coatings Ford Motor Company (SA) Engine blocks 12 Month Storage test No corrosion Part of a 6 Sigma Test Static Intercept was the clear winner

37 GKN Driveline - UK Analysis: The problem was not just Corrosion, it was also the Swelling of the nylon fitting 2 Desiccant Pouches were used

38 Ball Bearing Packs 3 Month Test High Sulfur Environment In addition to being able to pack without Oils the packaging helps prevent counterfeiting 6 Month Real Life Test without oils or coatings re-confirmed the results

39 Applications Ship Germany to Mexico ZF Lemförder Note: allowed standard Paper to be used for layer separation no oils, no VCI emitters, no VCI interleaf sheets

40 Applications BMW 15 Yr Storage BMW AG 15 Year Long Term Storage 5 mil Static Intercept With desiccant

41 Application Engine Manifolds Ship China to US The use of Intercept bags has allowed these engine Manifolds to be shipped from China to the US with No protective oil coating no oil to be applied, no Steam cleaning at receiving, no corrosion failures

42 Analogic World Wide Shipments 7 Years in Application No Failures Analogic switched from foil packaging which took up to 8 hours per unit to pack. The Intercept quick pack method with an Intercept base sheet and fitted bag takes less than 10 minutes

43 Applications Intercept Fabric Intercept Cover for Army

44 Applications Military Shrink Wrapping ISO Cranes Top side r ISO Cranes Top side Using Intercept Shrinkfilm Journey from US to Kuwait Journey from US to Kuwait

45 Total Cost Analysis Recyclable Meets All Current European initiatives Safe for rubber and Polycarbonate storage Eliminates the need and requirement for oils, sponges, VCI separator sheets and the required cleaning after oil coating The only material consented by BMW for long term storage Approved and used by such companies as NASA, Boeing, Intel, Siemens, Lucent, SAKS, Lemforder, etc.

46 Product Variety Gusseted-Bags Stretch and Shrink Film Bags (With and without closing) Flat-Film MVTR- and EMI-Film Injection Molded Products Corrugated (up to 2.94) CD-Protection Nylon-Bags

47 Service The Intercept Technology Group (ITG) together with our partner companies around the world will develop, with our own engineering and design capacities, tailor-made solutions for your individual needs. Technician and Application specialists are available in all regions (America, Africa, Asia and Europe). Shipment trials are recorded and evaluated. All Manufacturers are certified in accordance with DIN ISO EN , or have similar QC systems (Veritas, etc.). Intercept has been ISO Certified for use in Export Shipping bycargo Pack in Germany Both the material and the process

48 Test the various Intercept Technology products yourself! It will be worth your while... Intercept Technology Simply Better Prot Group FPM Incorporated