AGILITY PERFORMANCE LDPE IN BLENDS ELEVATES FILM MECHANICALS AND EXTRUSION OUTPUT TO THE NEXT LEVEL LORI KARDOS AND TERESA KARJALA THE DOW CHEMICAL COMPANY SPE POLYOLEFINS CONFERENCE FEBRUARY 2017
OUTLINE AGILITY TM LDPE Products LDPE Applications Characterization of High Output LDPEs Blown Film Processability Film Physical Properties Output Performance of Blends Summary 2
HIGH PERFORMANCE LDPE AGILITY Performance LDPE Resins are elevating the performance standards of the LDPE category through: SPEED: Enables higher throughput on existing extrusion equipment STRENGTH: Requires less LDPE in LDPE/LLDPE blends, improving physical properties while maintaining output AESTHETICS: Delivers improved optics and high shrink to meet the growing need for more transparent packaging FLEXIBILITY: Offers solutions for multiple markets extrusion coating, blown & cast film, and polyolefin foams 3
VERSATILITY AGILITY Performance LDPE Resins represent a new generation of LDPEs designed to offer converters a broad family of versatile products bringing the best performance attributes of conventional autoclave and tubular LDPEs into one pellet. This allows customers to challenge the limits in extrusion throughput and physical properties through enabling less LDPE usage in blends. Common Market Applications: ~ Extrusion coating ~ Performance polyolefin foams ~ Lamination films ~ Décor ~ Shrink films for beverages ~ Agricultural films ~ Frozen food packaging ~ Stand-up pouches 4
HIGH PERFORMANCE AGILITY LDPE RESINS Commercial Product Film Applications Melt Index (g/10 min, 190 C) Density (g/cm 3 ) Product Additives Extrusion Technology AGILITY 1000 Performance LDPE AGILITY 1200 Performance LDPE AGILITY 1001 Performance LDPE AGILITY 1002 Performance LDPE Agricultural, lamination, shrink 0.18 0.920 None Blown Films Agricultural lamination, shrink 0.25 0.919 None Blown Films Stretch films for logistics packaging 0.65 0.920 None Blown Films Food packaging and lamination films 0.65 0.921 AB Blown Films AGLITY 1021 Performance LDPE Protective foams, food packaging and lamination films 1.85 0.920 None Blown and Cast Films AGILITY 1022 Performance LDPE Food storage bags 1.85 0.921 S/AB Blown and Cast Films 5
HIGH PERFORMANCE AGILITY LDPE RESINS Commercial Product Film Applications Melt Index (g/10 min, 190 C) Density (g/cm 3 ) Product Additives Extrusion Technology AGILITY 2001 Performance LDPE High clarity retail collation shrink film 0.4 0.924 None Blown Films AGILITY EC7000 Performance LDPE Board laminates, food sachets, pouches, release liners for labels, imaging paper, medium to high density foams for protective packaging 3.9 0.919 None Extrusion Coating, Lamination, Polyolefin Foams AGILITY EC 7200 Performance LDPE Paper & board coating & lamination for liquid board laminates and pouches, very low density foams for protective packaging 1.5 0.918 None Extrusion Coating, Lamination, Polyolefin Foams AGILITY EC 7080 Performance LDPE Very high speed / lights weights for extrusion coating & lamination 8.0 0.918 None Extrusion Coating, Lamination, 6
LDPE APPLICATIONS SILAGE/AGRICULTURAL FILM HEAVY DUTY SHIPPING SACKS FROZEN FOOD LAMINATION FILMS COLLATION SHRINK FILMS 7
AGILITY 1200 PERFORMANCE LDPE FOR HIGH THROUGHPUT LDPE BLENDS
FASTER PROCESSING LDPES AND LLDPES Higher Output on Blown Film lines - a major need from film converters Equipment Technology Polymer Technology Output on a blown film line: Cooling capacity Winder speed Bubble stability Many film formulations are blends of LLDPE and LDPE resins Anywhere from 10% to 50% LDPE blended with LLDPE 9
THE NEWEST LDPE INNOVATION AGILITY TM 1200 PERFORMANCE LDPE ~ Higher throughput ~ Improved bubble stability even with large layflats ~ Less gauge variation ~ Enhanced physical properties ~ Maintain optics ~ Secure supply with asset flexibility 10
BENCHMARK LDPE RESINS Resin MI Density AGILITY 1200 Performance LDPE 0.25 0.9195 DOW LDPE 132i 0.25 0.921 NEW! Recent discoveries in LDPE have enabled us to disassociate conventional rules for melt strength and melt index. 11
MELT STRENGTH 26 24 22 20 190 o C 24 cn AGILITY 1200 shows 33% improved melt strength over Standard 0.25 MI LDPE Melt Strength (cn) 18 16 14 12 10 8 6 4 2 0 AGILITY 1200 Standard 0.25 MI LDPE 0 10 20 30 40 50 60 70 80 90 100 Velocity (mm/s) 18 cn 12
MELT VISCOSITY 100,000 190 o C AGILITY 1200 has reduced and improved viscosity over Standard 0.25 MI LDPE Viscosity (Pa-s) 10,000 1,000 AGILITY 1200 Standard 0.25 MI LDPE 100 0.1 1 10 100 Frequency (rad/s) 13
