Blow Molding - K-Tron

“Cost Reduction Opportunities
with Superior Calcium Carbonate”
Gil Morieras
Director Marketing Asia Pacific
Group Marketing – Plastics
Oftringen, Switzerland
11 June, 2014
Table of Contents

- Introduction to Surint Omya
- Vietnamese Product Portfolio
- Advancements in :
Thermoforming sheets
Blow Molding
Non Woven
Raffia
- Open discussion
2
This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
Key Facts & Figures
•
Corporate head office in Oftringen,
Switzerland
•
8,000 employees
•
More than 150 plants in over 50 countries
•
Turnover of EUR 3.0 billion
•
Ownership of mineral deposits for the next
100 years of business
•
Most plants are ISO 9001 / ISO 14001
certified
•
Pioneer in ISO 14001 for quarries
•
In business for over 125 years
•
Privately-owned Swiss based Corporation
3
This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
Operations by Region
Group Head Office
Oftringen, Switzerland
Europe
Americas
Greater South & East
Asia Pacific
Plant / Tank Farm
Office
4
This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
Surint Omya Vietnam & Omya Mineral Vietnam
•
Established since 2005, joint venture
between Surint Holding (Thailand) and
Omya Holding (Switzerland)
•
Quarry, stone crushing & coarse powder
grinding plant in Nghe An
•
Fine powder grinding plant in Dong Nai
•
ISO 9001:2008 / ISO 14001:2004 &
OHSAS 18001:2007 certified
5
This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
Product Portfolio
6
This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
Vietnamese Product Portfolio – Fine treated CaCO3
Omyacarb 2T - HO
Omyacarb 1T - HO
• Anti Blocking Masterbatches for Films
• Injection Molding
• Raffia
• Thermoforming Sheets
• Blow Molding
• Anti Blocking Masterbatches for Films
• Raffia
7
This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
Thermoforming
Advantages of GCC in
Polypropylene thermoforming
Sheets
8
This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
Why use CaCO3 for PP Sheet Extrusion?
- Improved thermal conductivity
- Faster melting in extruder
- More homogenous melt
- Faster sheet-cooling on calender rolls
 Faster Extrusion Line Speed
- Low coefficient of expansion
- Lower melt volume
- Lower friction to barrel surface
- Lower torque and die pressure
 Increased Extruder Output Rate (by volume)
9
This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
CaCO3 in Thermoforming Sheets
Heat Transport
Thermal diffusivity in
mm²/sec
Productivity improvements
Thermoforming:
0.3
0.3
0.2
0.2
0.1
0.1
0.0
HIPS
Cycle Time Reduction
no sheet preheating
with sheet preheating
cycles per min
18 cavities yoghurt beakers
30
12% & 35% more cycles
(with & w/o pre-heating)
25
20
15
10
10
HIPS
PPH
30% CaCO3
This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
virgin PP
PP 30%
CaCO3
PP 60%
CaCO3
CaCO3 in Thermoforming Sheets
Performance improvements
Stiffness:
E-Modulus in N/mm²
CaCO3 Enhancing PPH Stiffness
2500
2000
1500
1000
500
E-Modulus
Increase in CD & MD
=> 15% & 30%
CD
0
0 % carbonate 30
11
This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
MD
CaCO3 in Thermoforming Sheets
Performance improvements
Impact Resistance:
Dart Drop Impact Resistance Improvements
1200
Weight in g
1000
800
DDI Increase 250%
(at same weight or
at same gauge)
600
400
200
0
virgin PPH
30% CaCO3
same thickness
12
This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
30% CaCO3
same weight
CaCO3 in Thermoforming Sheets
Post-Shrinkage / Orientation
30% CaCO3
Virgin PPH
Thermoformed yoghurt cups after 30 min at 140°C
13
This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
CaCO3 in Thermoforming Sheets
Improved economics !!!
110.0
Cost Saving with CaCO3 in thermoformed PPH
overhead & labour
mould depreciation
machine production & depreciation
sheet cost
Cost in %
100.0
90.0
80.0
70.0
60.0
50.0
PPH
20%
CaCO3
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This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
30%
CaCO3
40%
CaCO3
HIPS
Application Examples
•
Disposable dishes and cups
•
Food trays, pots and covers
•
Plant pots and seeding trays
•
Profiled building products
•
Household articles
•
Automotive interior trim items
15
This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
Extrusion Thermoforming
Filling polypropylene with up to 60% calcium
carbonate is a proven solution for running
polypropylene on existing polystyrene
thermoforming machinery with comparable line
performance and end-product quality.
The main benefits of using Omya calcium
carbonate in polypropylene include:







