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Pagev dsm presentation pa6 in film

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Added value of polyamide in the extrusion process, in particular extrusion coating

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Pagev dsm presentation pa6 in film

  1. 1. 1Improved performance with PA6 in multilayerbarrier filmsPA6 with modified rheologyTed BrinkApplication Development ExtrusionDSM Engineering PlasticsPAGEV Turkish Plastics Industry Congress - 2006
  2. 2. Overview 2• Introduction• Why PA6 in food packaging• Trends in barrier films• Akulon XP – high productivity PA6• ConclusionDSM Engineering PlasticsPAGEV Turkish Plastics Industry Congress - 2006
  3. 3. DSM: over a century of successful 3transformationsEvolution Bioterials / Biologics Life Science Products Performance Materials Petrochemicals Fertilizers Coal Technological competences1902 1930 1950 1970 1990 2000 Mechanical engineering Chemical engineering Polymer technology Material science Fine chemicals BiotechnologyDSM Engineering PlasticsPAGEV Turkish Plastics Industry Congress - 2006
  4. 4. DSM today 4• Globally active “multi-specialty” chemical company • active on 5 continents, more than 200 locations • approximately ~ 21.000 employees• Leadership positions in ~75 % of the portfolio• R&D spending ~ 5 % of sales Life• Solid balance sheet Science • € 8 billion sales in 2005 Products Performance Materials DSM Nutritional DEP Other Products Industrial DSM Engineering Plastics Chemicals €705 million sales in 2005 1300 employeesDSM Engineering PlasticsPAGEV Turkish Plastics Industry Congress - 2006
  5. 5. DEP: partner for innovative film concepts 5• Today one of the leading PA6 film resin suppliers H O N• New plant started with 18.000 t/y capacity in 2001• Additional capacity of 35.000 t/y in 2005• Introduction of Akulon XP• Portfolio of resins for the film industryDSM Engineering PlasticsPAGEV Turkish Plastics Industry Congress - 2006
  6. 6. DSM product portfolio for film applications 6• Akulon PA6 portfolio of standard grades• Akulon PA66 for cast and blown film• Akulon XP high productivity PA6• Yparex PE-g-MAH tie resin• Stanyl PA46 high heat resistant for specialty films• Arnitel COPE breathable filmDSM Engineering PlasticsPAGEV Turkish Plastics Industry Congress - 2006
  7. 7. PA6 in barrier film 7• food packaging (> 80 %) • meat • cheese • fish • sausage casings• non-food applications • release films for SMC • medical film • protective bubble film • agricultural filmDSM Engineering PlasticsPAGEV Turkish Plastics Industry Congress - 2006
  8. 8. Food packaging 8DSM Engineering PlasticsPAGEV Turkish Plastics Industry Congress - 2006
  9. 9. Why PA6 for film in food packaging? 9• Oxygen barrier• Aroma and flavour barrier• Mechanical protection• Puncture resistance• Printability• Transparency• Heat resistanceDSM Engineering PlasticsPAGEV Turkish Plastics Industry Congress - 2006
  10. 10. Oxygen versus water permeation 10 film thickness 100μm 10000 oxygen permeability LDPE EVA HDPE PS [ml/m2*day*bar] 1000 PP PVC-P PC BOPP 100 10 PET PA6 1 PVDC EVOH 44 % cellophane 0.1 0.1 1 10 100 1000 water permeation at 23 °C, 85 % RH [g/m2*day]DSM Engineering PlasticsPAGEV Turkish Plastics Industry Congress - 2006
  11. 11. Trends in PA barrier film 11• Use of BOPA• Improvement of barrier properties • nanocomposites • oxygen scavengers • blends• Active & intelligent packaging• More complex film structures (Akulon XP)• Down gauging – improved productivity (Akulon XP)• Shift from PA6.66 to PA6DSM Engineering PlasticsPAGEV Turkish Plastics Industry Congress - 2006
  12. 12. Examples of coextruded multilayer structures 12 cheese/meat PA tie layer PE fresh meat PP tie layer PA EVOH PA tie layer PEDSM Engineering PlasticsPAGEV Turkish Plastics Industry Congress - 2006
  13. 13. Multilayer film with viscosity match 13 desired situationHowever, in practice ideal situations are rareDSM Engineering PlasticsPAGEV Turkish Plastics Industry Congress - 2006
  14. 14. Multilayer film with viscosity mismatch 14 Viscosity mismatch: • limits flexibility • more grades required • different film polymer with higher viscosity structures on one machine not always feasible • quality risk • more material useDSM Engineering PlasticsPAGEV Turkish Plastics Industry Congress - 2006
  15. 15. Viscosity curves of LDPE and PA6 15 10000 viscosity [Pa.s] 1000 LDPE Akulon F132 100 10 0.01 0.1 1 10 100 1000 shear rate [1/s]DSM Engineering PlasticsPAGEV Turkish Plastics Industry Congress - 2006
  16. 16. Polymer flow in a coat hanger die 16Coat hanger die:• different flow rates in the die• multilayer structures require viscosity match to prevent interface disturbancesDSM Engineering PlasticsPAGEV Turkish Plastics Industry Congress - 2006
  17. 17. Standard materials result in interfacial 17 instability Rheology mismatch PA6 and LDPE processing window 10000viscosity [Pa.s] 1000 PA6 LDPE 100 10 0.01 0.1 1 10 100 1000 shear rate [1/s] leads easily to problems poor elasticity and viscosity match creates wave effect one component missing at edges DSM Engineering Plastics PAGEV Turkish Plastics Industry Congress - 2006
  18. 18. Viscosity curves of unmodified materials 18 10000 viscosity [Pa.s] LDPE 1000 Akulon F126 Akulon F130 Akulon F132 100 Akulon F136 10 0.01 0.1 1 10 100 1000 shear rate [1/s]DSM Engineering PlasticsPAGEV Turkish Plastics Industry Congress - 2006
