CW December 2012

December 2012
HOW TO HANDLE HIGH-TEMPERATURE PLASTICS PICKING FLAME RETARDANTS FOR POLYAMIDES NEW DEVELOPMENTS IN LAB COMPOUNDERS GETTING TO GRIPS WITH GREEN CHEMISTRY
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contents
05 Industry news
PAGE 13
The latest compounding industry news including international acquisitions and alliances, plus new investments and plant openings.
13 Compounding heats up
High-performance plastics present challenges to compounders as processing temperatures soar to 400C and beyond. Jennifer Markarian reports.
PAGE 21
21 Picking ame retardants for polyamides

Pat Toensmeier speaks with resin producers and additives suppliers about recent developments in ame retardants for nylon compounds.
PAGE 33
33 Lab compounders: small machines for big ideas

Mikell Knights reviews the latest laboratory extruders and kneaders for developing new formulations and for small-scale production runs.
49 Inside the green revolution

Dr Sally Humphreys reports from the rst Green Polymer Chemistry conference
PAGE 49
on progress in renewable and sustainable plastics technologies.
57 New products: polymers and additives 63 New products: machinery and software
PAGE 57
66 Compounder of the month: F&D Plastics 68 Dates for your diary
coming next issue

S Polymer foam technologies S Pelletizers S Dispersants and coupling agents
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Applied Market Information Ltd AMI House, 45-47 Stokes Croft, Bristol, BS1 3QP, United Kingdom Tel:+44 (0)117 924 9442 Fax:+44 (0)117 989 2128 www.amiplastics.com Head of business publishing: Senior editor: Contributing editor: Designer: Advertisement manager: Andy Beevers Chris Smith Jennifer Markarian Nicola Crane Claire Bishop E-mail: abe@amiplastics.com E-mail: cs@amiplastics.com E-mail: editorial@compoundingworld.com E-mail: claire@amimagazines.com Direct tel: +44 (0)20 8686 8139
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www.compoundingworld.com December 2012 | COMPOUNDING WORLD 3
news
China XD commissions new compounding lines

China XD Plastics is adding new compounding lines at its production facility in Harbin, China. The company says that they will increase its total annual production capacity by 135,000 tonnes to 390,000 tonnes. The new lines are being installed at three newly built plants within China XDs Number 3 production base in Harbin and will start to contribute to production in the first quarter of 2013. The company says that the capacity expansion is backed up by investments in R&D equipment to support new product development. In December 2011, China XD added 20 new compounding lines that came on stream in the first half of this year, taking its extruder count to 58 and increasing its total annual capacity by 90,000 tonnes to 255,000 tonnes. China XD focuses on technical compounds for automotive applications. It says that its materials are used in components for 23 automobile brands manufactured in China, including Audi, BMW, Toyota, Buick, VW and Hafei. In its recently released third quarter 2012 results, the company reported a 57.4% year-on-year increase in revenues, achieving US$163.3 million for the three months. The total volume shipped during the period was 61,589 tonnes, while gross profit was US$40.4 million, representing year-on-year increases of China XDs compounds are used by 23 car manufacturers in China, including BMW 57.7% and 50.9% respectively.
Owens Corning expands

Owens Corning has started up new furnaces at its glass reinforcement manufacturing sites in Gous-Khroustalny, Russia, and in Tlaxcala, Mexico. Production capacity at both sites has been more than doubled and the new furnaces will be used to produce corrosion-resistant Advantex glass. The new Gous-Khroustalny furnace will produce roving and wet-use chopped strands, while the extra capacity at Tlaxcala will be used for assembled roving and dry-use chopped strands. Owens Corning has also recently opened its new China Composites Center in Shanghai to provide local R&D support and expertise.
www.chinaxd.net
www.ocvreinforcements.com
Songwon reveals one-pack plant location

Songwon Additive Technologies and Polysys Industries have announced plans to build an antioxidant OPS (one-pack systems) manufacturing plant in Kizad, Abu Dhabi. It will have an initial capacity of 7,000 tonnes and is expected to be completed in late 2013. The two companies are forming a new venture Polysys Additive Technologies to construct the facility. The announcement follows the formation of Songwon Additive Technologies, a joint venture between Songwon of South Korea, Pan Gulf Holding
www.compoundingworld.com
This is a very important step for Songwon in the development of our global OPS footprint following the acquisition of Additive Technologies Greiz and the capacity expansion which has already been implemented [in Germany]. The Middle East already represents a key market for OPS and polymer stabilizers and we Left to right: Khalid Al Hamdan, MD of Pan Gulf; Maurizio Butti, COO of Songwon; and Mohamed Al Muhairi, chairman of Polysys Company of Saudi Arabia and Polysys Industries of Abu Dhabi for the manufacture and sale of Songnox OPS (see expect this position to grow significantly in the near future. Songwon Additive Technologies also plans to build an OPS plant in the USA, but has not yet confirmed its location or timing.
Compounding World, Nov 2012: http://bit.ly/songwon). Maurizio Butti, Songwons chief operating officer, said:
www.songwonind.com
5
December 2012 | compounding world
news
FBW adds two Coperion lines

FBW has installed two new Coperion STS 35 Advanced twin-screw extruders at its compounding plant in Niederzier, Germany. They are being used to produce colour and additive masterbatches in small- and medium-sized batches from 25 to 300 kg. The extruders are equipped with 35 mm diameter screws and feature Coperions new STS Masterbatch die head, which can be quickly opened for rapid cleaning. An easily exchangeable breaker plate permits filtering of the masterbatch melt using insert screens. FBWs managing director Gerd Cornils explains the reasons for the extruder selection: Our aim was to invest in two flexible, easy-touse masterbatch machines FBW has added two Coperion STS 35 extruders to increase masterbatch production that offered a good price-performance ratio. We found that all these requirements were more than met by Coperions STS advanced series. Coperions STS extruders are developed at the companys main production site in Stuttgart, Germany, and are manufactured at its Chinese factory in Nanjing. This, says the company, enables it to provide a high-performance compounding system at relatively low investment costs.
www.fbwgmbh.de www.coperion.com
Albemarle invests in FR plant

Albemarle has announced plans to expand its manufacturing operations at Orangeburg, South Carolina, USA. It is investing a total of US$65 million over five years at the facility and expects to add 20 new jobs. The expansion plans include a new plant for the production of the companys GreenCrest high-molecular-weight polymeric flame retardant. This is designed to gradually replace hexabromocyclododecane (HBCD) for use in extruded (XPS) and expanded (EPS) polystyrene applications. Albemarle plans to commercialise the new technology in 2014.
Masterbatch group elects board

Masterbatch Verband, Germanys masterbatch industry association, elected a new board at its general meeting in Frankfurt on 23 November. Erhard Naumann of Lehmann & Voss was re-elected chairman, and he is joined on the board by Dr Martin Fabian of Lifocolor and Bernd Schfer of Deifel. The association is part of the broader pigments organisation, Verband der Mineralfarbenindustrie (VdMi). It has 19 member companies and says that it represents the leading masterbatch makers in Germany. At its general meeting it discussed its members concerns about REACH chemicals legislation, in particular regarding the classification of pigments and inconsistencies in information. Masterbatch Verbands new board (left to right): Erhard Naumann, Dr Martin Fabian and Bernd Schfer
www.masterbatchverband.de
Pantone picks Emerald as the colour of 2013

Pantone has named Emerald as its colour of the year for 2013. It describes the colour Pantone 17-1463 as a lively, radiant, lush green. The company, which is a division of X-Rite and provides professional colour standards and forecasts, says that green is the colour of growth, renewal and prosperity. It adds that the prevalence of green has been steadily rising for several seasons, especially in the fashion and couture markets.
www.albemarle.com
6 compounding world | December 2012
www.pantone.com
TIME TO IMPROVE YOUR IMPACT RESISTANCE?
New Jetfine optimizes the rigidity/impact strength balance of exterior automotive parts
Polypropylene bumpers and fenders need to be tough to meet increasingly stringent specifications in the automotive industry. With their high aspect ratio and ultrafine grind, Jetfine talcs: achieve very high impact resistance requirements for high-flow resins lower the CLTE for zero gap parts increase stiffness are compacted for easy handling
www.imerystalc.com plasticstalc.americas@imerys.com
news
BASF starts up additive blends plant in Bahrain

BASF Plastic Additives has begun production of customer specific antioxidant blends (CSB) at its new plant in Bahrain. It says that it is the largest facility of its kind worldwide. The new plant, which uses proprietary CSB technology, will provide local supply and services to the fast growing polymer market in the Middle East. Its production is in addition to BASFs existing CSB manufacturing agreement with Astra Polymer in Saudi Arabia, which was extended earlier this year. Speaking at the plants opening ceremony, executive board member Michael Heinz said: BASFs investment in this new site demonstrates our steadfast commitment to support growing industries in the Middle East, while at the same time setting standards with regard to quality, safety and employee training. Michael Heinz (far left) is joined by BASF colleagues and Bahrain officials at the opening ceremony for the CSB plant
Foster to expand in Asia

Foster, the US-headquartered compounder specialising in medical and drug delivery applications, is establishing an office in Belgaum, India to offer technical service and product development support to customers in Asia. The office will be headed up by Amar Nilajkar, who has a degree in polymer engineering from the University of Massachusetts at Lowell, and has been with the company for 10 years. According to Foster, the increase in catheter device manufacturing in the Asia Pacific region has resulted in sales growth of nearly 300% for the companys medical polymer compounds. In addition, the pharmaceutical industry in India has shown a strong interest in Fosters expertise in blending active pharmaceutical ingredients.
www.basf.com
Evonik goes phthalate-free

Evonik has announced plans to enter the phthalate-free and bio-based plasticizer market, and it is building a new 40,000 tonnes/year production facility at the Marl Chemical Park in Germany. The plant will produce the phthalate-free plasticizer 1,2-cyclohexane dicarboxylic acid diisononyl ester, a chemistry which is already produced and sold by BASF under the Hexamoll DINCH tradename. Start-up of the new facility is scheduled for the second half of 2013 and the company says it will be followed by the launch of bio-based plasticizers.
www.evonik.com
www.fostercomp.com
APS Compounding exceeds production goals

APS Compounding, which started up in Romulus, Michigan, USA just over a year ago, has produced its first 500,000 lbs (230 tonnes) of thermoplastic elastomer (TPE) compounds. The companys principal, Stephane Morin said: We actually exceeded our goal to reach the half million pound mark in the first year. APS Compounding was established by the polymer distributor Alliance Polymer & Services in 2011 and it operates two twinscrew compounding lines. The parent company distributes BASF Elastollen TPUs and Polymax Maxelast SBC-based TPEs and it wanted to add the ability to tailor custom grades.
www.apscompounding.com
8 compounding world | December 2012 www.compoundingworld.com
CREATING TOMORROWS SOLUTIONS
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news
CREATING TOMORROWS SOLUTIONS
Above: Luxus has installed 12 new silos to increase storage capacity at its Louth plant. Below: Luxus will use its new line to develop formulations based on recycled and prime resins
Luxus expands capabilities

