Functional Additive Masterbatches for Plastic Packaging: An Overview Dean Dodaro Polyvel, Inc 100 Ninth St Hammonton, NJ 08037
Outline About Us Additive Functions: Antiblocks Antifogs Antimicrobials Antistats Chain Extender Chemical Foaming Agent Clarifiers Fragrances Nucleators Process Aids Slips/Lubricants Stabilizers Biopolymer developments Other additive considerations
About Us Compounding and development of specialty additive masterbatches Proprietary masterbatches Custom masterbatches/concentrates Auxiliary processes: Mixing, blending Drying Laboratory Toll manufacturing ISO 9001 certified since 2002 Headquarters and manufacturing: 46,000 sq/ft located in Hammonton, NJ >10+ MM lb annual capacity Privately held - founded in 1982
Antiblocks - 1 Why use antiblocks? Plastic film and sheet, PE in particular, will adhere to itself making it difficult to handle Applications: Typical antiblock additives: Minerals: talc, CaCO3, silica Others: spherical particles/particulates Particle size is critical
Antiblocks - 2 How antiblocks work Surface is modified to reduce contact area between layers http://www.fuji-silysia.co.jp/english/image/pro_sylosphere001.jpg
Antifogs - 1 Why use antifogs? Aesthetics: moist or humid air gets trapped in a closed system, water condenses on cold surfaces (<dew point) Agricultural films: disrupts light transmission Applications: disposable containers, greenhouse films, hot/cold flexible food packaging Typical antifog chemistries: Fatty acid surfactants, amides, glycerols Characteristic lipophilic and hydrophilic portion of molecule http://www.face-kyowa.com/en/img/learning/learning_img05.jpg Material Polyolefins 29 31 PET 41 44 Water 72 Methanol 23 Surface energy (dyne/cm)
Antifogs - 2 How antifogs work: Migration of additive, surface orientation http://www.ptsuk.com/images/antistats.jpg
Antimicrobials Why use antimicrobials? Protection of sensitive materials/parts Dust control Applications: water purifiers, trays Typical antimicrobial additives: Silver salts, trichlosan, propionates, sulfur Migratory and non-migratory types Need to be careful with claimed performance
Antistats - 1 Why use antistats (antistatic)? Protection of sensitive materials/parts Dust control Applications: electronic packaging, packaging for sensitive powders, POS appearance enhancement Typical antistat additives: Temporary: surfactants, typically with hydrophilic heads and lipophilic tails Non-food contact applications: amines Permanent: create a network for charges to dissipate within the polymer Polymeric, carbon-based chemistries
Antistats - 2 How migratory antistats work: Migration of additive, surface orientation http://www.ptsuk.com/images/antistats.jpg
Chain Extenders Why use chain extenders? Improve IV Increase regrind use Combat hydrolysis Applications: recycle streams Typical chain extender additives: BASF Joncryl How chain extenders work One molecule with two or more activateable sites that will bond with multiple polymer chains Only available for condensation polymers (PET, PC, etc)
Chemical Foaming Agents Why use chemical foaming agents (CFA)? Lower density Reduce material cost Insulating properties Alternative to gas injection Aesthetic improvement Applications: Hot/Cold containers Typical CFA additives: Heat sensitive additives that are classified by their degradation mechanisms: Exo- and Endo- thermic Azodicarbamide, sodium bicarbonate How CFAs work: Generation of inert gases that become entrapped in polymer
Clarifiers Why use clarifiers? Aesthetics: improve transparency Applications: containers, lidding Typical clarifier additives: Sorbitol derivatives Suppliers: Milliken, Amfine How clarifiers work Courtesy of Milliken
Fragrances Why use fragrances? Consumer impression Masking foul odors Repellents Applications: trash bags, sachets Fragrance limitations Heat sensitive Polymer selection Emission control Subjectivity Scent transfer How fragrances work Deliver VOCs Low MW additives (C 6 C 18 )
Nucleators Why use nucleators? Improve physical properties Decrease cycle time Applications: sheet Typical nucleator additives: Minerals: talc, silica Organics: Milliken, Amfine How nucleators work:
Process Aids Why use process aids? Increase throughput Improve quality Applications: blown film, extruded sheet Typical process aid additives: Fluoropolymers Metal stearates How process aids work Lubricate polymer melt, aid wet out Coat metal surfaces
Slips/Lubricants Why use slips/lubricants? To reduce the tendencies of certain polymers from adhere to themselves and metal surfaces Applications: film/sheet, molded parts Typical lubricant additives: Fatty acid esters, waxes, metal stearates, amide Related uses: Antifog/Antistat Metal Release Dispersing Commonly used with antiblocks for synergistic affect
Stabilizers Why use stabilizers? Combat discoloration Ward off loss of mechanical properties due to processing or use conditions Applications: long shelf-life materials, aggressive processes Classes of stabilizers: UV Absorbers Antioxidants Light Stabilizers Use conditions: Processing parameters Substrate material Film/sheet structure Temperature gradient
Biopolymer Additives Common biopolymer issues: Ductility/Impact Heat resistance Supply Typical applications: Thermoformed packages Blown film packaging http://www.greenerpackage.com/sites/default/files/sunchips.jpg http://www.packaging-int.com/upload/image_files/suppliers/images/companies/2541/nworks-l.png
Other Additive Considerations Color Desiccants: zeolites, silica gels, or CaO for limiting moisture exposure Ethylene oxide absorbers: helps keep produce fresh, includes chemistries such as Ca/K permanganate Flame retardants Matte/Degloss: reduce shiny surface, aesthetic effect Odor managers: mineral based and organic, non-fragrant Oxygen scavengers: primarily aids food preservation, includes iron, sulfites, and calcium based chemistries Permeability regulators: additives and polymers that can be used to introduce barrier or selective barrier layers Plasticizers
Innovation
Thank You Booth 754 Dean Dodaro Sales Engineer/ISO Coordinator Polyvel, Inc. 100 Ninth Street Hammonton, New Jersey 08037 P: 609-567-0080 M: 609-760-2701 E: ddodaro@polyvel.com