Raw material for TQ Films Satish V. Awate Product Application & Research Centre Reliance Industries Limited IPI seminar Aug 2002 rev 0.1
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Index Overview on PP films in flexible packaging sector TQPP film extrusion process Repol H 100 EY for TQ film applications New Repol grades for advance applications Manufacturing process for Repol Product Application & Research Centre 3
Flexible Packaging Sector : Overview Total Film Market (01-02) ~ 1MMT 12% 17% 44% 27% LD/LLDPE PP HMHDPE PVC PP films: 2nd largest share in flexible packaging 4
Polypropylene film : overview PP Film Market (01-02) ~ 270KT 78% 2% 20% TQPP CPP BOPP...largest contribution from TQPP films 5
rowth of TQPP film sector 1600 1400 1200 250 200 CARG ~ 17% 1000 150 800 600 100 400 50 200 Machines 0 1996-97 1997-98 1998-99 1999-00 2000-01 2001-02 0 Consumption (KT)...supply driven market 6
Drivers for growth of TQPP films Growing demand in flexible packaging Excellent optical properties viz. clarity & gloss Better mechanical properties viz. stiffness Good barrier properties Cost effective packaging solution...aesthetic appeal of PP the key driver for growth 7
Characteristics of Polypropylene higher crystallinity formation of spherulites, as the melt solidifies slower crystallisation rates possible to get smaller size spherulite, by quenching of the film...need an extrusion process with an effective cooling arrangement 8
ubular Quenched Polypropylene (TQPP) film extrusion process 9
dvantages of TQPP process low capital lesser space requirement lower operating cost less demanding operating skills ease in changing the width / thickness of film tubular film is an added advantage in manufacturing of pouches / bags most cost effective process in plastics 10
Polypropylene grade for TQ film
Repol H 100 EY PP homopolymer, with slip and antiblocking agents MFI : 11.0 g/10min The grade is designed to provide: - Good processability - Good clarity and gloss - Good stiffness Typical applications : packaging of textiles / food / other commodities largest selling PP grade in India 12
Properties of TQ films made from PPHP narrow sealing window and low seal stregnth low impact properties lower tear resistance higher stiffness...yet to make a mark in more demanding applications 13
New grades for advance applications of TQ film Random Ter-polymer T 080 EY Repol H 100 EY (modified)
epol T 080 EY New random terpolymer from RIL 8 MFI grade, with slip & antiblock Repol T080EY is designed to provide : Soft in feel Lower sealing temperature Good dart impact and tear strength Good processability High melt strength Good gloss and clarity 15
art Impact Strength 5 PPHP Ter-polymer LLDPE(1 MFI) 4.5 4 3.5 3 2.5 4.6 3.5 2 1.5 1 1.2 0.5 0 Dart Impact Strength (gm/micron) 16
ear strength 14 12 10 PPHP Terpolymer LLDPE 9.9 12.5 8 6 4 3.4 2.8 2 1.2 1.2 0 MD TD 17
aling characteristics : Hot Tack Strength 200 150 PPHP Terpolymer LLDPE 185 @ 128 0 C 160 @ 116 0 C 120 @ 140 0 C 100 50 0 HTS 18
aling characteristics : Heat Seal Strength 1400 1200 PPHP Terpolymer LLDPE 1300 @ 128 0 C 1000 @ 140 0 C 1200 @ 116 0 C 1000 800 600 400 200 0 HSS 19
Advantages of Repol T 080 EY Lower melting temperature, hence lower processing conditions Lower sealing temperatures Better sealing characteristics Better mechanical properties..for more demanding applications 20
pplications for Repol T 080 EY liners carry bags lamination films (see-through pouch) packaging on form fill seal (FFS) machines stationery items (photo albums / document holders) value added products 21
odified Repol H 100 EY significant improvement in throughputs 20 kg/hr 150 kg/hr over stretching leads to bubble breakage /punctures at higher shear rates, extensional viscosity decreases melts becomes thinner (stress thinning of PP) resin has to be designed for higher extensional viscosity...tailor made for high output machines 22
Manufacturing process for REPOL
Manufacturing process for REPOL Unipol manufacturing process combines the fluidized bed reactor technology of Dow-UCC the Super High Activity Catalyst (SHAC) of Shell No atactic removal and deashing steps due to the highly active and highly selective catalyst Ability to make following grades of PP: Homopolymer (PPHP) Impact Copolymer (PPCP) Random Copolymer (RCP) Controlled Rheology (CR) 24
Unipol process 25
Resin Property Modification Type of catalyst and plant process parameters used during polymerisation, decide the following resin parameter: Tacticity Molecular weight Molecular weight distribution Resin parameters and additives incorporated are determined by the requirements processability end properties of a product 26
roduct Application & Research Centre : Vital link between Plant - Business - Processors Manufacturing PARC Marketing Processors 27
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Thank You! 30