Sustainability through Hydrocerol PAM-2016 Dr.Mahesh Dhekane BU Masterbatches Head of PM Additives- Region IMEA 09.12.2016
2 CONTENTS Company profile What is Sustainability Challenging needs and Solutions What is Hydrocerol Hydrocerol in Injection Molding Hydrocerol in Extrusion Hydrocerol in Blow Moulding
Company Profile CLARIANT Dr.Mahesh Dhekane BU Masterbatches Head of PM Additives- Region IMEA 09.12.2016
4 Public, Corporate Presentation, Clariant at a glance A globally leading company in specialty chemicals 5 807 Sales 2015 (CHF m) from continuing operations 853 EBITDA 2015 (CHF m) before exceptionals 4 Business Areas 227 Net result 2015 (CHF m) from continuing operations 14.7% EBITDA margin 2015 before exceptionals 17 213 Employees 2015 Corporate Center, Pratteln, Switzerland 110 in 53 companies countries
What is Sustainability CLARIANT Dr.Mahesh Dhekane BU Masterbatches Head of PM Additives- Region IMEA 09.12.2016
6 Confidential Today s global challenges World population is growing to >9 billion by 2050. Buying power and wealth in the emerging countries are growing. Today mankind is consuming the resources of 1.5 planets and exceeding the Earth s capacity to regenerate. Environmental issues are becoming more evident (climate change, biodiversity, water supply, waste). This conflicting situation causes social, economic, and ecological challenges we are facing today under the headline Sustainability. Demand is increasing for resources (fossil energy, minerals, water, renewables, nutrition, land).
7 Sustainability for Clariant
Challenging needs and Solutions PLASTIC INDUSTRY Dr.Mahesh Dhekane BU Masterbatches Head of PM Additives- Region IMEA 09.12.2016
9 Confidential Challenging needs - Packaging segments FOCUSED MARKET SEGMENTS Reduce packaging complexity Use less energy Use less packaging material Customers needs Enable recycling of packaging material Prolong shelf life of goods Reduce material wastage Health & Nutrition: Yogurt cups, Noodle pots Toiletries and Cosmetics: Jars, Bottles Industrial packaging: Pails, Drums, Jerry cans Industrial food packaging: Containers Lubricant Oil: Containers, Bottles
10 Challenging needs - Consumer Goods
11 Challenging Needs- Automotive Fuel Efficiency FOCUSED MARKET SEGMENTS Dashboards Use less energy Light Vehicle Air-ducts Vehicle emission control Customers needs Elimination of Sink Marks & Warpage Dimensional Stability Cooling units Ski Carrier Fans & Shrouds
12 Confidential Clariant s solution is Hydrocerol Conceivable material reductions Beyond compliance VALUE CHAIN Suppliers CLARIANT Converters Potential investment savings Improved cycle time
What is HYDROCEROL PRINCIPLE, TYPES AND PROPERTIES Dr.Mahesh Dhekane BU Masterbatches Head of PM Additives- Region IMEA 09.12.2016
14 Public Basic principle of Chemical Foaming Agents HYDROCEROL
15 Public Types of Chemical Foaming Agents HYDROCEROL Exothermic agents Endothermic agents CFA (exo) + E 1 N 2 + E2 + organic byproduct CFA (endo) + E CO 2 + H 2 O + inorganic byproduct T DSC profile Exothermic decomposition E+ T DSC profile Endothermic decomposition E+
16 Public Properties of Chemical Foaming Agents HYDROCEROL Decomposition range Polymer processing temperature I I I I I I I I I I I I I Hydrocerol 2020 Hydrocerol ITP 820 Hydrocerol 2056 Hydrocerol 2035 I I I I I I I I I I I I I 105 120 135 150 165 180 195 210 225 240 255 270 C Coarse Finer
Hydrocerol in Injection Molding Dr.Mahesh Dhekane BU Masterbatches Head of PM Additives- Region IMEA 09.12.2016
18 Public Hydrocerol in Injection Moulding Potential Advantages on Part: Reduction of weight Elimination of sink mark Compact Elimination of warpage / Improved dimensional accuracy on Process: Improvement of flowability Reduction of injection pressure Reduction of clamping force (enables to use smaller machines) Faster cycle time Foamed
19 Public Hydrocerol in Injection Molding Typical Foaming Process Plastic Hydrocerol Plastification Reaction Dispersion Foaming
20 Public Hydrocerol in Injection Molding Important parameters Back Pressure Holding Pressure Shot weight Injection Speed Temperature profile