  19. 19. What determines interfacial stability? 19Rheology of different components:• shear viscosity• normal stress• elongational viscosityDSM Engineering PlasticsPAGEV Turkish Plastics Industry Congress - 2006
  20. 20. The Akulon XP solution 20 Minimizes the difference in melt viscosity and melt elasticity of coextruded materials. Result: widening of processing window 10000 Akulon XP Akulon XP exhibits: enhancedviscosity [Pa.s] 1000 shear-thinning behaviour: 100 LDPE • less motor power at MFI 1.9 high rpm 10 • higher zero shear 0.01 0.1 1 10 100 1000 viscosity shear rate [1/s] wide processing window DSM Engineering Plastics PAGEV Turkish Plastics Industry Congress - 2006
  21. 21. The “trick”: branching of the PA6 chain 21Random long chain branching of PA6• increase of zero-viscosity• flow behaviour becomes more shear thinning• enhanced melt strength in elongational flowFurthermore:• branching allows very high molecular weights, not possible with linear PA6DSM Engineering PlasticsPAGEV Turkish Plastics Industry Congress - 2006
  22. 22. Effects of branched polymers 22Linear polymers show Newtonian flow behaviourShort chain branching: Long chain branching:• reduction of density • strong influence on rheology• minor influence on rheology • enhanced shear thinning • strain hardening DSM Engineering Plastics PAGEV Turkish Plastics Industry Congress - 2006
  23. 23. Effects of branching 23Control of viscosity• melt stability (uncontrolled polymerization)• gels !!Controlled branching is realized by:• branching agent: addition of a trifunctional compound• to prevent formation of gels: addition of a monofunctional compoundDSM Engineering PlasticsPAGEV Turkish Plastics Industry Congress - 2006
  24. 24. Neck-in on cast film and extrusion coating 24 maximum die width standard PA6 Akulon XP extruded film width chill rollDSM Engineering PlasticsPAGEV Turkish Plastics Industry Congress - 2006
  25. 25. Web stability in cast film and extrusion 25coating die standard PA6 Akulon XP chill roll web instabilityDSM Engineering PlasticsPAGEV Turkish Plastics Industry Congress - 2006
  26. 26. Improved layer thickness distribution 26 classical PA6 thin sections are quality riskedge trim and determine edge trim barrier and mechanical properties Akulon XP DSM Engineering Plastics PAGEV Turkish Plastics Industry Congress - 2006
  27. 27. The thermoforming process 27 IR heater film mould vacuumDSM Engineering PlasticsPAGEV Turkish Plastics Industry Congress - 2006
  28. 28. The thermoforming process 28 IR heater film mould vacuumDSM Engineering PlasticsPAGEV Turkish Plastics Industry Congress - 2006
  29. 29. Thermoforming issues 29 thin corners Issues: • thin corners • limited elongationDSM Engineering PlasticsPAGEV Turkish Plastics Industry Congress - 2006
  30. 30. Thermoforming behaviour 30• drawing is influenced by: • temperature • stretch ratio • drawing rate • polymer viscosity • molecular structure • crystallization rateDSM Engineering PlasticsPAGEV Turkish Plastics Industry Congress - 2006
  31. 31. Thermoforming of COPA and PA6 31• advantage COPA is lower crystallization rate• drawing of PA6 can be improved by: • keep the sheet as amorphous as possible • addition of amorphous polyamide • addition of COPA• improved thermoformability of Akulon XP compared to regular PA6 • more even thickness in the corners • higher elongation possibleDSM Engineering PlasticsPAGEV Turkish Plastics Industry Congress - 2006
  32. 32. Effects of Akulon XP in multilayer cast film 32• less neck-in waste reduction (side trims) improved machine efficiency• better web stability higher production speed• improved layer thickness less material use distribution better quality• wider processing window less down-time higher output• shear thinning less motor power at high rpm higher output possibleDSM Engineering PlasticsPAGEV Turkish Plastics Industry Congress - 2006
  33. 33. Akulon XP properties 33• improved processing efficiency • cast film • blown film • extrusion coating • thermoforming • stretching• barrier properties same as classical PA6• mechanical properties comparable to classical PA6• crystallization behaviour unchangedDSM Engineering PlasticsPAGEV Turkish Plastics Industry Congress - 2006
  34. 34. Advantages of Akulon XP in non-film applications 34• extrusion blow moulding • improved melt strength• monofilaments • improved roundness at large diameters• stock shapes • improved symmetry in tubes with large diameters due to high melt stabilty• convoluted tubes • improved dimensional stability at low diameters tubeDSM Engineering PlasticsPAGEV Turkish Plastics Industry Congress - 2006
  35. 35. Conclusion 35Akulon XP is a new polyamide 6with improved processingbehaviour, which can lead to lowerconversion costs and improvedfilm propertiesDSM Engineering PlasticsPAGEV Turkish Plastics Industry Congress - 2006
  36. 36. More information 36 Contacts and more information: www.dsmep.com www.akulon.comDSM Engineering PlasticsPAGEV Turkish Plastics Industry Congress - 2006
  37. 37. 37 İLGİNİZ İÇİN TEŞEKKÜR EDERİMDSM Engineering PlasticsPAGEV Turkish Plastics Industry Congress - 2006
  • KawtherMusawi

    Nov. 15, 2016
  • ChandreshShah2

    Sep. 14, 2016
  • OrunSTNDA

    Sep. 8, 2016

Added value of polyamide in the extrusion process, in particular extrusion coating

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