Luxus has installed a new compounding line for research and development projects at its plant in Louth, Lincolnshire, UK. The line includes a Coperion STS twin-screw extruder, a Brabender loss-in-weight feeding system and an Automatik strand pelletizer. Luxus produces thermoplastic compounds based on prime and recycled feedstocks at the site, which currently has a production capacity of 30,000 tonnes/year. Target markets include the automotive, retail logistics, wheelie bin and construction sectors. The new development line is part of the companys new technical centre which is scheduled to be fully operational in February 2013. It will be used to develop new formulations and optimise existing grades based on PC, ABS, PC/ABS, PA, PP and PE. In addition, it will assist with the recycling of increasingly complex waste streams to produce useable compounds.
UPGRADE YOUR PERFORMANCE!
Terry Burton, technical Manager at Luxus, said: Our specialist interior automotive business in particular will benefit from the new line. Client samples will be processed on the machine and then increased to full-scale production in just a single rapid step. Speaking about the selection of the Coperion extruder, Burton added: We were impressed with the overall quality of the machine, its flexibility and the support thats offered. Luxus has also recently taken delivery of 12 new 80 m3 silos at its Louth facility, boosting storage capacity from 125 tonnes to 700 tonnes.
Sometimes it takes just a little genius to cause huge effects: Our GENIOPLAST Pellet S is compatible with all thermoplastic polymers and is ideal for integration into continuous production processes. Moreover, it optimizes polymer compounds by improving their mechanical and ow properties, scratch resistance and demoldability. The result is an improved formulation quality. Or in other words: a performance upgrade! Contact us at www.wacker.com/genioplast Wacker Chemie AG, Tel. +49 89 6279-0, info@wacker.com
www.luxus.co.uk
High-temperature compounding | processing feature
The growing use of high-performance polymers presents many challenges to compounders as processing temperatures soar to 400C and beyond. Jennifer Markarian reports
Compounding heats up
There is growing interest in very high performance plastics, typically for the replacement of metals in ever more challenging applications. Polymers such as polyetheretherketone (PEEK), polyetherimide (PEI) and polysulphone (PSU) are being specied in critical components to withstand extreme conditions in the electronics, medical, automotive and chemical processing sectors, for example. Incorporating the required reinforcements, additives and colorants into these high-temperature polymers presents signicant challenges to compounders. High-temperature compounding is more demanding in every aspect. It has implications for the extruder design and its materials of construction, as well as requiring tighter process control, more precise pelletizing, careful compound formulating, and a rigorous approach to cleaning and maintenance. high melting points, such as those listed in Table 1, is getting the extra heat into the polymer to melt and mix it, and subsequently removing the heat to cool and pelletize the material. Techniques to meet these challenges include using high-wattage heaters, improved insulation, efcient cooling systems, and designs with good heat transfer. In addition, temperature sensors must be designed to measure high-temperature ranges. Standard grades of PEEK, for example, require a minimum processing temperature of about 400C (750F), notes Richard Leibfried, market development manager for Victrex Polymer Solutions. The companys higher-temperature versions of PEEK (HT and ST grades) require a minimum capacity of 430C (800F). Leibfried recommends ceramic heating bands and notes that the insulation of bare metal helps dramatically. Twin-screw extruders are generally used, and longer length/diameter (L/D) ratios are typically employed to enable adequate melting and mixing. Longer extruder
Equipment design
The basic challenge of compounding polymers with very
Table 1 - Typical melting points of high-performance polymers

Resin Polysulphone (PSU) Polyetherimide (PEI) Polyethersulphone (PES) Polyphenylene sulphide (PPS) High-temperature nylon (HTN) or polyphthalamide (PPA) Polyetheretherketone (PEEK) Liquid crystal polymer (LCP)
Source: Solvay Specialty Polymers
Amorphous resin glass transition temp (C) 190 215 220 -
Crystalline resin melting point (C) 285 300-330 (depending on grade) 345 325-400 (depending on grade)
December 2012 | COMPOUNDING WORLD
13
processing feature | High-temperature compounding
Entek says that materials used in extruder parts need to meet the high temperature requirements
lengths also allow more flexibility in downstream feeding and venting zones. Screws and dies must be designed to minimize dead-space, because any material caught in a dead-spot will quickly degrade. Materials of construction should also be considered. If a process is run hotter than the tempering temperature of the metal, the metal could lose hardness, which could result in premature wear, comments Craig Benjamin, design engineer at Entek Extruders. The process used to heat-treat or temper the metal must be changed in order to adjust the temperature at which the metal maintains hardness. Corrosion can also be amplified at higher temperatures, and the corrosionresistance of extruder materials should be considered, adds Benjamin. KraussMaffei Berstorff makes twin-screw extruders with heat-treated steel designed for processing up to 420C (790F), or with a special design that allows processing up to 450C (840F). Barrel elements with a special heating and cooling system provide direct and intensive heat transfer or cooling, notes Dr Thomas Winkelmann, head of the processing department for twin-screw extruders at the company. The extruders barrel housings are designed to increase the heating performance in the barrel section by using more heating cartridges and by reducing the distance to the processing chamber. This barrel design can deliver up to 50% more heating power compared to the standard version, which ensures that the required processing temperatures are reached quickly, reliably maintained and exactly controlled, says Winkelmann. In addition, the barrel sections and strand die heads have insulating plates to limit heat losses and decrease heating energy consumption. The optimized layout of the cooling bores provides high-efficiency, counter-flow cooling with standard injection of water. Using a strand pelletizing system requires high-power heating of the die head and sometimes additional heating of the die plate to achieve a common temperature distribution and permit stable material flow out of the die. In addition, screw designs are chosen to add thermal energy by optimizing shear stress without degradation. Because processing windows are typically narrower with higher-temperature processing, there is a finer line between melting and degradation. Screw designs are thus targeted for different materials and different grades to balance shear and dispersion for that formulation. Operators must be aware that different grades are set up differently, notes Glenn Desio, technology manager for crystalline polymers at Solvay Specialty Polymers. Additives used in high-temperature formulations must be chosen to withstand the higher processing temperatures. Matching colours can be challenging, notes Desio, because the colours must be both stable during compounding and the right colour match at room temperature and the applications use temperature. Colorants are generally limited to inorganic pigments, adds Leibfried. There are few restrictions, however, on inorganic fillers and fibres, and a wide range, including nano-fibres, are used. Kevlar and other aramid fibres can be temperature sensitive, so care must be taken when using these, says Leibfried. Pelletizing high-temperature polymers presents challenges as well, plus extra care must be taken because customers expect high pellet quality from these high-value materials. Strand pelletizers have been the traditional choice for high-temperature resins. However, they typically need more space for such applications because they
KraussMaffei Berstorff has developed barrel housings that significantly increase heating capacity
14
compounding world | December 2012
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This BKG underwater pelletizer has an insulated closed water system to handle hightemperatures
require a longer distance to cool down from a high temperature. Cooling with a spray mist and an air belt is an alternative to a water bath that has been found to work well in Enteks processing lab, notes Dean Elliott, laboratory manager at Entek Extruders. Trained maintenance personnel are important because thermal expansion during processing changes the gaps in the pelletizer, notes Desio. There is a narrow window of optimal temperature, knife-blade speed, and roll pressure needed to make good pellets, he adds. While strand systems are widely used, die-face pelletizers can now also be used due to technology advances in die-plate design, and suppliers note an increased interest in underwater, die-face systems for processing high-performance resins. Pelletizing high-temperature resins using underwater, die-face pelletizers requires specially designed systems, says Ralf Simon, managing director at BKG, a supplier of underwater pelletizer systems. The die-plate must be designed to minimize heat loss and maintain a good temperature distribution in the plate, and must be made of steel designed for higher temperature use. Insulation can be used to keep heat in
the die, which prevents die freezing. In addition to die-plate design, the entire pelletizer and screen-changer assembly must be designed to operate at higher temperatures using insulation, specially designed hydraulic cylinders, and cooling for some parts. Mark Tate, technical manager for underwater pelletizer supplier Gala Industries, says that the companys Heat Flux Die Plate technology combines surface-insulation methods and manufacturing techniques to reduce or eliminate die-hole freezing, and can therefore be used to pelletize high-temperature polymers. He notes that another possible concern when using underwater pelletizing for high-temperature compounds is the resulting hot process water; Gala uses double-insulated tanks to ensure operator safety. Todays systems from Gala come standard with coil heaters, which are more energy efcient than earlier cartridge-heater technology and have improved conductivity of heat into the die. We have seen 30-60% reduction in energy use, which is particularly a benet
when running higher temperatures, says Tate.
BKG demonstrates the improved temperature distribution of a die with thermal insulation (right) compared to one without (left)
16
COMPOUNDING WORLD | December 2012
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Preventive maintenance is crucial for high-temperature processing because there is less tolerance in all aspects of the process. Because the cycle from room temperature to processing temperature is more extreme, expansion and contraction of metal parts is also more significant, and regular maintenance should be done at shorter intervals. This maintenance should include tightening barrel bolts, checking alignment, and checking that elements on the screw shaft are tight, says Enteks Benjamin. If gaps develop between the screw elements, polymer could leak through onto the shaft, which would make pulling the screw more difficult. These are all maintenance items that processors should normally do, but they may need to be done more frequently, he Above: Gala says that mechanical seals require less maintenance and endure faster speeds and higher temperatures Right: Galas Heat Flux Die Plate is designed to reduce or eliminate die-hole freezing He adds that another technology that is beneficial for high-temperature processing is a mechanical seal to prevent water from entering the pelletizer motor. Compared to radial shaft or lip seals, mechanical seals require less periodic maintenance and better endure faster speeds and higher temperatures, says Tate. While everyone wants to minimize downtime, it is particularly important to reduce the polymer wasted during downtime when running expensive engineering resins, comments Tate. He claims that Galas EAC (Electronically Advanced Cutter) technology increases uptime and reduces blade and die-face wear. The system incorporates automated blade advance, periodic blade sharpening, and blade monitoring. Underwater pelletizers have an advantage for high-temperature resins with low viscosities that can cause problems when trying to draw a strand. The temperature difference from the molten material to the cooling water, which is at 80-90C in these applications, creates a skin around the molten material, and low-viscosity materials are then easy to cut, notes BKGs Simon. Underwater pelletizers are closed systems, which can be an advantage compared to open, strand systems for some materials in which evaporation of volatile components may be an environmental risk. Underwater systems also offer the general benefits of throughput, automation, and a smaller footprint. Underwater systems are broadly used with polyamides, and are increasingly used with PEEK, PPS, and PSU, for example. Some grades of LCP have been run successfully in small-scale and larger commercial systems, but other grades of LCP remain a challenge, note suppliers.
recommends. Cleaning is also important. While standard, commercial purge compounds may not work well in high-temperature processes, a few high-temperature purge compounds are available. For example, Sun Plastechs Asaclean purging compound comes in high-temperature grades. Asaclean SX is designed to clean in the temperature range of 300-390C (570-735F). Asaclean PX is designed to clean at temperatures up to 420C (788F) with low levels of smoke and processing odour. Some use neat resin as a purging compound between different grades of that resin. When making extreme colour changes, the most effective technique is still to pull the screw and clean it, says Solvays Desio. With PEEK in particular, adds Berstorffs Winkelmann, mechanical cleaning of screws and barrel borings is necessary. It takes special training and care to clean and operate a high-temperature processing line. Not only is it hot, but there can be a fire risk because processing can be close to the auto-ignition temperature of materials. Operators must be comfortable working with high-temperature equipment and must take appropriate precautions. Training and documentation of procedures are critical. Click on the links for more information:
www.asaclean.com www.bkg.de www.entekextruders.com www.gala-industries.com www.kraussmaffei.com www.solvayspecialtypolymers.com www.victrex.com

www.kraussmaffei.com
Substantial gain in productivity Compounding lines

Compounding lines are system solutions of conventional or modular design, strictly tailored to customer requirements. As your prime contractor and system partner, KraussMaffei Berstorff optimizes the entire production process and offers professional assistance in all project phases. We integrate special solutions into an existing infrastructure and provide pre-assembled modular lines with all accessories that perfectly complement your KraussMaffei Berstorff twin-screw extruders. info@kraussmaffei.com
Flame retardants | additives feature
Pat Toensmeier speaks with resin producers and additives suppliers to nd out the latest trends and technical developments in ame retardants for polyamide compounds
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Picking ame retardants for polyamides

