Additives Miracle Workers for The Plastics Industry ! Dr. Y.B. - - PowerPoint PPT Presentation

Additives Miracle Workers for The Plastics Industry !

• Dr. Y.B. Vasudeo
• Sr. Vice President

Product Application & Research Centre

Reliance Industries Limited

Jayvee Organics Endowment Lecture 26th September 2003 Mumbai

Opening Remarks !

• “Additives are rapidly becoming the miracle

workers for the plastics industry, whether they are traditional favourites like plasticizers, impact modifiers and antioxidants or new technologies such as nanocomposites and antimicrobials; their importance is increasing all the time”

Additives – A Curtain Raiser !

“Innovation is the ticket for suppliers who seek to stay competitive in a tough global market From improved versions of workhorse grades to better service strategies and formulations, designed for new emerging polymers and interpolymer competition, will be the rule

• f the additives business”

Scope Of The Endowment Lecture

• Global scenario and market trends
• From additives to product innovation
• Additive-driven plastics business avenues for

the Indian entrepreneur

Additives - An Introduction

• Additive

– “A chemical added in minor amounts to a host plastic to improve the overall performance of the system” – Additives are categorized by the functions that they perform rather than their chemistry

• Additive functions

– Modifiers – Property extenders – Processing aids

Additive Classes

• Modifiers

– Plasticizers – Chemical blowing agents – Coupling agents – Impact modifiers – Organic peroxides – Nucleating agents

Additive Classes

• Property Extenders

– Flame retardants – Heat stabilizers – Antioxidants – Light stabilizers – Antistatic agents

• Processing aids

– Lubricants – Mould release agents – Antiblock / slip agents

Additives : Global Business Snapshots

• Additives : Growing sector of the speciality

chemicals industry – Industry overview – Technical trends – Commercial trends

Industry Overview

Industry Overview

Industry Overview

Performance Additives

• Coming to the true ‘performance’ additives, flame

retardants are largest, estimated at about 850,000 tonnes worldwide, with a value of some $2 billion. Heat and UV stabilizers are about 300,000 tonnes, but one estimate puts them as high as 462,000 tonnes.

• Latest power bill and attention drawn to theft and

percentage revenue loss, counter by SEBs to install meters and likely revenue generation. Effect on flame retardant additive business.

FRPP Compounds : First Success !

Flame Retardant Repol PP for Battery Box Applications

Technical Trends

Consumption of plastics additives in Polyolefins Source : TownsendTarnell

Technical Trends

% Sales in PVC (By Volume)

Consumption of plastics additives in PVC Source : TownsendTarnell

Additives : Business Perspectives Worldwide Suppliers

• 350 companies of additive

suppliers worldwide

• 100 companies have annual sales
• ver $100,000

Additives business has a high proportion of very small suppliers of speciality products

Additives : Business Perspectives

Worldwide suppliers of chemical additives by class

Involved in one class 83% Involved in all three classes 4% Involved in two classes 13%

Involved in one class Involved in all three classes Involved in two classes

350 companies

Worldwide suppliers

• f additives by

class

50 100 150 200 250 Modifiers Property extenders Processing aids

• No. of companies

Worldwide suppliers of chemical additives by class

Additives : Business Growth

1 2 3 4 5 6 7 8 Modifiers Property extenders Processing aids 2001 1996

Commercial Trends In Additive Suppliers Business

• Globalization

– Following key end user sectors (auto, medical, electronics, packaging) – Set up manufacturing worldwide – Deliver same formulation everywhere

• Redefinition of core business and identification of key

sector – For new technology – For new product development – Examples : » Great Lakes : Flame retardants » Elf Atochem : Peroxides » Crompton : OBS additives

Commercial Trends In Additive Suppliers Business

Cost of new product development driven by

• Competition
• Patent expiration
• Environmental regulations
• Interpolymer competition
• Smart and intelligent packaging systems

