A Leap in Polyolefin Applications with Advanced Calcium Carbonates Gil Morieras Director Marketing Asia Pacific / Greater South East Group Marketing Plastics Oftringen, Switzerland 03 September, 2015
Table of Contents Introduction to Omya, MENA structure Local Product Portfolio Advancements in : Films Thermoforming sheets PP tapes or Raffia Open discussion 2
Product Portfolio 3
Product Portfolio Fine treated CaCO3 Omyacarb 2T / Omyafilm 720 Omyacarb 1T / Omyafilm 707 Anti Blocking Masterbatches for Films Injection Molding Raffia Thermoforming Sheets Blow Molding Anti Blocking Masterbatches for Films Raffia 4
Advantages of GCC in Thermoforming Polypropylene thermoforming Sheets 5
Why use CaCO 3 for PP Sheet Extrusion? - Improved thermal conductivity - Faster melting in extruder - More homogenous melt - Faster sheet-cooling on calender rolls Faster Extrusion Line Speed - Low coefficient of expansion - Lower melt volume - Lower friction to barrel surface - Lower torque and die pressure Increased Extruder Output Rate (by volume) 6
CaCO3 in Thermoforming Sheets cycles per min Productivity improvements Thermoforming: 30 25 20 18 cavities yoghurt beakers Cycle Time Reduction Thermal diffusivity in mm²/sec 0.3 0.3 0.2 0.2 0.1 0.1 0.0 no sheet preheating with sheet preheating 12% & 35% more cycles (with & w/o pre-heating) Heat Transport HIPS virgin PP PP 30% CaCO3 PP 60% CaCO3 7 7 15 HIPS PPH 30% CaCO3
CaCO3 in Thermoforming Sheets Performance improvements Stiffness: CaCO 3 Enhancing PPH Stiffness E-Modulus in N/mm² 2500 2000 1500 1000 500 0 E-Modulus Increase in CD & MD => 15% & 30% 0 30 % carbonate CD MD 8
CaCO3 in Thermoforming Sheets Performance improvements Impact Resistance: Weight in g Dart Drop Impact Resistance Improvements 1200 1000 800 600 400 200 0 virgin PPH DDI Increase 250% (at same weight or at same gauge) 30% CaCO3 same thickness 30% CaCO3 same weight 9
CaCO3 in Thermoforming Sheets Post-Shrinkage / Orientation 30% CaCO 3 Virgin PPH 10 Thermoformed yoghurt cups after 30 min at 140 C
CaCO3 in Thermoforming Sheets Improved economics!!! 110.0 100.0 Cost Saving with CaCO 3 in thermoformed PPH overhead & labour mould depreciation machine production & depreciation sheet cost Cost in % 90.0 80.0 70.0 60.0 50.0 PPH 20% CaCO3 30% CaCO3 40% CaCO3 HIPS 11
Application Examples Disposable dishes and cups Food trays, pots and covers Plant pots and seeding trays Profiled building products Household articles Automotive interior trim items 12
Films 13 03.09.2015
Description of the study Production of 5 blown films with the Dr. Collin Lab. Line Reference: 33% LDPE + 67% C 4 -LLDPE 10% Omyafilm 707: 30% LDPE + 55% C 4 -LLDPE + 15% MB 20% Omyafilm 707: 27% LDPE + 45% C 4 &C 6 -LLDPE + 28% MB 25% Omyafilm 707: 25% LDPE + 39% C 6 -LLDPE + 36% MB 30% Omyafilm 707: 23% LDPE + 34% C 6 -LLDPE + 43% MB Remarks Reference is related to a typical carrier bag formulation All films were produced at constant weight (43g/m 2 ) LDPE/LLDPE ratio was kept constant in all formulations 14 03.09.2015
Film weight vs. thickness when adding Omyafilm 707 Density of film (kg/dm 3 ) 1.16 1.12 1.08 1.04 0.96 0.92 By adding Omyafilm 707 the density of the film increases, i.e. to keep a constant film weight, the film gauge has to be reduced: 1 0% 5% 10% 15% 20% 25% 30% Omyafilm 707-content 50 48 46 44 42 40 38 Thickness of film (micron) 100% PE 46g/m 2 @ 50μm (ρ film : 0.92 kg/dm 3 ) +15% Omyafilm 707 46g/m 2 @ 45μm (ρ film : 1.02 kg/dm 3 ) 15
Film performance Film weight (g/m 2 ): 50 Grammage (g/m 2 ) 45 40 35 42.8 42.6 41.6 43.6 43.8 30 Reference 10% OF 20% OF 25% OF 30% OF Films were produced at the same weight (grammage), i.e. the film gauge was adjusted to the Omyafilm 707 content 16 03.09.2015