smoke and corrosion, have minimal effects on electrical properties, maintain high-temperature stability and are compatible with colours. Many companies are also looking at innovative co-ame retardant combinations, which along with the use of synergists such as boehmites (an aluminium oxide hydroxide), achieve properties at lower loadings. The chief benet is that ow is not as greatly affected during moulding, extrusion or compounding, explains Hanley. Maintaining thermal stability in higher processing temperatures and end-use environments also affects FR chemistries. There is a lot of work underway in non-halogenated chemistries, mostly for ame retardants based on phosphorous or nitrogen-containing materials, says Richard Wenger, technical product manager for the PA 6 business of DSM, which also produces PA 46. At elevated temperatures low-level Densely packed circuit boards that use high-heat lead-free soldering demand upgraded FRs Invista supplies an FR grade of Torzen PA 66 for this Peugeot 508 relay and fuse box
Polyamides are widely used in high-volume markets such as the automotive, electrical, electronics, appliance and industrial sectors. Like all engineering thermoplastics, polyamide (PA) formulations are continually tweaked to enhance properties and performance for changing applications and regulatory needs. One critical formulation area for PA is ame-retardant (FR) additives. Resin producers and compounders are working with FR suppliers on a range of additive chemistries to meet shifting re and toxicity requirements while minimizing trade-offs in performance and cost. Almost all new FR grades are free of halogens and bromines, which are effective and economical, but for regulatory and environmental reasons are being phased out of many applications. In their place, additive suppliers and resin producers are seeking alternative FRs that do not affect the properties of PA formulations, including those that use reinforced grades. Other considerations include FRs that do not migrate during processing or use, have no affect on part colour, and importantly, do not impede processing or contribute to machine corrosion from release of by-products. Melamine compounds, alkylphosphinates, phosphorus derivatives and metal hydroxide are among the leading materials that are being specied in PA grades for ame retardance, says Steve Hanley, product development manager for engineering plastics at PA 6 producer BASF, which also makes FRs. These chemistries are compliant with international regulatory standards, yield low levels of
21
additives feature | Flame retardants
This micro switch is moulded using BASFs Ultramid A3U40G5 25% glass-reinforced PA 66
breakdowns can occur that generate phosphoric acid and other signatures. A lot of suppliers are working at the molecular level or with additives to mitigate the release of acidic by-products.
Evaluating chemistries
In interviews, resin and additive producers discussed materials that are gaining ground in FRs. Vikram Gopal, technology and product marketing director at PA 66 resin and compounds producer Invista, focused on four. Melamine cyanurate, versions of which contain nitrogen, is good where requirements include a UL94 V-0 rating, comparative tracking index (CTI) above 500 volts, and coloured parts. Melamine cyanurate, Gopal says, produces intumescent and runaway effects that remove fuel from a fire. The material, which is also economical, is generally limited to unreinforced resins. Aluminium diethylphosphinate, a metal phosphinate used with synergists, is similar in performance to melamine cyanurate but uses solid-phase charring, which minimizes fuel supply, for flame retardance. Gopal notes, however, that the chemistry increases corrosion in processing equipment and lowers mechanical properties compared with retardants such as red phosphorous and brominated polystyrene. Red phosphorous FRs meet UL94 V-0 standards and CTI is in the range of 450-550 volts. The material uses not surprisingly, corrosive smoke. Other chemistries include three cited by BASF: melamine polyphosphate, which contains nitrogen; nitrogen/phosphorous compounds; and magnesium hydroxide. Martin Klatt, head of plastic safety and regulatory affairs at BASF, discussed these at AMIs Fire Retardants in Plastics conference in Denver, CO, USA, last summer. He indicated that like any additive, selection of FRs involves trade-offs. Magnesium hydroxide, for example, has high thermal stability, good electrical properties, low smoke density and colour neutrality in parts. But it requires relatively high loadings, is high in density and affects mechanical properties. Some chemistries work better in PA 66 than in PA 6, owing in part to the inherent flame-retardant properties of the former. Nitrogen/phosphorous compounds, which BASF supplies in 25% glass fibre-reinforced grades of its Ultramid PA 66, provide good toughness and electrical properties, and have no colour issues, Klatt said, though trade-offs include high loadings and processability issues. Suppliers also tout innovative chemistries as FR options. FRX Polymers developed phosphorous-based polymeric formulations for PA 6. Maggie Baumann, marketing adviser, says the material, called Nofia, uses a catalyst and two monomers, bisphenol A and dimethyl phenyl phosphinate, to form under heat and pressure a homopolymer of polyphosphinate. The homopolymer is combined with diphenyl carbonate and building blocks to produce a polymeric FR. Nofia is used at loadings of 10-20%, or as a copolymer at loadings of 20-50%. An end-user can replace a copolymer with our material, Baumann says. Benefits include permanent flame retardance. Because its in polymeric form, there is no migration of component materials, she explains. Nofia grades are processable they have high melt flow and high melt strength, and thus can be extruded or injection moulded without dramatically rebuilding a polymer.
Engine components, such as this thermo-switch control module moulded using Invista PA 66 for the Audi A7, must resist increasingly high continuous-use temperatures
Photo: A2Mac1 Automotive Benchmarking
charring and gas-phase scavenging (oxygen limitation). Red phosphorous is limited to black parts due to its colour incompatibility, is difficult to process as a result of corrosiveness, and poses a safety risk from phosphine emissions in processing. While brominated materials are no longer specified in certain applications, they remain viable in parts where they can still be used. Gopal says that FRs based on brominated polystyrene and synergists are especially effective. The chemistry uses gas-phase radical scavenging to minimize oxygen and reduces the intensity of exothermic reactions. Trade-offs include a low CTI, high specific gravity, high smoke density and,
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Flame retardants | additives feature
Photo: rhodia
Importantly, the grades deliver a UL90 V-0 fire rating in thin-wall parts. Since it is based on phosphorous, the material generates low smoke. It is transparent, and has no toxic by-products, Baumann adds. Nyco, a producer of wollastonite mineral reinforcements, is offering the material as a way of extending properties of FRs. Im not sure if it would reduce the need for a flame retardant, but could be feasible as a partial substitute, says Gary Phillips, vice president of marketing and application development. One reason is that wollastonite fibres have a high melting point of 1,540C. Phillips says that when the fibres are silanated for resin compatibility, a tight fibre/ resin matrix develops, which extends FR properties and increases structural strength. The companys Nyglos wollastonite fibres are acid scavengers that slow polymer degradation in a fire. They can help achieve UL94 V-0 ratings in some applications, he adds, and meet UL94 V-1, 2 or 3 in others. The fibres replace milled glass and 10-15% of chopped glass in reinforced PA. When replacing milled glass, they reportedly improve surface appearance in parts. Three grades are available: Nyglos 12 is 195 microns long and 15 microns in diameter; Nyglos 8 is 156 microns long and 12 microns in diameter; and Nyglos 4W is 63 microns long and 7 microns in diameter. Targets include under-the-hood electrical connectors. A high-temperature additive applied to the fibres enhances thermal stability for such applications and resists scorching during compounding. Nyco says that the fibres recrystallize rapidly with chopped glass, which improves cycle times. One benefit apart from their properties is price the
When micro circuit breakers are moulded in light colours it restricts the use of FR additives to colour-compatible chemistries
fibres are about one-third less expensive than most conventional flame retardants, Phillips says. A well-established technology for coupling agents could be an option for increasing loadings of FR additives without affecting processing. Kenrich Petrochemicals offers the titanates and zirconates it supplies as coupling agents for use with conventional FRs, to increase their loading and performance. According to Kenrich president Salvatore Monte, the companys Ken-React organometallic coupling agents proton coordinate to form 1.5-nanometer atomic monolayers on the flame retardant/filler particulate/fibre surface, as well as catalytically react with the polymer to change morphology and flow. As a result, the monolayers electrochemically deagglomerate the flame
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A nitrogen/phosphorous FR compound was specied for this UL94 V-0 generator cover moulded by Bosch using PA 66 from BASF
business director for the re resistance business unit of Rhodia, a resin producer (mostly PA 66) and compounder that is part of the Solvay Group. Mitchell highlights the difculty of working with a wall thickness of 0.4 mm by saying that such a material is virtually lm. There is also the ongoing issue of reducing cycle times, which raises performance questions. Faster cycle times demand faster crystallization capability [in polyamide] while maintaining good dimensional tolerance, remarks Invistas Gopal. FR additives must be tailored for these changes as well. Many of these challenges impact other applications. In automotive, greater under-the-hood use of engineering PAs and higher underhood temperatures generated by small, fuel-efcient engines raise performance requirements of FRs. Similarly, the use of PA in high-voltage components of electric and hybrid vehicles, such as batteries, power electronics and other
retardant, ridding the matrix of water and air voids and creating a continuous phase. This is said to dramatically lower compound viscosity, thereby reducing resin demand for a given pigment-to-binder ratio. The chief benet, Monte notes, is that more ame retardant can be added without sacricing processability. Monte states, for example, that when 50% melamine cyanurate is dispersed in mineral oil, the in-situ addition of 0.7% Ken-React KR 238NF reduced Brookeld viscosity to 30,000 cps at 25C from 1.6 million cps.
types of electric vehicle specialty equipment (EVSE), raises heat, mechanical and other performance requirements for additives. BASFs Dombrowski says that while automotive components have typically been rated at UL94 HB, we will continue to see more applications requiring UL94 V-2 or V-0 ammability ratings due to the introduction of high-voltage components. Additional concerns include the interaction of FR additives with UV stabilizers, since EVSE components such as vehicle chargers have signicant outdoor exposure.
Impact of product trends

Market trends inuence additive formulations. Among the most signicant are the downsizing and miniaturization of electrical and electronic devices. As parts become smaller, thinner and more densely packed in assemblies, FR additives must meet challenging re and smoke requirements, as well as resist arcing and short-term bursts of electromagnetic energy, maintain dielectric strength, and withstand high continuous-use temperatures and heat aging. Where higher-heat lead-free soldering is used for regulatory reasons in circuit boards and other applications, FR additives must maintain properties without decomposing. Like everything else in the electronics industry, form factor is becoming smaller, says LeeAnn Dombrowski, electrical and electronics market segment manager at BASF. As a result, FR additives have to be even more effective than before, as ame resistance has to perform the same but with thinner cross sections. Materials for connectors in the appliance segment are now looking at glow wire certications at 0.4 mm thickness versus 0.75 mm previously. This is the new normal for many electrical and electronic parts, afrms James Mitchell, global
26 COMPOUNDING WORLD | December 2012
The green inuence

Environmental considerations play an ongoing role in FR chemistry, as OEMs continue to move away from halogens in formulations. Specifying a ame retardant chemistry for PA is sometimes helped by the inherent properties of the polymer. PA 66 has inherent UL94 V-2 performance, and is generally credited with outstanding tensile strength at elevated temperature and good processability, both of which aid in nding compatible FRs and facilitating product development. Some resin producers are tweaking PA 6 formulations to improve mechanical properties such as modulus, bringing the stiffness of grades near that of PA 66, which also broadens additive selection. Importantly, regulation of FR additives is becoming a global standard. OEMs and other manufacturers dont need to worry about complying with different regulatory rules when specifying FRs. Flame retardants is the only fully global business in engineering polymers, says Rhodias Mitchell. The regulatory standards in China are as high as in Europe and elsewhere. A lot of whats produced in one country is shipped around the world. There is no need to reinvent the wheel when it
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helping to improve FR properties and processability. Work is also underway to reduce moisture uptake and increase the dimensional stability of FRs. These properties are important in thin-wall electrical parts used in humid environments. An example is the new Technyl XA1426, which is extending PA use by reducing moisture uptake 40% in a 30% glass-reinforced UL94 V-0 grade. BASF recently added Ultramid A3U40 G5, a 25% glass-filled PA 66, which achieves a V-0 rating at 0.4 mm wall thickness and is glow wire-certified. Developed for household appliances, connectors, low-voltage switchgear and railway applications, it has high flow, can be fabricated in complex shapes, and exhibits low smoke toxicity and density. Also new is Ultramid B3U30G6, a 30% glass-filled PA Clariant has doubled Exolit FR capacity at its HrthKnapsack plant to meet burgeoning demand for non-halogenated products comes to flame retardant additive use in products. Green is reality, Mitchell adds, noting that European initiatives such as RoHS (restrictions on hazardous substances) and other standards are enforced in much of the world. One coming trend will be development of FR additives for recycled PA resins. Mitchell and others report that customers are asking about reclaim as a matter of sustainability, and Rhodia and other resin producers say they are working with formulations that incorporate some recycled PA. But there are challenges. One is getting FRs certified for use with recyclate; another is assuring the integrity of reclaimed resins. We can source recycled materials, Mitchell remarks, but contaminants and UL certification are problems. Suppliers are commercializing FRs that meet demands for improved performance, stability and processability. Following are representative examples, all non-halogenated. Rhodia is working on polymer technologies that significantly reduce FR loadings to enhance processing and mechanical performance of PAs. One example is the new Technyl alloy AT20 V25, based on red phosphorus, which substantially reduces FR concentration while 6 for similar applications and miniature circuit breakers, which are popular in Europe. It has high modulus (similar to PA 66), is compatible with light colours, and achieves UL94 V-2 at 0.8 mm. Invista formally launched an FR portfolio in October at Fakuma in Germany. Based on its proprietary Torzen Marathon process technology, the materials reportedly provide 30C higher continuous-use temperature than conventional PA 66 resins and 40-50% greater flow. DSM recently launched Stanyl grades SC50 and MC50. Target markets include integrated and miniature electronics. Both are glass-reinforced. Grade SC50 has a UL94 V-0 rating, and MC50 is UL94 V-2. The materials have high-flow properties, thin-wall strength, and meet glow wire ignition temperature requirements. On the additives front, Clariant has been investing to meet the fast growing demand for its Exolit OP nonhalogenated organo-phosphorous flame retardants which are used in PA formulations. In October, the company opened a second production line for the additive at its plant at Hrth-Knapsack near Cologne in Germany. The new line doubles the sites total capacity for FRs based on DEPAL (diethyl phosphinic acid aluminium salt). The company says that the expansion was driven by
Applications for Exolit OP include switches, plugs, PC fans, and structural and housing components. Smartphones, washing machines and airplane parts are among the wide range of products that contain the product.
More information
AMIs Fire Retardants In Plastics conference is being held in Denver, Colorado, USA on 13-14 June 2013. The programme features speakers from Sony, BASF, FRX Polymers and many more. For details, visit http://bit.ly/FRP2013, or contact Kelly Cressman: +1 610 478 0800, kc@amiplastics-na.com. Target markets for Clariants Exolit OP FR include the electronics and electrical engineering sectors the growing demand for halogen-free ame retardants in the electronics and electrical engineering market. The environmental and safety awareness of our customers has increased considerably, resulting in growing demand for our non-halogenated ame retardants, says Michael Grosskopf, head of Clariants additives business unit. Key customers are indicating that their requirements will see further strong increases in the years ahead. Click on the links for more information:
S www.basf.com S www.dsm.com S www.invista.com S www.frxpolymers.com S www.nycominerals.com S www.4kenrich.com S www.rhodia.com S www.clariant.com
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Lab compounders | machinery feature
Mikell Knights reviews the latest developments in lab-scale extruders and kneaders for carrying out research work, formulation development, customer trials and small-scale production
Small machines for big ideas