Additive Supplier’s Strategies

• Approach I

– Concentrate on specific industries, meeting specific regulatory requirements

• Approach II

– Concentrate on specific materials and chemistries

• Additive business in recent years has

emerged as a major global segment of “value-added” speciality chemistry

Additives : Ingredients For Growth Of Plastics

• Food Packaging – Role of Additives
• Additives
• Antioxidants
• Pigments
• Processing aids
• Lubricants
• Clarifiers
• Issues
• Organoleptic

properties

• Migration

A Quick Guide To Food Contact Additives

• Generally regarded as most effective
• Highest performance at lowest dosage
• Contribute to colour and transparency

retention when required

• Improvement of organoleptic

properties, a continuing aim Stabilizers

• Phosphites /

phosphonites Comments Additives Class

A Quick Guide To Food Contact Additives

• For direct food and medical applications
• Citric acid esters
• Widespread food contact approval
• Epoxidized

soyabean oil

• Usually polyesters – based on adipic acid

– extend life of PVC end products; retard migration, extraction and volatility Plasticizers

• Polymeric
• Suitable for PE & PP (indirect food

contact)

• Most clarifiers approved for food contact

applications in RCP Processing aids

• Fluoropolymers
• Nucleating agents

Comments Additives Class

Contribution Of Additives To Success Of Polymers In Packaging

• PPAs and lubricants eliminate melt fracture in

PE blown film, cast film and thin-walled extrusion

• PPAs are now targetted for increased output

rates and increasing filler and additive dispersion

Contribution Of Additives To Success Of Polymers In Packaging

• The success of flexible packaging is

attributed to “PPAs”

• The success of rigid packaging in clear

applications is attributed to “Clarifiers”

Additives Drive Automotive Plastics In New Directions : Growth Drivers

• Increased demands on polymer performance
• Plastics with increased thermal stability
• Plastics with longer weatherability
• Pressure to reduce costs of of plastic parts
• Ability to lower moulding cycle times
• Beneficiaries :

– Antioxidants – Light and heat modifiers – Viscosity modifiers – Impact modifiers – Glass beads – Nanofillers

Additives Facilitate Growth Of Wood Plastic Composites

• New stabilizer package
• New coupling agents
• New antimicrobials

Wood / PP Door Trims Wood / PVC Profiles

Growth Areas For Additives For Plastics In Auto Applications

• Light stabilizers for TPOs and PVC (6.5% pa)
• Coupling agents for glass filled formulations (6% pa)
• Nucleating agents

– Speed crystallisation – Shorten moulding cycle and productivity

• Flame retardants for PP and PVC
• Additives for long glass fibre reinforced thermoplastics

(30% pa) & masterbatches for LFTs (80% filled)

• Additives for nanocomposites based on PE & PP
• Additives for TPV masterbatches for replacement of

thermoset rubber

Additives for Interpolymer Material Competition

Styrenics Vs Filled Polypropylene Compounds

• Attribute for ABS replacement

– Additives for imparting high gloss to PP compounds – Additives for improving scratch resistance of PP

Thermoformed Door Liner From Blend of Repol C015EG & Repol H020EG With Modifiers

Additives for Interpolymer Material Competition

Styrenics Vs Filled Polyproyplene Compounds

• Low cost additive formulations of PP

will win the game over styrenics

Niche Products With Help From Additives

Additives for tribological polymers used in bearing applications

• Friction – complex phenomenon
• Neat polymers cannot satisfy demands
• Tribological additives contribute to the best balance of

– Co-efficient of friction – Wear – Cost – Performance

• Examples

– MoS2 – Graphite – PTFE – Silicones

Tribological Effects In PP

• Effect of silicone masterbatch content on the

co-efficient of friction of PP

35 10 20 5 10 1 Decrease in COF % Silicone Content %

PVC Plasticizer Adds Value To Waterbeds

• Waterbeds : means for combating sleep and

back problems

• Waterbeds : cure for allergies
• Waterbeds : hygenic alternative to foam

mattresses

• The high level of acceptance of waterbeds even

among conservative customers is attributed to improved properties of PVC film, the crucial component of a waterbed mattress

PVC Plasticizer Adds Value To Waterbeds

Attributes Of PVC Membrane For Waterbeds

• Soft
• Seams must be weldable to avoid leaks
• High tear strength
• High elongation properties
• Role of Additives
• Selection of plasticizer – key to PVC performance
• Phenol alkyl sulphonate – new emerging additive
• Advantages
• Greater saponification resistance compared to

phthalates

• Reduced tendency to migration

Additives For The Extrinsic Conductive Polymers

• Polymers – intrinsically insulating

(non-conducting)

