Raw material for TQ Films Satish V. Awate Product Application & - - PowerPoint PPT Presentation

Raw material for TQ Films

Satish V. Awate Product Application & Research Centre

Reliance Industries Limited

IPI seminar Aug 2002 rev 0.1

“ a better product at affordable price ”

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Index

Overview on PP films in flexible packaging sector TQPP film extrusion process Repol H 100 EY for TQ film applications New Repol grades for advance applications Manufacturing process for Repol Product Application & Research Centre

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Flexible Packaging Sector : Overview

44% 27% 17% 12%

LD/LLDPE PP HMHDPE PVC

Total Film Market (01-02) ~ 1MMT PP films: 2nd largest share in flexible packaging

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Polypropylene film : overview

2% 20% 78%

TQPP CPP BOPP

...largest contribution from TQPP films

PP Film Market (01-02) ~ 270KT

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Growth of TQPP film sector

200 400 600 800 1000 1200 1400 1600 1996-97 1997-98 1998-99 1999-00 2000-01 2001-02 50 100 150 200 250 Machines Consumption (KT)

...supply driven market

CARG ~ 17%

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Drivers for growth of TQPP films

...aesthetic appeal of PP the key driver for growth

Growing demand in flexible packaging Excellent optical properties viz. clarity & gloss Better mechanical properties viz. stiffness Good barrier properties Cost effective packaging solution

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Characteristics of Polypropylene

higher crystallinity formation of spherulites, as the melt solidifies slower crystallisation rates possible to get smaller size spherulite, by quenching of the film

...need an extrusion process with an effective cooling arrangement

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Tubular Quenched Polypropylene (TQPP) film extrusion process

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Advantages of TQPP process

• low capital
• lesser space requirement
• lower operating cost
• less demanding operating skills
• ease in changing the width / thickness of film
• tubular film is an added advantage in manufacturing
• f pouches / bags

…most cost effective process in plastics

Polypropylene grade for TQ film

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Repol H 100 EY

PP homopolymer, with slip and antiblocking agents MFI : 11.0 g/10min The grade is designed to provide:

• Good processability
• Good clarity and gloss
• Good stiffness

Typical applications : packaging of textiles / food / other commodities

…largest selling PP grade in India

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Properties of TQ films made from PPHP

narrow sealing window and low seal stregnth low impact properties lower tear resistance higher stiffness

...yet to make a mark in more demanding applications

New grades for advance applications

• f TQ film

Random Ter-polymer T 080 EY Repol H 100 EY (modified)

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Repol T 080 EY

New random terpolymer from RIL 8 MFI grade, with slip & antiblock Repol T080EY is designed to provide :

• Soft in feel
• Lower sealing temperature
• Good dart impact and tear strength
• Good processability
• High melt strength
• Good gloss and clarity

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Dart Impact Strength

1.2 4.6 3.5 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5

Dart Impact Strength (gm/micron) PPHP Ter-polymer LLDPE(1 MFI)

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Tear strength

1.2 1.2 3.4 2.8 9.9 12.5

2 4 6 8 10 12 14 MD TD PPHP Terpolymer LLDPE

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Sealing characteristics : Hot Tack Strength

120 @ 1400C 185 @ 1280C 160 @ 1160C

50 100 150 200

HTS

PPHP Terpolymer LLDPE

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Sealing characteristics : Heat Seal Strength

1000 @ 140 0C 1300 @ 128 0C 1200 @ 116 0C

200 400 600 800 1000 1200 1400 HSS PPHP Terpolymer LLDPE

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Advantages of Repol T 080 EY

• Lower melting temperature, hence lower processing

conditions

• Lower sealing temperatures
• Better sealing characteristics
• Better mechanical properties

..for more demanding applications

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Applications for Repol T 080 EY

liners carry bags lamination films (see-through pouch) packaging on form fill seal (FFS) machines stationery items (photo albums / document holders)

… value added products

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Modified Repol H 100 EY

significant improvement in throughputs 20 kg/hr 150 kg/hr

• ver stretching leads to bubble breakage

/punctures at higher shear rates, extensional viscosity decreases melts becomes thinner (stress thinning of PP) resin has to be designed for higher extensional viscosity

...tailor made for high output machines

Manufacturing process for REPOL

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Manufacturing process for REPOL

Unipol manufacturing process combines

• the fluidized bed reactor technology of Dow-UCC
• the Super High Activity Catalyst (SHAC) of Shell

No atactic removal and deashing steps due to the highly active and highly selective catalyst Ability to make following grades of PP:

• Homopolymer (PPHP)
• Impact Copolymer (PPCP)
• Random Copolymer (RCP)
• Controlled Rheology (CR)

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Unipol process

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Resin Property Modification

Type of catalyst and plant process parameters used during polymerisation, decide the following resin parameter: − Tacticity − Molecular weight − Molecular weight distribution Resin parameters and additives incorporated are determined by the requirements − processability − end properties of a product

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Product Application & Research Centre :

A Vital link between Plant - Business - Processors

Marketing Manufacturing Manufacturing Processors Processors

PARC

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WE believe in building strategic relationships

Between business enterprises and their vendors Converting basic needs into commercially viable technology Helping produce useful products

Research Institutions Polymer Processors End Users Machinery Manufacturers

PARC

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PARC

End Product Evaluation Interaction with professional bodies/Nodal Institutes Research Institutes

Grade Benchmarking/ improvement

Developmental Activities

Resin Evaluation Product Designing BIS / ISO Activities

Technological Evaluation

VALUE ADDITION

Customer Service/Support

Resin Evaluation Additive Optimization Product Designing

Areas of activities

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Thank You !