Laboratory compounders continue to proliferate, from bench-top models with outputs measured in grams of material through to stand-alone units that can be used for small production runs. Machinery makers are responding to demands for quicker machine changeovers and wider processing exibility. In addition, they are developing lab machines that are capable of handling sensitive bio-based resins, higher additive loadings, or very expensive medical or pharmaceutical grade materials. Over the following eight pages, we review the latest lab compounder developments from B&P, Brabender, Buss, Coperion, Entek, Feddem, KraussMaffei Berstorff, Leistritz, Randcastle, Steer and Thermo Fisher. B&P Process Equipment has upgraded the controls of its TriVolution-60 Tri-Kneader pilot demonstration line located at its technology centre. The 30 mm laboratory scale Tri-Kneader has also been commercialized and B&P now offers the model in three output versions. The line is designed to process 80% of jobs typically run on a twin-screw extruder, and all of the formulations that can be handled by traditional reciprocating
co-kneaders. It now features new PLC controls, new wiring and a new touch-screen interface all mounted integral to the machine base making a completely self-contained system, says Michael Lazorchak, global product manager for mixing systems at B&P. The model, which features a 30 mm extruder with reciprocating kneader technology, is now offered in a light-duty version with 300 screw rpm and able to process 3-15 kg/h of HFFR (halogen-free, ame-retardant compounds); a standard 450 rpm version handles 5-30 kg/h; and a heavy duty 600 rpm version is designed for 10-50 kg/h. The three versions are being offered on every model in the line, allowing for systems to be cost-effective and yet custom-engineered to the process. B&P is planning to build its rst TriVolution 30 Tri-Kneader for a customer, and will build a second unit for its technology centre as a demonstration model. The company is also planning to create a bench-top TriVolution Tri-Kneader. The Tri-Kneader provides three axial oscillations of the shaft for each revolution, instead of the single stroke per revolution used in traditional kneaders. It
December 2012 | COMPOUNDING WORLD 33
machinery feature | Lab compounders
screw configuration adjusted accordingly. This method can be used to change the unit to 30:1 or 20:1 L/D. Metering or venting ports are located at 10D, 20D and 30D, with side feeding capability at 12D and 22D. The TSE 20/40 is offered with a 7.5 hp motor and 600 rpm screw speed, or with a 16 hp, 1,200 rpm drive. The latter is said to process throughputs from as little at 250 g/h up to 20 kg/h depending on material. Brabender is also developing a lower-cost bench-top version of its KETSE 12/36 twin-screw mini-compounder, slated for release during the second quarter of 2013. The standalone KETSE 12/36 features a 12 mm B&Ps TriKneader provides three axial oscillations of the shaft for each revolution, instead of the single stroke used in traditional kneaders features a single screw with its mixing flights interacting with stationary pins on the barrel wall to provide the required mixing interface. In traditional designs, there are three or four flights providing mixing interfaces each time the screw rotates. B&P says that the Tri-Kneader can have a maximum of 12 flights interfacing six times to provide up to 72 pin/flight interfaces in a single revolution, thus improving mixing levels. Lazorchak presented a paper at AMIs Minerals in Compounding conference last month in Atlanta, GA, USA, that illustrated the TriVolution Tri-Kneaders ability to compound mineral formulations with greater efficiency and control, as well as handling loadings greater than 60%. Buss has been busy this year introducing its latest MX 30 four-flight laboratory kneader at trade shows around the world, including Wire in Germany, NPE in the USA, Chinaplas in China and Plast in Italy. The company reports high levels of interest from compounders and took orders for its first production series. Featuring a 30 mm diameter screw, the MX 30 is the smallest machine in the MX range and according to Buss is the first laboratory kneader to feature four Brabender now offers removable barrel liners for its TSE lab-scale twin-screw extruders. This development brings much shorter machine downtime and changeover times, says Kevin Van Allen, vice president sales and marketing for the companys US chemical division. The barrel liner, now available for its TSE 20/40 lab compounder, reduces changeover time from two hours to about 15 minutes. Screw swap out takes about 15 minutes, Van Allen says, adding; Processors Brabender is adding removable barrel liners for its TSE lab-scale extruders to speed up changeovers running colour concentrates will find it tremendously shortens downtime. The TSE 20/40 is a stand-alone co-rotating unit with a segmented screw and clamshell barrel. The standard design is a 20 mm diameter screw and 40:1 L/D. Users that require shorter barrel and screw lengths can sheath the first 10D of the screw with a special blank sleeve. The material feed device is attached on a downstream port on the barrel and the
diameter screw with 36D processing length and a 3.2 hp, 600 rpm drive. Van Allen says this unit has an updated control system that is more user-friendly and allows for better tracking of motor load. A removable barrel liner is also an option.
www.brabender.com
www.bpprocess.com
flight technology. It has a maximum screw speed of 800 rpm and is rated for outputs of 5 to 25 kg/h. The maximum processing temperature is 280oC. Like the larger machines of the MX Series, the MX 30 is particularly suitable for the compounding of heatand shear-sensitive polymers and for the production of compounds with high loadings of reinforcing materials and other fillers. It is equipped with a discharge extruder, a pelletizer and a user-friendly control system, offering the same process versatility as larger models in the MX Series. Buss says that processing parameters obtained with the MX 30 can be reliably scaled-up and applied to larger MX kneaders because of the lab machines high conveying stability and linear output-to-speed ratio. In addition to being used as a laboratory extruder for formulation and product development, the MX 30 is also suitable for customwww.compoundingworld.com
Busss new MX 30 has been generating interest at exhibitions during 2012
nents. Plug and play features help to make installation and start-up swift, says the company. The ZSK 18 can process batches as small as 200 g up to throughput rates of 40 kg/hr. It has a specific torque of 11.3, and with its screw diameter, could be used as a pilot production unit when you have a very specialized product program, says Bernd Ormanns, business segment manager, engineering plastics. He adds that the ZSK 26, 32 and 34 (a high volume version of the 32) provide enough throughput to be used as pilot lines if a processor has a production line facing a difficulty. Users can achieve throughput rates up to 140 kg/h depending on the formulation. Coperion also offers a special GMP version of the ZSK 18 Megalab for pharmacutical compounding applications. It is completely clad in stainless steel and is equipped with leak-proof cooling water couplings.
www.coperion.com
Entek says that its entry into twin-screw extruders for er trials and for small-scale production of a wide range of compounds. laboratory tasks, the E 27 Max, allows users to test out recipes and determine if they can actually process a formula. Compounders are willing to try out more expensive materials and new, complex formulations Coperion says its ZSK Megalab line is aimed at users looking for quick changeovers and production-machine features in a unit that works mostly in a laboratory. Its newest model, the ZSK Megalab 18, joins the existing 26 mm and 32 mm models in the line. The ZSK 18 Megalab is developed especially for processing small batch sizes while offering features similar to production units for scalability. It features 18 mm parallel co-rotating intermeshing screws with a 1.55 OD/ID screw ratio. The screw geometry Coperions ZSK 18 Megalab is supplied on a mobile base frame, incorporating all the major components features feeding, mixing and kneading elements similar to those used on full-scale production models. Each barrel and screw section is 4D. The barrel has an improved heating and water cooling system for temperature control to +/- 1 C. Coperion offers
o
www.busscorp.com
because they feel the smaller machines deliver more reliable results, says Dean Elliott, Enteks laboratory manager. Processors are pushing the envelope regarding how much pigment, or how much additive can be used, and they are using small volumes of more expensive materials for medical, military, and pharmaceutical applications, Elliott adds. If they can produce a stable formula it will transfer to a larger production machine. Customers are also using Enteks lab compounders to investigate biomaterials and soluble polymers, says John Effmann, the companys director of sales and marketing. The E 27 Max is the smallest model in Enteks six-model E Max line. The unit features a 27 mm diameter screw with 1.47 OD/ID ratio, and a choice of three motors and three screw speeds: 15 hp for 400 rpm; 20 hp for 600 rpm; and 40 hp for 1200 rpm. The parallel, co-rotating intermeshing twin-screw unit is designed with a segmented barrel, with each barrel segment 4D in length. The unit is offered in lengths from 28D -52D. It can compound PE pellets with colour, additives and fillers at a rate from 20-45 kg/h with a standard 20 hp, 600 rpm drive. Entek is developing new feed elements
the Megalab models with a standard length of 40D standard, with options to extend the unit up to 60D. A quick-release design with two retaining bolts allows for easy removal of the screws and die-head. The compact unit is supplied on a mobile base frame which incorporates all the major compo36 compounding world | December 2012
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Lab compounders | machinery feature
to 150 kg/h, depending on the material formulation. For example, Feddem says that the 26 MTS can process 50% glass-filled PA 66 at rates of 100 kg/h, 45% glass-filled PET at 90 kg/h, and POM at 80 kg/h. The company highlights the versatility of the MTS line and its ability to process a wide range of formulations without changing the screw configuration. This is a primary philosophy of the company, that a processor can handle a wide variety of different compound grades and new mixing elements that will better handle low bulk density materials. Elliott says the new kneading block mixing element, called the Ultimate Kneader, will improve dispersion while lowering energy consumption. and recipes with one screw design, without having to open the machine or change the screw, says Dieter Gross, Feddems managing director. With this machine we have focused on the typical masterbatch producer or compounder with a wide product portfolio that processes two or three formulaFeddem extended its Multi-Task Standard (MTS) series of intermeshing, co-rotating twin-screw compounders with the launch of its smallest model at this years Fakuma show in Germany. The FED 26 MTS unit is designed for lab-scale to pilot production, and shares many design features with the four larger units in the series. The new unit has a 26.6 mm screw diameter with a 1.55 OD/ID ratio and typical barrel lengths of 32, 42 or 52D. The extruder can achieve processing temperatures up to 400oC, and has drive power of 28 KW and screw speeds up to 1200 rpm. The unit can be used for small batch processing for material development, processing just 1 to 3 kg of material if required. Throughput rates range from 10 up tions on a machine every day and requires changeover times as short as possible, he adds. Feddem offers a multitasking screw design for a wide variety of different technical compounds, and a different multi-tasking screw design for a wide variety of different masterbatches. The MTS line employs specially designed melting and mixing elements on its
Enteks E 27 Max is being used to develop high-cost resins and bioplastics
Feddem has entered the lab-scale market with the FED 26 MTS machine
www.entek-mfg.com
KraussMaffei Berstorffs new KMD 35-26/L can be used to develop recipes for PVC pipe, profile or sheet
standard screw that eliminate the requirement for a kneading block. The allows for processing of a wide variety of materials with one screw design. Compared to a classic kneading block based configuration, there is much less shear with Feddems screw design and more mixing is used to heat up the material. We use more heating energy than shear energy; there are more mixing elements in a given L/D versus a conventional twin-screw compounder, explains Gross. He claims that the combination of lower shear and extended mixing zones delivers a better resultant mix, and can also help to retain longer glass fibre lengths in reinforced compounds. According to Gross, more than 90% of the formulations and recipes developed for compound extrusion can be processed without kneading blocks, and that includes masterbatch production from a premix. He concedes that some recipes, such as calcium carbonate filled PP or PE, require kneading blocks and Feddem does supply equipment for such applications. down of the production process that creates premium quality end product without producing large numbers of rejects. The behaviour and flow is similar to what occurs on a larger production machine, Mack says. Different screw geometries are offered for pipe, profile KraussMaffei Berstorff recently launched a new counter-rotating twin-screw lab extruder for processors looking to reformulate their PVC recipes for the production of pipe, profile or sheet products. Its new KMD 35-26/L is said to be the smallest extruder of its type on the market, and features 35 mm screws and machine lengths of 26 or 32D. The model is ideal for processors looking to find out and sheet extrusion, and it is suitable for all commercially available hard and soft PVC mixtures. The new model can produce profiles and sheets at 15-40 kg/h, and pipe at 30-70 kg/h. Counter-rotating units are not modular like our co-rotating units; you cannot adjust screw geometry by pulling off an element then adding an extra mixing element. There is no splined shaft and everything is rigid for maximum strength, Mack says. The unit is designed with internal screw tempering and barrel air cooling, and features several transducers mounted on the barrel. The unit is a low-speed, high-torque and high-pressure system, delivering screw speeds from 50- 80 rpm and pressure from 500 to 5000 psi. The unit uses KraussMaffei Berstorffs C5 control system.
www.feddem.com
Leistritz says that its Nano 16 has the lowest free volume available of any twin-screw extruder
how to save on stabilizer, or to adjust the amount of filler without compromising material strength, says Martin Mack, vice president, research and development, in the extrusion division of KraussMaffei Berstorff in Florence, Kentucky, USA. Processors benefit from enormous cost savings when they can test the formulation on a small scale, and this machine provides a scale
www.berstorff.com
Leistritz offers a range of lab-scale machines from the Nano-16 for processing tiny volumes of pharmaceutical materials, through to the ZSE 27 Maxx capable of delivering more than 300 kg/h. It also has a lab extruder that can be switched from co-rotating to counter-rotating operation. The Nano-16 was primarily developed for the pharmaceutical industry, where a low volume machine is needed for early stage development. Processors had grams of new material available to them, and with other conventional lab units, a feeder could not reach a steady state (for accurate testing) with less than 200 g, says Charlie Martin, president and general manager at
40 compounding world | December 2012 www.compoundingworld.com
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would be best processed on a co- or counter-rotating extruder when scaled up to full production.
S www.leistritz.com
Randcastle says that compounding with a single rotor or single screw featuring its spiral-uted extensional mixer (SFEM) technology delivers high levels of product mixing for smaller volumes of material. The company offers the SFEM technology on its expanded line of micro-batch mixers, and the mixing elements can be scaled up for use on its single-screw extruder. Initially one would think that it impossible to get material elongation using one shaft until there is the realization that there are two forces at work on the material; pressure ow and drag ow, says RandcasRandcastles batch mixer uses the companys SFEM technology to deliver very high levels of mixing American Leistritz Extruder. The Nano-16 can process batch sizes of 50 g or smaller, and the polymer compounding industry is starting to take notice of the model for high-value formulation developments. The unit integrates a twin-screw extruder with a unique micro-plunger feeder that simulates a continuous extrusion process for batch samples from 20 g to 100 g. The 16 mm diameter screw has the lowest free volume available for a twin-screw extruder, claims the company. The micro-feeder plunger delivers material to the feed barrel for precision feeding at extremely low rates, and it can meter materials in virtually any form, including powders, micro-pellets, pastes, slurries, and granules. At the other end of the lab scale, Leistritzs ZSE 27 Maxx has 28.3 mm diameter screws with a high-volume 1.66 OD/ID conguration. The company reports that customers are achieving throughputs of more than 300 kg/h with the machine which bridges the gap between lab and production models. For example, Innovative Polymer Compounds (IPC) of Ireland is using a ZSE 27 Maxx for the production of compounds for medical Steers new OMicron 10 model can process high-end polymers in batch sizes as small as 15 g applications in its Class 100,000 clean room, as reported in last months Compounding World. The processing units of the ZSE 27 Maxx are interchangeable with the companys Micro 27 GL/GG modular twin-screw extruder which can operate in both co-rotation and counter-rotation modes. The operating mode is selected using a switch in the gearbox. Leistritz says that this is a unique feature that allows users to decide whether a formulation
42 COMPOUNDING WORLD | December 2012 www.compoundingworld.com
tles president Keith Luker. Rather than designing screw ights that wrap around the screw in a helical manner, Randcastle instead splits a certain section of the rotor into two design halves. Each half of the rotor at that section features a melt channel with drag ows similar in depth, pitch and length, but designed to move material in a direction exactly opposite to the melt channel design on the other half. Grooves at each end of this special section allow pressure ow and drag ow forces to create elongation and mixing. Material washes over the geometry in the section, creating ow that is dominantly elongational, says Luker. A paper delivered at the SPE Antec 2011 conference by Dow Chemical and Randcastle showed that the use of SFEM elements can deliver better mixing than a twin-screw. Luker says that the SFEM elements mixed eight times better than the twin-screw, and 1,000 times better than a conventional single-screw extruder.
S www.randcastle.com
blends, shear-sensitive materials, fibre-grade polyester or PE masterbatches. Three sizes are offered the Omega 20, 25 and 30 featuring 1.71 OD/ID, 1,200 rpm screw speed and throughputs ranging from 5 -100 kg/h. The OmegaLab is offered with special screw configurations for handling a range of renewable resins, reinforcements and fillers. For example, Steer was awarded a contract in North America to develop and commercialize a manufacturing process for a product compounded from chicken feathers and PP. Proprietary mixing elements help the OmegaLab line to achieve the required mixing, while avoiding excessive shear levels, says Roden. You cannot put too much energy in a biopolymer too fast so you need the machine length to gently heat it. Thermo Fisher Scientifics Process 11 is the companys smallest twin-screw co-rotating extruder Steer has introduced a second model into its OMicron line of laboratory twin-screw extruders designed to process special, high-end polymers in batch sizes as small as 15 g. The new OMicron 10 has a screw diameter of 10 mm and joins the existing 12 mm model. It has a 1.55 OD/ID ratio and throughputs range from 0.15 to 1 kg/hr. The machine is typically supplied with an L/D ratio of 30-36. Steers OMicron models are offered with a clamshell design that allows processors to stop the process, open the machine and immediately inspect what is happening to the material at any point in the process. Traditional segmented barrel designs are also offered for processing materials under high pressures or for running liquids. The OMicron line employs special screw geometry created by the company to improve material processing at low volumes. For example, Steers proprietary shovel elements, which assist the processing of difficult-to-feed density materials with low bulk densities, are available for its laboratory machines as well as its production lines. Quick change features with this model allow the user to go from operation to screw removal in a matter of seconds, says Robert Roden, technology manager at Steer America. The company plans to add this ease of accessibility and ease of cleaning technology to the other lab lines. The Omicron is the smallest of Steers four lines of laboratory extruders. The AlphaLab series comes in two models with 18 or 20 mm diameter screws, a 1.46 OD/ ID ratio, 1,200 rpm screw speed, and throughputs from 5-40 kg/h. They are designed for processing specialty polymers, alloys and blends, mineral-filled polymers, additive- and colour-masterbatches and flame retardant compounds. Steer also offers its OmegaLab series, designed for applications such as automotive compounds, polymer
Some think a long residence time burns the material, but it is really about the amount of energy put into the mix, says Janit Panchal, who is taking over the technology manager role at Steer America as Roden is transferring to Steer India in Bangalore to focus on new equipment development. The fourth of Steers lab lines is the Mega series, designed to handle more conventional polymer blends and colour compounds, as well as short fibre reinforced thermoplastics. Three models are offered - the Mega20/ Lab, Mega25/Lab and Mega 32 featuring 1.55 OD/ID and throughputs from 5 to 100 kg/h.
www.steerworld.com
Thermo Fisher Scientific recently introduced its Process 11, a new bench-top twin-screw co-rotating extruder for small-scale experiments. It has 11 mm diameter segmented screws and can deliver throughputs from 20 to 2,500 g/h. The space-saving unit, which is the smallest from the company, has a user-friendly touch screen with integrated feeder control, and all electronics reside in the extruder housing. A removable top barrel half allows users to stop and inspect material along the screw shaft and enables them to modify the screw design with individual screw elements in order to optimize the process. The removable barrel also simplifies screw and barrel cleaning, and offers optional barrel designs to suit the application. Atmospheric venting ports are standard with an option to add a vacuum stack. Due to the small dimensions of the unit, top feeders are used in place of side feeding. Split feeding from a secondary or tertiary feeding port is possible. Process results and conditions generated from the Process 11 can be successfully scaled up to Thermo Fisher Scientifics 16 mm and 24 mm lines.
www.thermoscientific.com/mc
PLASTIC CLOSURE INNOVATIONS 2013