MELT STRENGTH OF BLENDS 30 25 AGILITY 1200 improved blend melt strength over Standard 0.25 MI LDPE Melt Strength (cn) 20 15 10 AGILITY 1200 Standard 0.25 MI LDPE 5 0 0 10 20 30 40 50 60 70 80 90 100 % LDPE 14
MEASUREMENTS OF MAXIMUM OUTPUT Bubble Stability Flattened Tube Internal bubble cooling External Air Temp. profile- Melt Temp. Frost line height (FLH) Nip rolls Max. rate criterion Maximize IBC Maximize External Air Increase screw RPM Bubble Shape Air Ring Bubble breathing in & out (Layflat) FLH stability Gauge control P M r z h(z) R f FLH 15
EXPERIMENTAL PARAMETERS Monolayer blown film line, Freeport, TX Dual lip air ring Die size = 8 inch Die gap = 70 mils Blow up ratio (BUR) = 2.5:1 IBC Melt Temp. Range of 420-450 F (216-232 C) Film gauge = 2 mil Film samples Standard rate (10 lbs/hr/inch of die circumference) Maximum rate 16
AGILITY PERFORMANCE LDPE TECHNOLOGY DELIVERS UNPRECEDENTED THROUGHPUT 600 500 % Increase vs. Standard 0.25 MI LDPE % Increase vs. without LDPE: +18% + 57% 500 Output (lb/hr) 400 300 319 425 200 AGILITY 1200 Improved Processability 100 0 DOWLEX 2045G 20% Standard Frac Melt LDPE (0.25 MI) 2 mil monolayer blown film LDPE blended with DOWLEX 2045G 20% AGILITY 1200 (0.25 MI) Processing Conditions: 8 Trademark die, 70 mil of The die Dow gap, Chemical 2.5 Company BUR, ( Dow ) Dual or an affiliated lip air company ring of & DowIBC, 420-450 F melt temp. 17
SCREEN PRESSURE REDUCTION VS. STANDARD 0.25 MI LDPE Screen Pressure (psi) 4,000 3,000 2,000 1,000 3,730 3,190 Standard 0.25 MI LDPE AGILITY TM 1200 AGILITY TM 1200 is Easier to Process 13% Reduction in Back Pressure at 20% LDPE 8% Reduction in Back Pressure at 50% LDPE 3,590 3,470 0 20% LDPE (2 mil film) Monolayer blown films - LDPE blended with DOWLEX 2045G 50% LDPE (4 mil film) Processing Conditions: 8 die, 70 mil die gap, 2.5 BUR, Dual lip air ring & IBC, 410-440 F melt temp. 2 mil film: 10 lb/hr/inch die circ. 4 mil film: 12 lb/hr/inch die circ. 18
600 NO TOUGHNESS TRADEOFFS VS. STANDARD 0.25 MI LDPE Standard 0.25 MI LDPE 600 AGILITY TM 1200 500 487 454 500 430 440 500 497 Dart (g) 400 300 200 283 286 MD Tear(g) 400 300 200 100 100 0 20% LDPE (2 mil film) 50% LDPE (4 mil film) 0 20% LDPE (2 mil film) 50% LDPE (4 mil film) AGILITY 1200 has similar dart and MD tear to Standard 0.25 MI LDPE 19
OPTICS 30 25 AGILITY 1200 Standard 0.25 MI LDPE AGILITY 1200 has slightly reduced optics compared to Standard 0.25 MI LDPE 20 Haze (%) 15 10 5 0 0 10 20 30 40 50 % LDPE 20
SHRINK TENSION (MD) 40 MD Shrink Tension (psi) 35 30 25 20 15 10 AGILITY 1200 Standard 0.25 MI LDPE AGILITY 1200 has similar shrink tension (MD) compared to Standard 0.25 MI LDPE 5 0 0 10 20 30 40 50 % LDPE 21
BLENDING WITH INNATE RESINS Raw talents and special abilities of extraordinary nature. The chemistry behind INNATE resins allows scientists to accurately control and dial-in precise and extraordinary properties like never before. Elemental or essential to success. INNATE resins are building blocks for innovative packaging. 22
RAISING THE BAR Improved Stiffness/Toughness Balance with Excellent Processability 23
OPTIMUM INNATE TM -AGILITY TM PROPERTY BALANCE 10% LDPE loading 20% LDPE loading Max Output Inverse Haze 1.20 0.80 0.40 0.00 Dart INNATE ST50+XUS AGILITY 60019.97 1200 INNATE ST50+AGILITY 2001 INNATE ST50+AGILITY 1000 Max Output Inverse Haze 1.20 0.80 0.40 0.00 Dart 2% MD Modulus MD Tear 2% MD Modulus MD Tear At 10% loading, the AGILITY 1200 shows the best balance of properties. At 20% loading, the AGILITY 1200 shows the best abuse-output balance. At 20% loading, the AGILITY 2001 shows the best abuse-optics balance. 24
INNATE TM -AGILITY TM BLENDS FOR SUPERIOR ABUSE AND HIGH PROCESSABILITY > +60% Improved Dart > +20% Improved Tear Use less AGILITY LDPE to maintain output and provide higher abuse performance All films at 1 mil and blended with INNATE ST-50 10% LDPE blends with >20% improved output without LDPE 20% LDPE blends with >30% improved output without LDPE 25
OTHER APPLICATIONS: FOAM & EXTRUSION COATING AGILITY TM 1021 (1.85 MI, 0.920d) AGILITY EC 7000 (3.9 MI, 0.920d) AGILITY EC 7080 (8.0 MI, 0.918d) PROTECTIVE PACKAGING EXTRUSION COATING 26
AGILITY TM 1200 Performance LDPE A Good Balance of Processing & Film Properties Improved Processability 33% Higher Melt Strength than Standard 0.25 MI LDPE 18% Improved Output in Blown Film at 20% LDPE loading levels Efficient Blend Partner with INNATE TM resin for superior toughness with less LDPE and downgaugability 27
THANK YOU FOR YOUR ATTENTION For more information or to discuss your application, please feel free to contact us: Lori Kardos, lkardos@dow.com Teresa Karjala, tpkarjala@dow.com