• Adding additives to naturally insulating polymers

yields conductive polymers

• Examples

– Conductive carbon black – Conductive fibres (carbon or steel)

Polyethylene Resistivity Vs. Carbon Black Level

Properties Of Conductive PP

4.3 1.4 Flexural modulus, GPa 41 41 Tensile or flexural strength, MPa 103 103 Resistivity, ohm-cm Carbon Stainless Steel Fibres

Ceramics As Lubricating Additives For PE Film

• Boron nitride at 100 ppm in PE acts as a processing

aid

• At 100 ppm, advantages are :

– Decrease in processing temperature – Decrease in pressure – Reduction in onset of melt fracture – Increase in output – Decrease in COF

0.9 4 Dynamic 0.6 3 COF static 38 10 Output (kg/hr) PE + 100 ppm, BM PE Material

Modern Dispersing Agents For Polypropylene

• Required for good pigment dispersion in PP
• Metallocene waxes provide the answer
• Yellow 155 or Toner Red 48:2 can be processed

easily with new generation waxes

• Useful for PP fibres applications

New Avenues For Chemical Blowing Agents

• PE rotational moulding
• PP / wood composite

New Avenues For Chemical Blowing Agents

• PP / wood composite
• PE Rotomoulded foamed Product

Selecting Peroxides For Crosslinking PE

• Masterbatch in a PE carrier
• Let-down in

– Blow moulding – Rotomoulding

Effect of peroxide content on Izod Impact strength 300 350 400 450 500 550 50 100 150 200 250 Peroxide Level (ppm) Izod Impact (J/m) Effect of peroxide content on Izod Impact strength 300 350 400 450 500 550 50 100 150 200 250 Peroxide Level (ppm) Izod Impact (J/m)

Effect of presence of antioxidant on the extent of cross linking with peroxide. 30 32 34 36 38 40 42 44 100 200 300 400

Antioxidant level (ppm) MFI (dg/min)

Effect of presence of antioxidant on the extent of cross linking with peroxide. 30 32 34 36 38 40 42 44 100 200 300 400

Antioxidant level (ppm) MFI (dg/min)

New Trends In Plastic Additives For Packaging Applications

• Plastics additives industry is always looking for

new effects and performance like : – Barrier properties at low cost – UV protection of goods to improve shelf-life – Improved shelf-life of foods – Permanent antistatic performance – Transparent PP products for aesthetic / price ratio – Smart and intelligent packaging

Solutions From New Generation Additives For Packaging Applications

• UV filters for PET bottles

– Polyether block polyamide copolymers (PEBA) as permanent antistats – High barrier properties with nanofillers

• Fresh Keeping Additives

– O2 absorbers – C2H4 scavengers – CO2 scavengers and emitters – Moisture regulators – Antimicrobials – Odour scavengers – Radical scavengers

Solutions From New Generation Additives For Packaging Applications

Peformance of UV filters in PET bottles Nanocomposites for high barrier clear films

Animal Repellants For Plastics

• Denatonium products
• Available as aerosol spray
• Used as gel on roofs
• Used in polymer formulations
• Successfully used in plastic

– Pipes – Screens – Sidings – Railway doors – Wires & cables Effectiveness in PVC Wire & Cable

Antimicrobial Additives In Plastics

• Global market potential is worth $ 220 million
• Expected global growth rate 4% pa

– Applications – Kitchenware – Hosiery – Carpets – Hospital waste bags – Refuse containers – Packaging Halo Test Results for PE Film

High Performance Polymer Applications & New Business Opportunities For The Indian Plastics Industry !

PLASTICS IN AGRICULTURE !!