Trends and technical developments in the international closures industry
23-25 April 2013

Maritim Hotel, Cologne, Germany
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industry
The Good Regrind Guide

Regrind is typically a term that applies to plastic components/products, which have been mechanically, reduced in size to particles less than 10mm in diameter. The source of these plastic components can be pre-consumer waste such as process scrap, or less commonly post-consumer waste (Typically this source of material is handled by specialist recycling companies).
This process takes place in a device called a grinder, in which the plastic components are fed in through the throat of the grinder and then pass into a chamber that typically contains rotating knifes which mechanically cut the plastic component dimensions to a size small enough to pass through a screen. This regrind may then be: 1. Fed directly back into the manufacturing process on a continuous basis 2. Fed directly back into the manufacturing process on a batch basis 3. Used in another manufacturing process such as a component for a compounded material containing the regrind (and other ingredients). Given that thermoplastics are by definition capable of being heated and re-shaped many times the use of regrind would appear to be an obvious solution to achieve greater rates of operational efficiency through the use of process scrap and/or reject components. However care must be taken to ensure that the use of regrind does not significantly impact on either processing and/or the performance
of the product being manufactured and in order to determine the possibility to use regrind the following factors must be considered: -
Degradation
Thermoplastic raw materials are inherently unstable at processing temperatures. The extent of degradation will be dependent upon: Type of polymer The use of stabilsers Thermal history (Time spent at processing temperature) Presence of other materials such as pigments and fillers In the case of closed loop type recycling operations it is worth considering the addition of additional staibisers during the manufacturing process. The degree of degradation when processing a standard MFR 4 PPHP by injection moulding and subsequent granulation is depicted in the graph where the melt flow (an approximate measure of degradation) is increased by 13% after two cycles.
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PP Processing Degradation
4.6 4.4
MFR g/10min
4.2 4 3.8 3.6 0 1 Pass Number 2
Contamination
As most plastics are incompatible great care should be taken not to mix material types. It is therefore essential that no purgings, or scrap product resulting from material changes are recycled and it is vital that machinery is thoroughly cleaned between material types. Other sources of contamination include: Oil Dirt / Rubbish Masterbatch All contaminated material should be eliminated from any recycling process and disposed of. Failure to do so will result in the contamination of more material and further scrap.
Dust
The mechanical abrasion that constitutes the regrind process tends to result in dust. Ideally this should be removed and disposed of. In the case of some polymers dust will significantly affect the physical properties of the end product.
Food and Medical Applications