Film performances Yield force ISO 527-3 9 Yield force (N) 8.5 8 7.5 7 6.5 7.4 7.1 6.9 6.5 7.4 7.3 8 7.8 8 7.3 MD CD 6 Reference 10% OF 20% OF 25% OF 30% OF All 3 formulations with high Omyafilm 707 -content are okay 17 03.09.2015
Film performances Elmendorf tear propagation resistance ISO 6383 Elmendorf tear resistance (cn) 600 500 400 300 200 100 0 156 419 151 503 187 MD: All formulations containing Omyafilm 707 are okay CD: Dramatic increase for all formulations containing Omyafilm 707 18 03.09.2015 778 962 1165 212 163 Reference 10% OF 20% OF 25% OF 30% OF MD CD
Film performances E-modulus, i.e. secant 0.02-2% ISO 527-3 600 E-modulus (N/mm 2 ) 550 500 450 400 350 300 250 200 243260 266 276 405 369 498 502 449 430 MD CD 150 100 Reference 10% OF 20% OF 25% OF 30% OF Increase for all formulations containing Omyafilm 707 19 03.09.2015
Film performances Dart drop impact resistance ASTM D 1709 A 225 200 Falling dart (g) 200 175 150 176 182 192 189 125 100 Reference 10% OF 20% OF 25% OF 30% OF Higher for all film formulations containing Omyafilm 707 20 03.09.2015
Film performance Sealing force (at 70 N, 2 sec) Internal method* Sealing force (N) 15 12.5 10 7.5 5 2.5 Reference 10% OF 20% OF 25% OF 30% OF 0 120 130 140 150 Temperature of bars ( C) No significant variations for formulations containing Omyafilm 707 * : sealing equipment Kopp, lowest pressure set-up, film width of 15mm 21 03.09.2015
Line output rate Extruder output rate (Collin teach line) at 100 rpm: Extruder out-put (kg/h) 3.5 3.25 3 2.75 2.5 2.25 2 1.75 2.39 2.55 2.75 3.02 3.25 1.5 Reference 10% OF 20% OF 25% OF 30% OF The extruder output rate increases with increasing Omyafilm 707 level 22 03.09.2015
Variation of formulation cost (general) The use of Omyafilm 707 reduces the raw material cost (at constant film grammage): With increasing polymer prices, the savings become more significant 23 03.09.2015
CaCO3 in PP Woven Tapes Calcium carbonate is conventionally used in PE or PP woven bags, weaving tapes or bands to offer antisplitting and anti-fibrillation effects. Polyolefin masterbatches based on appropriate calcium carbonate offer: Reduced splitting propensity of oriented polypropylene Increased stiffness Reduced amount of titanium dioxide Reduced raw material consumption Conventional calcium carbonate loadings are in a range of 2% to 30% in final articles. 24
CaCO3 in PP Woven tapes Advantages of using Omyafilm 720 in PP woven tapes : Achieve high filler loading in Masterbatches Optimized mineral dispersion (Low FPV) Prevent using waxes and lubricants which reduces WCO and Die build up Low humidity level in masterbatches Reduce WCO Increase life time for knives and increased screen pack change over time 25 Reduces dust accumulation (spinning and knitting)
CaCO3 in PP Woven tapes : Higher requirements For high speed line or high demanding applications, Omyafilm 707 is the optimum solution : Appropriate surface treatment to avoid Die build up during processing and dust accumulation Lower WCO : Speed could be increased Increased elongation @ break compare to coarser grades. Improves post-weaving operation and production efficiency. Improve knitting process less yarn breakage Increase tensile strength thus enabling higher filler loading Higher tape surface smoothness 26
Cost Savings 27 A finer product allows you to increase the CaCO 3 addition level maintaining mechanical properties (+3%)
Tenacity Cost Savings 5.5 Tenacity vs. CaCO3 content and CaCO3 type 5.0 4.5 4.0 Omyafilm 707 Omyafilm 720 3.5 3.0 7% 15% 22% 30% Omyafilm 707 Omyafilm 720 Compounding Costs 50 Formulation PE 2000 Omyafilm 707 USD + 30 / Ton Omyafilm 720 Masterbatch @ 80% OFM 720 562 Masterbatch @ 78% OFM 707 623 28 Tapes with 22 % Omyafilm 720 28% 1614 Tapes with 25 % Omyafilm 707 32% 1559
Thank You www.omya.com 29