Equipment & Material Considerations for Physically Foamed Films and Sheet. Mark Lindenfelzer, President, MuCell Extrusion
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1 Equipment & Material Considerations for Physically Foamed Films and Sheet Mark Lindenfelzer, President, MuCell Extrusion
2 Addressing market needs Packaging functionality/mechanical performance & appearance Minimal packaging use Cost / Sustainainability key market drivers Result is an ever increasing requirement to down gauge products; however stiffness quickly becomes a limitation to product functionality.
3 The Role of Foam Films & Sheet #1 Benefit is increasing Bend Stiffness for a given gram weight Foaming offers an light-weighting alternative in both rigid and flexible applications Monolayer or coextruded structures* Foamed Core Solid Skin Stiffness depends on thickness cubed D = ke young t 3 30% - 50% light-weighting is possible while properly balancing mechanical properties
4 Equipment Required Super Critical Fluid System: Required to inject directly into the melt stream via ported barrel or extension Proper Mixing and Melt Temperature Uniformity: MuCell MTM critical for this function Die Modifications: Required to achieve the required pressure drop rate for optimum cell size. Controls: Coordination between process data and SCF control system
5 Super Critical Fluid System Injection while Gas is in its Supercritical State: High level of accuracy critical Single phase solution: Injector design + screw design allow the gas to go into solution effectively. Pressure Capability: Should be capable of injecting into pressures generated by extrusion.
6 Typical MuCell Installation: SCF System, MTM and Temperature Controller All items pre-wired and tested prior to shipment for fast installation
7 Gas Injection Location aligned with the Rotor and Stator pockets MuCell Transfer Mixer (MTM)
8 Die Modification Standard Die vs. Optimized Die
9 Controls Integration & Reliability Coordinating Process data with SCF system: Reliable way to determine a consistent foam structure in continuous production. SCF Flow Rate Delivery Pressure
10 MuCell Microcellular Foam Extrusion Advantages - Lowest cost of foaming - Once installed, MuCell hardware will process BOTH foamed and non-foamed products - No byproducts from the breakdown of chemical foaming agents (CFA s) - Extrude at significantly lower melt temperatures vs. solid & CFA s - Precise control of the foam density, typically +/- 1% - Wide range of foam densities available, allowing processors to design the sheet structure that best matches the product application. - For flat sheet applications, processors can Dial In any density between 0.33 to This allows the operator to optimize the skin layer(s) and thickness to match the product requirements
11 How it works Structures can be designed to match or improved stiffness vs original film while consuming lower material resources Conventional Film / sheet 25% Thickness Reduction Down-gauged Film / sheet 25 60% Thickness Increase Thickness reduced resulting in lower stiffness Engineered Foamed Product 400 micron 300 Micron micron Thickness increased, stiffness restored with reduced resin consumption Performance or Value Resource Use or Footprint
12 Typical Thermoformed Example Existing meat tray made from HIPS, 16.0 grams - Currently made using 520 gram / m 2 sheet Goal: Produce a gram PLA product using a 3-layer extrusion line and a MuCell Machine. Sheet requires equal or better than the current physical properties. Target sheet Gram Weight: 375 gr/m2 Next two slides show 4-different possibilities
13 EXAMPLE 400 Micron PLA, weight reduced by 25% - maintain skin layers THICKNESS 400 MICRON % % GRAM WEIGHT SPEC. GRAVITY OUTPUT A EXT No Change 125 No Change OUTPUT B EXT (33%) 250 (33%) TOTAL (KG / HR) (25%) 375 (25%)
14 EXAMPLE 400 Micron PLA, weight reduced by 25% - Increase Skin Layers by 50% THICKNESS 400 MICRON % % GRAM WEIGHT SPEC. GRAVITY OUTPUT A EXT % % OUTPUT B EXT (50%) (50%) TOTAL (KG / HR) (25%) 375 (25%)
15 Net Result: 355 gram sheet (12 Grams)
16 A Complete Technology Package Collaboration along the Packaging Value Chain Hardware & Engineering Providing sufficient pressure drop rate Enabling efficient nucleation: very small cells Dispersing Super Critical Fluid SCF Engineered screw and injector port Materials expertise to match application needs IP & Know- How Successful Packaging Application Material Selection Controlling cell growth Proper raw material selection: melt strength
www.reedychemicalfoam.com FOAMS 2016 Kinetic Nucleators maximize cell distribution in foam extrusion September 14-15, 2016 2 1. Why Use Chemical Foam? 2. CFA types 3. Modern CFA Expectations 4. Nucleation
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