21 Public Hydrocerol in Injection Molding Machinery requirements Equipment/Process Hydrocerol can usually be processed on every common injection molding machine!!! Advantageous: Shut-of-nozzle, to avoid premature foaming Gates and flow path should be configured in a way as to allow a fast and even mold filling Very good venting at the end of the flow path Mold material: high alloy steel (approx. 13% Cr) SFM machines with separate transfer cylinder (for High Injection Velocity)
22 Public Different foaming technologies Property Hydrocerol, Chemical Foaming Agent Direct Gassing Process Machine Requirements No changes needed to the standard process Easy dosing, high flexibility A lot changes to the standard process Investment Low Very high Foaming Agent Process stability Good reproducible, reduced temperatures, medium backpressure Source: Frauenhofer ICT complex process, high backpressure, high shear screw
23 Public Advantages of Chemical foaming vs. Physical foaming Cell Size / Homogeneity Surface Finish PP LGF with PFA, inhomogeneous LGF=long glass fiber Cell size Source Neue Materialien Bayreuth PP LGF with CFA homogenous Cell size PFA Foam, streaks visible, often no painting possible CFA smooth surface Cell Size / Skin Layer PP T20 with PFA, big Cell Size, thin Skin Layer PP T20 with CFA, small Cell Size, thick Skin Layer Thick Skin Layer contributes to better mechanical properties
24 Public Hydrocerol in Injection Molding Paint Pails Polymer: PP Weight Reduction 8 % Productivity increased by 10 %. Less manpower and energy. Excellent dimensional stability of Pails Elimination of shark skin Improvement in the properties like Printing, In-mould and Heat transfer labelling, Sleeving and Decoration. 0.5 % Hydrocerol
25 Public Hydrocerol in Injection Molding Dashboard carrier Reference: BMW 3 and 5 series dash board carrier Polymer: PP 20% LGF Process: BMW SGI Process Source: BMW Group Weight Reduction 20% 2012 Technology transfer to new BMW models 1,5 2,0% Hydrocerol Source: BMW Group
Hydrocerol in Extrusion Dr.Mahesh Dhekane BU Masterbatches Head of PM Additives- Region IMEA 09.12.2016
27 Hydrocerol in Extrusion Typical Foaming Process Plastics Hydrocerol Foam Plastification Reaction Dispersion Foaming
28 Hydrocerol in Direct Gassing Plastic* GAS N 2 CO 2 C x H y CFC * and Additives (Nucleants, Colorants, etc.) Without Nucleation With Nucleation Foam Pipe-insulation, seals, profiles, food-trays, boards PE, PP, LDPE, PS, PET, EVA
29 Applications in Extrusion Food trays (PE, PS) Foam Core Pipe (HD) Extruded Profile (PS, PVC) Min. 15% weight reduction 15 % weight reduction Weight reduction up to 30% Thermoforming possible CO-Extrusion (surface) Workability (sawing) Direct gassing Higher output Higher output - HYDROCEROL NUC Series Thermal insulation Lamination Chemical foaming - HYDROCEROL PEX Series Hydrocerol New generation HYDROCEROL PEX Series
Hydrocerol in EBM Dr.Mahesh Dhekane BU Masterbatches Head of PM Additives- Region IMEA 09.12.2016
31 Hydrocerol in EBM process Value Proposition Material (weight) savings A weight reduction up to 10% can be achieved, depending on the geometry and production process of the bottle part. 8-10% in mono-layer and 10-12% in multilayer (in core layer) Improved process cycle time Up to 15% cycle time reduction in 1mm wall thickness Higher stiffness in bottle structure The micro cellular structure can improve the stiffness-to-weight ratio Applicable FDA Hydrocerol grades are FDA approved for food-contact applications Enhances aesthetic surface effect on multilayer structures Generate pearl feeling on top of the surface. Brighter overall look of the product
32 Confidential Clariant provides a solution for lubricant 0il bottles Processing needs Polymer grade Marlex HHM 5502 BN Masterbatch grade White MB / Dosage at 1% Hydrocerol grade Hydrocerol 2225 / Dosage at 1% Mould use 2 + 2 shuttle blow moulding machine Temperature Feed 180 C/195 C/195 C/194 C/ Die 180 C Success findings Weight Reduced from 215gm ~ 190gm (11%) Cycle time Reduced from 45s ~ 41s (9%) Drop test No leakage
33 Confidential Clariant provides a solution for general bottles Processing needs Polymer grade Marlex HHM 5502 BN Masterbatch grade Pearl MB / Dosage at 1% Hydrocerol grade Hydrocerol 2225 / Dosage at 1% Mould use Shuttle blow moulding machine Temperature Feed 180 C/195 C/195 C/194 C/ Die 180 C Success findings Weight Reduced from 23g 20g(12%) Cycle time Reduced from 15.5s 13s (16%) Drop test No leakage (1.2m)
34 Hydrocerol in EBM
35 THANK YOU!!!!