In both these cases special consideration should be given to the use of regrind. Normally in medical applications regrind is not used. In the case of food packaging careful evaluation must be undertaken to ensure that compliance with required standards are maintained as well as overall suitability for any given application. It is strongly advised that if there is any cause for concern about the use of regrind then further advice should be sought from the material supplier. Where it is not desirable to use regrind the scrap can be sold to specialists companies who will recycle the waste.
Fibre Fillers
The mechanical abrasion that takes place in the regrind process dramatically affects the physical properties of plastics that contain glass, carbon or other fiber reinforcement. In addition to reducing the length of the fibers, any chemical coupling agent (size) will also be affected, and since the fibres depend upon their interface with the plastic that surrounds them the grinding process can dramatically reduce physical properties.
Plastribution is the UKs leading distributor of plastics raw materials, delivering reliability, know-how and true business partnership to the worlds best polymer suppliers and our UK customers.
In the event that you require further information about the shrinkage of polymers, please do not hesitate to contact a member of the Plastribution team for further information by emailing sales@plastribution.co.uk or phone 0845 3454560
Plastribution Limited. All rights reserved. 2012
GREEN POLYMER CHEMISTRY 2013

International conference on manufacturing conventional plastics from sustainable sources
19-21 March 2013

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Green polymer chemistry | conference report
The rst Green Polymer Chemistry conference provided a fascinating insight into efforts to develop renewable and sustainable polymers. AMIs Dr Sally Humphreys reports
PHOTO: UNICA
Inside the green revolution

Opinions may differ on whether the world has yet reached the point of peak oil production, but most agree oil prices will continue to rise and alternatives will have to be found in the future to fossil-based fuels and chemical feedstocks. Renewable and sustainable sourcing for plastics is one key area of development and AMIs Green Polymer Chemistry conference, which took place in Cologne earlier this year, brought experts from agriculture, chemical engineering, biotechnology and the polymer industry together with sustainability managers from major consumer brand owners and the automotive industry to discuss all aspects of this challenging sector. LMC Internationals senior research economist Dr Sarah Hickingbottom presented an analysis of the global agricultural feedstocks market at the event. Her data showed that worldwide, corn wheat and cassava production amounted to 1.7bn metric tonnes in 2010/11, and sugarcane and sugar beet totalled 160m tonnes (the leading sugar producer is Brazil). On the vegetable oil side, palm predominates at 48m tonnes (85% grown in Malaysia and Indonesia). Palm oil is unique in being
harvested from trees rather than from seeds, which is the case for other vegetable oils. Hickingbottom said the agricultural industry is already seeing a battle for acres emerging on a global scale. This began in 2002 along with the drive to use bioethanol/biofuel, which has increased demand on arable land to grow the required feedstocks. By 2010, the area of land under cultivation had expanded worldwide by 70m hectares. But biofuels are not the only demand driver. The rise in per capita income across Asia means that consumers are eating more meat, creating a corresponding increase in demand for animal feed. Bio-based plastics and other ne chemicals are now also being produced from agricultural feedstocks and the challenge is to nd sources that are sustainable in this global marketplace both nancially and environmentally. Hickingbottom said more land is certainly available for cultivation in areas
Ford is using 12% soy-based polyols in its US seating foams
49
conference report | Green polymer chemistry
by approximately 14.3m tonnes. All Ford cars produced in the US currently use a minimum of 12% soy content polyol, with the aim to increase this to 25%. One problem faced by car makers with regard to renewable materials is the large number of cars produced, currently 4.8m a year, which means any green option must be available in considerable quantity. In the case of soy, the United Soybean Board was keen to nd a use for the oil, which is effectively an unavoidable side-product of bean production for animal feed. Braskem has exploited Brazils position as the worlds number one producer of sugar cane to position itself as the leading producer of bio-based polyethylene and polypropylene. The polymer producer has current GLOBAL PRODUCTION OF AGRICULTURAL FEEDSTOCKS 2000-2011 (CALCULATED IN EQUIVALENT ETHANOL LITRES)
Source: LMC International
annual production capacities for its green polymers of 200,000 tonnes and 30,000 tonnes respectively. The companys commercial director for renewable materials Fabio Magalhes Carneiro said 86.5 tonnes of sugar cane is required to produce 7200 litres of ethanol, which yields three tonnes of polyethylene. That means approximately 65,000 hectares of sugarcane is required to meet its 200,000 tonne PE production capacity at present. Data from the countrys sugar cane industry association UNICA shows Brazil currently farms more than 7.5m hectares of sugar cane, around 2% of its available arable land. Braskems current PE production would require less than 1% of total production. Competition between food and feedstocks is one of the challenges faced by developers of bio-based chemicals and plastics. One way of tackling the problem is to develop technologies capable of producing chemical raw materials from non-food cellulose. There have been several technology breakthroughs in the past few years in these so-called second generation technologies. Italys M&G Group built a pilot plant in 2009 using its
around the Black Sea, South America and South East Asia if conversion proves cost-effective. Brand owners and retailers have studied sustainable sourcing extensively. Unilevers global director of sustainable sourcing development Dr Jan Kees Vis has been involved in projects including the Sustainable Palm Oil roundtable and said the companys aim is to double its size while reducing our environmental impact. Unilevers plans include a commitment to source 100% of its agricultural raw materials sustainably. At present, palm oil is the top material at 1.4m tonnes annual consumption, primarily for surfactants, then paper, soy and sugar, followed by other oils. Unilever has put together a Sustainable Agriculture Code and wants to use products with certication, such as Rainforest Alliance and Fair Trade. But BASF is working with blends of PCC derived from CO2 and starch based PHB as an ABS replacement there are many other issues, such as the need to ensure the security of food supplies. Vis said brand owners such as Unilever will in future be asking questions of suppliers about the sustainability, not just renewable sourcing, of new products. The automotive industry is also pushing forward in the sustainability arena. Ford Motor Companys Maira Magnani, who is a reseach engineer within the car makers Advanced Materials & Processes group at its research centre at Aachen in Germany, detailed some of the rms notable new developments in renewable sourcing, including the use of a soy polyol-based polyurethane foam which cut carbon dioxide emissions
50 COMPOUNDING WORLD | December 2012
GLOBAL AVAILABILITY OF LIGNOCELLULOSIC FEEDSTOCKS BY MAIN TYPE AND REGION

Source: Sd Chemie, UN Food and Agriculture Organisation
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production of monomers for plastics such as PE and PET. According to Professor Andre Koltermann, group vice president of Sd Chemies corporate R&D unit, global biomass production amounts to between 120 and 165bn tonnes a year. Asias rice growing industry is the biggest potential source, contributing around 750m tonnes of rice straw a year. Koltermann said the SunLiquid process can produce one tonne of ethanol from four tonnes of straw, which is the typical straw yield from one hectare of farmed ENVIRONMENTAL BENEFITS OF PEF AGAINST PET (NON-RENEWABLE ENERGY AND GREENHOUSE GAS EMISSIONS)
Source: Avantium, Copernicus Institute at Utrecht University
wheat. The process is energy neutral and almost carbon neutral, offering an approximate 95% reduction in greenhouse gas emissions compared to ethanol produced by petrochemical means. It has been running a 1,000 tonne/year demonstration plant since the beginning of this year. China-based Cathay Industrial Biotech, which claims to be the largest global producer of biobutanol at more than 7m gallons last year, is also moving into lignocellulose technology. The companys director of international development Charlie Liu said it has developed a process to produce a bio-based PA5 monomer. The monomer is based on lysine converted via decarboxylation to pentamethylenediamine, which can be combined with a biobased di-acid to produce a variety of PA5,X polymers including PA5,10, PA5,6, and PA5,4. Indian company Petron Scientech has developed an ethanol to ethylene technology with a claimed conversion rate of near 100% and close to 99% ethylene selectivity. Wim van der Zande, director of the companys Netherlands-based operations, said the process is highly endothermic so heat recovery is built into its reactors. Petron Scientech has also supplied technology to companies such as Oswal in India to maximise its use of sugar cane the sugar is sold, bagasse is sent to fuel power stations, and the molasses used to make industrial ethanol. Greencol Taiwan (a JV between CMFC and Toyota Tshuho) has also taken the Indian companys technology to produce mono ethylene glycol (MEG) monomer for bio-PET production at a new 100,000 tonne plant due to start up this year. Production of bio-based MEG is already commercial Coca-Cola being the most prominent user in its PlantBottle polymers. However, a fully bio-based PET requires the development of a commercial route for the puried terephthalic acid (PTA) component. One solution to this challenge could be Avantiums development of PEF from furan dicarboxylic acid (FDCA) synthesised by dehydration and oxidation from carbohydrates. According to new business development director Dirk den Ouden, FDCA produced using its YXY Technology could act as a drop-in replacement for PTA to produce polyethylene
Proesa technology, which generates C5 and C6 sugars in a continuous process from bio-mass cellulose. Chief technology ofcer Dario Giordano said the plant has now been in operation for 400 days continuously and many enzymes and 15 types of biomass feedstock have been tested. It is now building a new demonstration unit at Crescentino in Italy that will have capacity to make 40,000 tonnes of cellulosic ethanol and will generate 15 MW of power from lignin by-products. Meanwhile, the VTT Technical Research Centre of Finland has examined the feedstock potential of the countrys forests, where growth is expected to rise by 25% over the next ve years due to the effects of global warming. VTTs Professor Ali Harlin, industrial biomaterials research programme leader, said it has piloted manufacture of ethanol from lignocellulose with Braskems green HDPE unit in Brazil has a capacity of 200,000 tonnes, equivalent to 65,000 Hectares of sugar cane paper-making partner UPM. Biomethane can also be used in the olen supply chain by conversion of methanol to olens (MTO) and VTT has also experimented with wood oils and the manufacture of LDPE from tall oil. German company Sd-Chemie has partnered with Sabic in the development of the SunLiquid process, which takes lignocelluose feedstocks and converts them to second generation sugars or ethanol for use in
52
COMPOUNDING WORLD | December 2012
WOOD-PLASTIC COMPOSITES 2013

The international business conference & exhibition for the wood-plastic composites industry
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25-27 February 2013

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Above left: Bayer MaterialSciences PCC from CO2 plant at Leverkusen. Above right: Development of bio-based polyols in Fords US laboratory
furanoate (PEF). It could also be used as a feedstock in production of polyurethanes and polyamides. Avantiums partners include Teijin, Coca-Cola, Solvay, Rhodia and Danone. The PEF-based material is said to have been successfully tested on commercial blow moulding, fibre and film lines and is claimed to provide a higher gas barrier than PET. A pilot PEF plant is being constructed at Chemelot in the Netherlands with an annual capacity of 40 tonnes. Work underway at the Leibniz Institute for Catalysis is focused on the development of catalysts for production of monomers from vegetable oils. Institute group leader Angela Kckritz said the German vegetable oil market comprises 5.16m tonnes of rape seed oil and 50,000 tonnes of sunflower oil, with imports of sunflower, linseed, soybean oil (from USA), castor oil (from India), palm and coconut oil (from Malaysia and Indonesia). These vegetable oils can be used in the synthesis of polyurethane, polyester, polyamide, polyacrylate and epoxy resin, said Kckritz. Emery Oleochemicals has achieved ozonolysis of oleic acid, which can be used in polyamide 6,9. Evonik has chemical pathways for the production of ricinoleic acid to give polyamide 10,10 and 6,10. Arkema has a polyamide 11 produced from 11-undecanoic acid from castor oil. BASF has made a polyamide 6,10 and a variety of polyols from sources such as castor oil. Royal DSM is producing a polyamide 4,10, thermoplastic copolyester and unsaturated polyester resin from bio-sources. Director of sustainability Frederic Petit said DSM is also a partner in the Biosuccinium project with Roquette, which intends to produce succinic acid using a yeast-based process. The two companies hope to begin large scale production in a 10,000 tonne/year unit in Italy this year. Plans are also in hand to make bio-based adipic acid,
which is a precursor for polyamide 66. There is also a great deal of interest in technologies to synthesise polymers from carbon dioxide. Several companies worldwide are involved in the production of polypropylene carbonate from CO2, including BASF and Bayer MaterialScience in Europe, Novomer in the USA, SK Innovation in Korea, and Mengxi in China. BASF is motivated by low monomer costs, reducing CO2 emissions trading and the abundant feedstock from power plants. It is testing the polypropylene carbonate materials in several applications, including using it in blends with PLA as an ABS replacement in electrical appliances, in agricultural films and in paper coatings. BASF research chemist Dr Anna Brym said one issue that must be dealt with is the low activity of catalysts, as well as the need to remove the catalyst after polymerisation. Bayer MaterialScience has generated polyetherpolycarbonate polyols from CO2 for use in polyurethane. The CO2 supply is scrubbed at the coal-fired power plant where it is captured from the flue gases and then reacted with propylene oxide. It has taken the company time to reduce the by-products and improve catalyst use towards its dream production target level but some slab stock foam has been produced and tested, said Dr Christoph Grtler, head of the companys new catalytic processes competence centre.
Green Polymer Chemistry 2013