“All applications are driven by additives incorporated into polyolefins to meet end use requirements”

Agriculture Sector

Opportunities in – Mulch films – Greenhouse films – Packaging of fresh agricultural produce

Mulch Film For Groundnut From LLDPE

• Salient Features of Groundnut Cultivation

– Total area under groundnut cultivation : 6.8 million hectares

• Even as 1% of this land is cultived

: PE required is 5000 MT for 1 season

• 7 µm LLDPE clear mulch films have been tested
• Latest development : photo-selective mulch films

Cost / Benefit Analysis For Producing Groundnut Mulch Film

Net gain / hectare : Rs. 26,500/-

• Rs. 87,250/-
• Rs. 60,750/-

Revenue / hectare

• Rs. 8.92
• Rs. 7.63

Cost of cultivation per kg Rs. 1,14,000/-

• Rs. 76,000/-

Value of produce 3 tons 2 tons Yield / hectare

• Rs. 26,750/-
• Rs. 15.250/-

Cost of cultivation per hectare Mulched Unmulched Parameters

Mulch Film For Groundnut From Reclair Linear Low Density Polyethylene

Mulch Film For Groundnut

• Introduction

Mulch Film For Groundnut

• Advantages

Mulch Applications

Laying the Mulch

Groundnut Mulch Film – Post Extrusion Operation

Mulch Film For Groundnut - Observations

Groundnut pods without Mulch Groundnut pods with Mulch

Speciality Greenhouse Films From LLDPE

• Global floriculture business : 50 billion USD
• Established players : Holland, USA, Japan
• Upcoming players : India, China, Kenya,

Tanzania

• Major flowers under greenhouse : Rose,
• rchids, gerbera, carnation
• Area under greenhouse : 500,000 hectare

(worldwide)

• In India : 500 hectares

New Government initiative for export of flowers to Europe expected to increase floriculture business

Business Opportunities For The Entrepreneur

• Expected high growth of UV stabilized PE films
• Octene – LLDPE is an ideal film grade material
• Present market : 1000 MT
• Market size in the next five years : 3000 MT
• RIL – PARC initiative : Blend of Octene LLDPE

& LDPE for 3 years lifespan

Greenhouse Films

Greenhouse Films

Greenhouse Films

Active Packaging Films For Fresh Agricultural & Horticultural Produce

• India : Largest producer of banana, mango, cauliflower

and peas in the world

• India’s share in world’s fresh produce trade : 1%
• Annual loss of fresh agri produce : Rs. 1,00,000 crore
• Non-adoption of new technology
• Lack of post-harvest facility
• Absence of farm cold storage

Business Opportunities For The Entrepreneur In Development Of Active Packaging Films For Fresh Produce

• PE films may be engineered to control gases inside the

bag

• The film material “breathes” at a rate neessary to

maintain the correct mix of O2, CO2 & H2O vapour inside the bag

• Since cash produce has its own unique requirement,

modified atmosphere packaging material must be especially engineered for each item Shelf-life of fresh produce is extended considerably by this packaging

Active Packaging Films Based On Reclair LLDPE

• For post-harvest packaging and protection of

fresh fruits and vegetables

• Extension of shelf-life of bananas by 10 days at

ambient conditions

1 kg Active Packaging Bag Sample

Performance of Active Packaging Films

• A Picture

Essay

4 2 1

Banana loading in Trucks Carrying langoors from field

3

Loading in wagons at Savda Unloading at Savda Station

5 6

Bananas in contact with walls of wagon Bananas opened after 46 hours of packing

Trials on Banana Packaging Results after 2 days on unloading

Plastic Additives – The Indian Scenario

• Presence of multinationals

– Ciba, Clariant, Great Lakes, Crompton, Cognis (formerly Henkel), Atofina, DuPont, 3M, BASF etc.

• Emergence of Indian companies and strong presence in

global markets – High Polymer Lab – Fine Organics

• Strong established players in PVC additive business

– A.L.A. Chemicals, Rohm & Haas, Barlocher, Aryavart, Jayvee Organics, Kaneka Corporation

Vision For The Next Ten Years !

• Strong additive-based plastics applications
• Key areas for focus

– Agriculture – Automotive – Appliances – Packaging

Grateful Acknowledgements

• Jayvee Organics and Polymers (P) Ltd.
• Indian Plastics Institute
• Plastics additive suppliers
• Plastics processors
• End-users

Additives – Truly Miracle Workers For The Plastics Industry ! Additives – Truly Miracle Workers For The Plastics Industry !

Thank You Thank You