Higher extruder output and faster cooling on chill roll
Reduced cooling time in mold, faster cycles
Higher stiffness
Lower shrinkage
Processing on existing PS thermoforming machinery
More isotropic physical properties
Improved forming accuracy
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This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
Blow Molding
The higher thermal conductivity and lower specific heat of
calcium carbonate are key advantages in molding
applications.
Blow Molding
Calcium carbonate is used in blow molding applications to
produce bottles or containers by offering substantial
benefits such as:
Increased flexural modulus
Sustained top load and drop impact
Improved ESCR (Stress Cracking Resistance)
Reduced cycle time
Lower melt temperature
Reduced titanium dioxide amount
Improved printability
Cycle time improvement
17
This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
GCC in blow molding – mechanical properties: top load
18
This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
GCC in blow molding – mechanical properties: Drop test
Minimum
Requirement
19
This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
GCC in blow molding – properties: ESCR
20
This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
Nonwoven
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This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
Spunbonding nonwoven with mineral additive
Wide range of application options for existing and new markets
• Hygiene
• Baby and adult diapers
• Female hygiene
• Medical
• Protective clothing
• Technical products
• Architectural nonwovens
• Coating substrates
• Agrotextiles & Geotextiles
• Filtration
• Disk covers
• Wipes
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This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
Spunbonding nonwoven with mineral additive
• Product
Masterbatch spunbonding grade
70% Omyafiber, ultra fine special treated calcium carbonate
• Let down
2 - 5 % wt. as a mineral additive
7 - 18 % wt. as extender properties
• Cost & Benefit ratio
 Antiblocking
 Soft touch
 Cooling
 Elongation
 E-Modulus
 Antistatic
 Tenacity
 Dimensional stability
 Weldability
 Wind up speed
 Line Efficiency
 Productivity and formulation costs
23
This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
Application with Omyafiber mineral additive
Hygiene & Medical
Automotive
Furniture & Bedding
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This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
Wipes
Application with Omyafiber mineral additive
Agriculture
Construction – Roofing Filtration
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This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
Protective Apparel
Trials on Multifilament Lab Line
Collin Multifilament Lab Line CMF 100
PP Moplen HP 561R (LyondellBasell),
MFR = 25
Spinneret
 115 mm
with 100 filaments  0.35 mm
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This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
No GCC
5 % GCC
15 % GCC
PP multifilament fibers containing CaCO3
2 % GCC masterbatch
10 % GCC masterbatch
Scanning electron micrographs (SEM)
Fiber surface (top) & fiber cross section (bottom)
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used and disclosed without Omya explicit written authorization.
40 % GCC masterbatch
Advantages of Omya mineral modifier addition
Performance
• Reduced stickiness
• Increased softness and smoothness
• Improved dimensional stability (isotropic shrinkage)
• Similar wind-up speed
• Slightly reduced tenacity
Processing economics
• Better heat transport when using GCC may allow an increased line
speed
• Reduced extrusion pressure
• Less polymer to melt  reduced energy consumption
Raw material economics
• Save resin via mineral addition and thinner fibers
• Lower carbon footprint
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This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
CaCO3 in PP Woven Tapes
Calcium carbonate is conventionally used in PE or PP
woven bags, weaving tapes or bands to offer antisplitting and anti-fibrillation effects.
Polyolefin masterbatches based on appropriate
calcium carbonate offer:
Reduced splitting propensity of oriented
polypropylene
Increased stiffness
Reduced amount of titanium dioxide
Reduced raw material consumption
Conventional calcium carbonate loadings are in a
range of 2% to 30% in final articles.
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This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
CaCO3 in PP Woven tapes
Advantages of using Omyacarb® 2T in PP woven tapes :
• Achieve high filler loading in Masterbatches
• Optimized mineral dispersion (Low FPV)
• Prevent using waxes and lubricants which reduces WCO and Die
build up
• Low humidity level in masterbatches
• Reduce WCO
• Increase life time for knives and increased screen pack change
over time
• Reduces dust accumulation (spinning and knitting)
30
This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
CaCO3 in PP Woven tapes : Higher requirements
For high speed line or high demanding applications, Omyacarb® 1
T is the optimum solution :
• Appropriate surface treatment to avoid Die build up during
processing and dust accumulation
• Lower WCO : Speed could be increased
• Increased elongation @ break compare to coarser grades.
• Improves post-weaving operation and production efficiency.
• Improve knitting process less yarn breakage
• Increase tensile strength thus enabling higher filler loading
• Higher tape surface smoothness
31
This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
Cost Savings
5.5
5.0
4.5
4.0
g/D
3.5
3.0
2.5
2.0
7% Dosage
15% Dosage
Omyacarb 1T
22% Dosage
Omyacarb 2T
30% Dosage
Coarse Competitive
A finer product allows you to increase the CaCO3
addition level maintaining mechanical properties (+3%)
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This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
Cost Savings
Omyacarb 1 T
Compounding Costs
Formulation
50
PE
Omyacarb 1T
Omyacarb 2 T
2000
USD + 30 / Ton
Omyacarb 2T
Masterbatch @ 80% OM 2T
562
Masterbatch @ 78% OM 1T
33
623
Tapes
with 22 % Omyacarb 2T
28%
Tapes
with 25 % Omyacarb 1T
32%
This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
1614
1559
Thank You
www.omya.com
34
This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.