The first Green Polymer Chemistry conference provided a unique opportunity for agro-economic and bio-based polymer experts to gather and debate the key issues around this novel technology. The second event, Green Polymer Chemistry 2013, will be held in Cologne, Germany from 19-21 March 2013. For more information or to book your place contact Rebecca Utteridge: rju@amiplastics.com or visit www.bit.ly/Green2013
54
The international conference and exhibition for the plastic cable industry
HEADLINE SPONSOR
5-7 March 2013

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Polymers and additives | products
biomaterials
Consortium tests almond shell masterbatch

Spanish researchers plan to develop masterbatches containing almond shells AIJU Spains toy research institute is co-ordinating a project that aims to develop masterbatches using agricultural waste products, such as almond shells, together with biodegradable polymer carriers. Target applications include toys and furniture, say the researchers. Partners in the three-year project, which is funded by the Spanish Life+ programme, include masterbatch maker IQAP, toy manufacturer Injusa, and injection moulder Perez Cerda Plastics. The first meeting took place in October.
www.aiju.info
masterbatch
Americhem launches black nigrosine masterbatches

Colour and additive systems supplier Americhem has a new line of highly concentrated low-aniline nigrosine black masterbatches, which are available in PA 6 and 6,6 carriers at concentrations up to 40%. Compared to carbon black, the new products are said to provide a deeper black, higher gloss and minimal stress whitening. Due to their minimal impact on physical properties and suitability for use with glass reinforced polyamides, Americhem says the new masterbatches are likely to find applications in sectors such as under-the-hood automotive parts. They can also be combined with carbon black where high UV stability is required. Americhem has also pvc plasticizers introduced ePVC a precoloured capstock compound for the decking and exterior profile market. According to the company, the ePVC capstock compound provides improved strength and weathering resistance along with better colour retention, scratch and mar resistance and impact performance. The compounds also reduce moisture penetration into exterior profiles, reducing risk of rot. The ePVC compounds have undergone extensive weather testing. They can also be used with Americhems nGrain simulated woodgrain effect. Target applications include under-the-hood components
pigments
Cappelle targets technical polymers

Belgium-based Cappelle Pigments has introduced a new bismuth vanadate pigment Lysopac Yellow 6619B intended for use in technical polymer compounds up to 300C. The 6619B pigment offers a green-yellow shade providing high light fastness as well as the thermal stability required for polymers such as PA and PC. It is said to be easy to disperse in the polymer. Also new is Lysopac Yellow 6618B. Providing thermal resistance to 230C, the grade provides improved reflow in powder coating applications.
www.americhem.com
www.cappelle.be
Galata extends Drapex plasticizer range

Galata Chemicals has added Drapex Alpha 200C to its family of natural oil-based primary plasticisers.
Intended for use in white and clear PVC formulations or applications requiring high levels of performance, the
200C grade is said to provide improved extraction resistance, reduced VOCs and better processing. The company says
the plasticizer is pitched at applications requiring the performance of trimellitates.
www.galatachemicals.com
57
December 2012 | compounding world
products | Polymers and additives
functional fillers
Modified mineral filler can raise thermal performance
pvc additives
The latest additions to the functional filler product line from Quarzwerke subsidiary Mineral Engineers allow users to modify thermal conductivity and optical performance. The company has developed a range of modified mineral fillers based on a naturally-occurring alumina-silicate designed to impart thermal conductivity in polymer compounds when used at moderate to high volume fractions. The mineral filler is processed to particle sizes between 5 and 30 microns, then coated using a special surface treatment. Mineral Engineers says the new fillers are likely to find applications in the electronics sector where increasing energy density requires more effective heat dissipation without sacrificing electrical insulation. It says the fillers are engineered to minimise any negative impact on both mechanical performance and processing and it is applying for patents on the new materials. Also new from the company is Silglow, a modified fused silica that is anorganically treated to provide glow-in-thedark performance. According to the company, the materials are charged when exposed to natural daylight or artificial illumination and release a strong glow in darkness. Silglow fillers provide a luminance of more than 20 mcd/m2 after 60 minutes, making them suitable for applications such as road markings, warning signs and guide lighting. The materials are characterised by a density of 2.2 g/cm3, hardness of 6.5 mohs and are available in grain sizes from 0.1 to 5.0 mm. A new thermally conductive filler from Mineral Engineers can assist heat dissipation in electronic devices
Bio-based modifiers for PVC

Bio-based polymers developer Metabolix has introduced a series of polyhydroxyalkanoate (PHA) copolymers that it says could be used as modifiers in rigid and flexible PVC formulations. According to the company, the copolymers can be used as low extractable plasticizers or as processing aids to prevent excessive shear heating. Certain copolymer grades have also been found to act as impact modifiers in transparent formulations. Metabolix worked with AlphaGary to validate the materials. AlphaGary is beginning to test the polymeric PHA modifiers in some current high-value applications. Metabolix hopes to ship the first production samples early next year.
www.hpfminerals.com
www.metabolix.com
pvc plasticizers
PolyOne lifts bio-content for reFlex 300

Target applications for reFlex 300 include healthcare tubing PolyOne has introduced reFlex 300, a 99% bio-based plasticizer that is claimed to provide a one-for-one replacement for general purpose phthalate plasticizers in flexible PVC applications. It is the second product in the companys newly-introduced reFlex range, which is the result of a development alliance between PolyOne and agricultural products group
Archer Daniels Midland (ADM). The new grade is certified 99% bio-based under the USDA BioPreferred programme. It is said to be suitable for a range of applications, including healthcare tubing and connectors, electrical plugs and insulators, gaskets, seals, flooring and toys. We continue to see increased marketplace
demand for renewable technology for plasticizers, according to Rob Rosenau, president of PolyOne Performance Products and Solutions. Our reFlex 300 bioplasticizer enables customers to expand their offerings with differentiated alternatives that heed consumer calls for eco-conscious solutions.
www.polyone.com
PVC Formulation 2013

Market trends and technical developments in PVC additives and compounding
12-14 March 2013

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products | Polymers and additives
reinforcements
AGY develops high modulus S-glass

applications that would have previously required more costly alternatives. It brings a new level of tensile modulus to the arena of glass fibre without losing any of the unique properties that glass brings as a component of composites such as electrical and thermal insulation, and high impact absorption and low coloration of the resin system, he says. The introduction of the new glass follows an updating of the AGY sizing options, with a number of new sizing systems being made available to improve compatibility with a range of engineering thermoplastics, including PA 6 and 6,6, PA 11, PA 12, PBT, PC, PEI, PEKK and PEEK. The new sizings are said to have been evaluated on a range of fibres from low diameter E-glass to S-2 types and are claimed to provide improved mechanical and AGY is producing glass fibre with a tensile modulus of 99 GPa impact performance compared with traditional chopped products. This could result in higher performance compounds or allow glass content to be reduced to make weight savings without sacrificing performance, says the company. We expect these sizings, combined with our S-2 Glass technologies, to open up new applications in the automotive, aerospace and industrial markets, says Walker. The sizings are available on directly sized rovings or as chopped fibre in lengths from 3.2 mm (0.125 inch) to 6.4 mm (0.25 inch).
US-based glass reinforcement maker AGY has introduced a new high-modulus glass fibre and extended its range of sizings for thermoplastic composite applications. Developed using AGYs Modular Direct Melt (MDM) manufacturing method and a proprietary S-glass formulation, the new S-3 UHM glass fibre provides a tensile modulus of 99 GPa, which the company says is a 40% improvement over traditional E-glass products. According to AGY president Drew Walker, the new grade will allow material formulators to use glass in
www.agy.com
conductive compounds
masterbatch
RTP meets ATEX pump challenge PCC goes

US compounder RTP Company has developed a special electrically conductive version of its 100 Series glass-reinforced PP for an all-polymer diaphragm pump that meets the most stringent requirements for use in potentially explosive environments. The pump is produced by All-Flo, a well-established supplier of polymer-based pumps for applications such as mining where the light weight and improved corrosion and wear resistance is a major benefit over metallic alternatives. One of its most popular models for mining applications is the All-Flo It 1 inch (25 mm)
AOD air-operated diaphragm pump, which is manufactured in RTPs Series 100 PP. While the pump meets the requirements of the international ATEX Directive for use in potentially explosive requirements, All-Flo sales and marketing manager Paul McGarry says certain national
markets and end-users have their own more demanding specifications. One of these customers asked for a special design using conductive polymers. Working in partnership with All-Flo and its injection moulding partner Ohiobased Royal Plastics RTP developed an RTP 100 Series compound using a carbon powder additive. Not only did RTP Company provide a conductive material that had the properties and met the requirements, it had the same processability and worked with our existing moulds, says McGarry.
direct with PLA blue pigment
Plastics Color Corporation (PCC) is now marketing its SoluPLAs TN 920259 blue tint masterbatch, originally developed for Ingeo PLA producer NatureWorks, directly as a new addition to its SoluPLAs family of PLA enhancers. Aside from the TN 920259 colour concentrate, the SoluPLAs product line includes additives for modifying the clarity, UV protection and acoustics of bio-based PLA resins.
www.rtpcompany.com
www.plasticscolor.com
This months free brochure downloads

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AGC: Fluon MPC compounds

This eight-page brochure from AGC Chemicals covers the companys Fluon MPC melt processable uoropolymer compounds, which are used to pigment and enhance ECTFE, ETFE, FEP, MFA, PFA and PVDF.
Plastribution: know-how
Issue 03 October 2012
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In this issue The Olympic torch Momentum Joining the App revolution Recycle with industry know-how Nylon replaces metal in cars 13 14 16 32
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Nyco: engineered reinforcements

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Steer: EPZ screw elements

This 20-page brochure from Steer Engineering features its wide range of screw elements including many innovative designs developed by the company. It also covers replacement barrels and shafts.
Wo l l a s t o n i t e : E n g i n e e r e d R e i n f o r c e m e n t s f o r Polymer Applications
A Specialty Mineral That Provides Excellent Balance in Stiffness and Impact

IMPROvEd MEChANICAl PROPERTIES IMPROvEd MElT STRENGTh lOWER dENSITY ThIN WAll COMPOSITES ClASS A SURFACE APPEARANCE CONdUCTIvE MOdIFIEd
This brochure from Nyco covers the companys Wollastonite engineered reinforcements for polymer applications. The specialty mineral provides excellent balance in stiffness and impact, plus Class A surface appearance.
Pl ASTICS
Imerys: Jetne talcs

This eight-page technical brochure from Imerys Talc covers the companys Jetne talcs for highperformance polypropylene and engineering thermoplastics compounds. It includes property comparisons for different formulations.
Poly.ERP: case study

This 16-page case study from Kirchhoff Datensysteme examines the development of its Poly.ERP customised ERP system for compounders and how it was successfully implemented at Polymer Chemie.
Jetfine talcs
Unique ultrafine milling technology
for high performance polypropylene and engineering thermoplastics

Improved TPO and ETP impact strength at very low temperatures Excellent dimensional stability Reduced part thickness
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Machinery and software | products
extruders
Battenfeld-Cincinnati to demonstrate wood-plastic composite capabilities

Battenfeld-Cincinnati will demonstrate its latest WPC processing technology for solid decking profiles during AMIs 9th Wood Plastics Composites conference in Vienna, Austria, in February. The company will be running its new fiberEX 114 parallel twin-screw extruder a high output WPC production unit that the company says is well suited for the extrusion of solid WPC decking profiles. Demand for WPC products is growing at around 20-25% a year in Europe, says Battenfeld-Cincinnati. Solid decking profile is one of the emerging trends, originally developing in Germany but now gaining market share across Europe. Compared to traditional hollow profiles, solid decking offers the ability to accept diagonal cuts and does not require injection-moulded finishing caps. The reduced surface area also minimises water absorption. Battenfeld-Cincinnati has more than 250 WPC lines in Battenfeld-Cincinnatis fiberEX 114 is particularly suitable for the extrusion of solid WPC profiles operation worldwide covering outputs from 20 to 1,000 kg/h. The fiberEX 114 extruder is the second model in a new range of high-performance WPC extruders, joining the recently introduced fiberEX 135 model. Both are claimed to provide optimal process stability along with maximum production outputs and degassing performance. AMIs Wood Plastics Composites conference takes place in Vienna on 25-27 February. For more information, visit http://bit.ly/WPC2013.
www.battenfeld-cincinnati.com
Dynisco performs better under pressure

Dynisco has added two new pressure transducers to its range the Echo series targets general purpose extrusion monitoring applications, while the Vertex units deliver the additional performance required for more demanding markets such as the medical sector. Echo sensors use a proven sensor design that offers accuracy to within 0.5% over pressures ranging from 0-1,500 psi or 0-10,000 psi. They feature stainless steel construction on all surfaces in contact with the melt, while the diaphragm is coated with titanium aluminium nitride for additional durability, enabling Dynisco to offer a two-year warranty. Vertex models are the first Dynisco units to offer direct pressure measurement. Eliminating the typical mechanical pressure transfer systems or liquid fill media means improved precision and longer service life, according to the company. The absence of any liquids also eliminates leakage risk. Key to the new Vertex Dyniscos Vertex models offer direct pressure measurement for demanding applications design is the sensor tip arrangement, which incorporates a single highly robust diaphragm manufactured from high corrosion resistant Inconel 718 steel and finished with a DyMax diamond-hard protective coating. This new construction also includes an improved sensor wall structure with improved ability to handle side stresses. Vertex accuracy is within 0.25% of full scale over the standard pressure ranges of 1,500, 3,000, 5,000, 7,500 or 10,000 psi. A four-year warranty is provided.
instrumentation
www.dynisco.com
www.compoundingworld.com December 2012 | compounding world 63
products | Machinery and software
materials handling
Conair improves flake feeding

through an oversized opening at the base to a horizontal auger that positively conveys it to the mixing chamber. Where high volume throughputs have to be accommodated, the company uses lift augers positioned at an angle in a corner of the regrind bin (pictured). Instead of forcing the material into the base of the bin, these lift it to avoid compaction in the feed zone. According to Conair, this allows the flake to flow easily through into the mixing chamber. TrueBlend units are available to handle throughputs of less than 23 kg/hour on the smallest TB45 unit to 5,455 kg/hour on the largest TB3500 models. They can be supplied with up to 12 ingredient bins. l Conair has also introduced the new TrueFeed LQ liquid feeder for handling liquid colours and additives. The unit uses standard peristaltic pump dosing but the liquid container is mounted on a load cell to provide real-time loss-in-weight dosing. Conair claims the improved accuracy can enable significant savings on costly colorants.
mixers
Conair has introduced two new developments for its TrueBlend blending systems to improve the handling of flake recyclate and other difficult-to-feed regrind materials. Certain thin, flaky regrind like PET bottle scrap or thicker film and sheet scrap has granules with relatively large, flat surfaces so they tend to pack together and bridge in conventional hoppers, says Conairs blend product engineer Jeff Bickel. The TrueBlend range uses two different approaches to overcome feeding problems. For smaller throughput quantities, the units can be fitted with side feeders with steeply angled sides that help prevent regrind from hanging or bridging. The material can then flow easily
Kreyenborg upgrades mixer at Ponachem

Hamburg, Germany-based compounder Ponachem has slashed mixing times and reduced energy consumption from its 20-year old silo mixer system after Kreyenborg upgraded its pipe auger to an open mixing screw. Kreyenborg Plant Technology replaced the original pipe auger in the 20 m3 silo with an open mixing screw incorporating a special segment design. The result was that Ponachem gained a reduction in the required mixing cycle for its plastic regrind from 4 hours to just 20 minutes. Similar results can be achieved with any free-flowing material, says Kreyenborg.
www.conairgroup.com
www.kreyenborg.de
software
Rowa completes its ERP integration

Germanys Rowa Group says the integration of its Infor Blending Lab information and Management System (LIMS) into its ERP system is now complete, improving management of its quality systems. According to the company, the LIMS system allows customer-specific test profiles - which may deviate in either test criteria or in threshold values - to be created, recorded and recalled for subsequent testing. This
64
speeds up the administration and management of the entire testing process. The LIMS system also allows test compliance certificates to be generated for every product delivery and incorporated into the documents delivered to the customer. LIMS records all control results on a product, customer and batch basis, and manages them in a central database, which the ERP accesses. This means, among other things,
that blending only releases a batch for delivery when all tests have been completed and fully documented, says Wulf Hagemeister, technical manager at Rowa Masterbatch. Because the system makes all data for a product centrally accessible and interlinked, we can conduct statistical comparisons of the performance of different product batches quickly and comprehensively. We can thus
gain important data relating to the entire product history, such as the quality of the raw material deliveries. We can then assess this data and integrate our findings into production planning and control, he says. The LIMS ERP integration project commenced in September 2011, with the roll-out scheduled to take 12 months to complete.
www.rowa-masterbatch.de www.infor.com
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Pipes in Infrastructure
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2013 Pipes in I n f r a s t r u c t u re
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compounder of the month
F&D Plastics
Head ofce location: Date founded: CEO: Ownership: No. of employees: Sales 2012: Plant locations: Production 2012: Prole: Leominster, Massachusetts, USA 1967 Jean Rosbury Privately owned 92 US$20 million Leominster, MA, USA, and St-Laurent, QC, Canada 5,000 tonnes F&D Plastics is a family-owned business that started as a grinding rm and began masterbatch production in 1993. In 2004, it invested in new extruders and then expanded into Canada by acquiring CEK Colorplast in Lachine, Quebec. In 2008, Canadian production was relocated to a new facility in St-Laurent. During 2010, F&D increased capacity by 37%, installing four new lines. It is among the 50 largest masterbatch producers in North America. In addition to serving the North and South American markets, it has a partner in Malaysia and is looking at developing a sales network in the UK. F&D Plastics produces white, black and colour pigments and masterbatches based on polyolens, as well as engineering polymers, recycled material and biopolymers. Its strongest markets include housewares, lawn & garden, hardware and medical. It does some toll compounding for select customers. F&D focuses on service, price and technical support. It has invested more than US$1.5 million over the past three years to be more competitive in these areas.
Product line:
Product strengths:
Forthcoming features
The next issues of Compounding World magazine will have special reports on the following subjects: January Polymer foam technologies Pelletizers Dispersants and coupling agents February Thermally-conductive compounds Materials handling Additives for polyolens
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dates for your diary
Global exhibition guide

7-10 January 29 Jan - 1 Feb 22-25 February 6-7 March 6-8 March 12-15 March 12-15 March 3-5 April 3-6 April 10-11 April 10-12 April 7-10 May 14-16 May 20-23 May 20-24 May 16-23 October ArabPlast, Dubai, UAE Interplastica, Moscow, Russia GAIL Plastasia, Bangalore, India Plastec South, Orlando, FL, USA Plast Bulgaria, Sofia, Bulgaria Plastimagen, Mexico City, Mexico Pro-Plas Expo, Johannesburg, South Africa Plastex Uzbekistan, Tashkent, Uzbekistan Tiprex, Bangkok, Thailand PlastTeknik, Malmo, Sweden Plastic Japan, Tokyo, Japan PlastPol, Kielce, Poland Plast-Ex, Toronto, Canada Chinaplas, Guangzhou, China Feiplastic, Sao Paolo, Brazil K 2013, Dsseldorf, Germany www.arabplast.info www.interplastica.de www.plastasia2013.com www.plastecsouth.com www.plast.bg www.plastimagen.com.mx www.proplasafrica.co.za www.plastex.ite-uzbekistan.uz www.tiprex.com www.easyfairs.com www.plas.jp/en www.plastpol.com www.plast-ex.org www.chinaplasonline.com www.feiplastic.com.br www.k-online.de
AMI conferences
29-31 January 18-20 February 25-27 February 5-7 March 12-14 March 18-20 March 19-21 March 7-8 May 14-15 May 14-16 May 3-5 June 4-6 June 13-14 June Thermoplastic Concentrates, Coral Springs, FL, USA The Grass Yarn & Tufters Forum, Cologne, Germany Wood-Plastic Composites, Vienna, Austria Cables, Cologne, Germany PVC Formulation, Dsseldorf, Germany Masterbatch Asia, Singapore Green Polymer Chemistry, Cologne, Germany Bioplastics Compounding & Processing, Miami, FL, USA Polymers in Cables, Miami, FL, USA Polymer Sourcing, Vienna, Austria Masterbatch, Frankfurt, Germany End of Life Plastics, Cologne, Germany Fire Retardants in Plastics, Denver, CO, USA
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December 2012

ANDROID VERSIONS NOW AVAILABLE

21 Picking ame retardants for polyamides

33 Lab compounders: small machines for big ideas

49 Inside the green revolution

on progress in renewable and sustainable plastics technologies.

66 Compounder of the month: F&D Plastics 68 Dates for your diary

coming next issue

China XD commissions new compounding lines

Owens Corning expands

Songwon reveals one-pack plant location

December 2012 | compounding world

FBW adds two Coperion lines

Albemarle invests in FR plant

Masterbatch group elects board

Pantone picks Emerald as the colour of 2013

TIME TO IMPROVE YOUR IMPACT RESISTANCE?

BASF starts up additive blends plant in Bahrain

Foster to expand in Asia

Evonik goes phthalate-free

APS Compounding exceeds production goals

CREATING TOMORROWS SOLUTIONS

Best Selling Books in 2012

PLASTICS INFORMATION DIRECT

Energy Management in Plastics Processing: Strategies, Targets, Techniqus and Tools

Biaxial stretching of lm: Principles and applications

Polyethylene Film Extrusion: A Process Manual

Cost Management in Plastics Processing: Strategies, Targets, Techniques and Tools

Advanced Thermoforming: Methods, Machines and Materials, Applications and Automation

11 Solar Module Packaging: Polymeric Requirements and Selection

Blown Film Extrusion

REACH for the Polymer Industry A Practical Guide

Luxus expands capabilities

UPGRADE YOUR PERFORMANCE!

High-temperature compounding | processing feature

Table 1 - Typical melting points of high-performance polymers

Amorphous resin glass transition temp (C) 190 215 220 -

December 2012 | COMPOUNDING WORLD

processing feature | High-temperature compounding

compounding world | December 2012

The one-two punch.

processing feature | High-temperature compounding

when running higher temperatures, says Tate.

COMPOUNDING WORLD | December 2012

Basic and Specialty Antioxidants

Hindered Amine Light Stabilizers

Songlight SongSorb SongStab SongStab SongCat

processing feature | High-temperature compounding

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Substantial gain in productivity Compounding lines

Flame retardants | additives feature

Picking ame retardants for polyamides

December 2012 | COMPOUNDING WORLD

additives feature | Flame retardants

compounding world | December 2012

Conductive Carbon Black electrical conductivity easy-dispersion high purity

Graphite & Coke thermal conductivity electrical conductivity lubrication

Unbeatable deals for 2013

Flame retardants | additives feature

additives feature | Flame retardants

Impact of product trends

The green inuence

POWERFUL LITTLE PELLET

compounding world | December 2012

compounding world | December 2012

compounding world | December 2012