Post on 26-Aug-2018
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
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• 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
Antifogs - 1
Material Surface energy (dyne/cm)
Polyolefins 29 – 31
PET 41 – 44
Water 72
Methanol 23 http://www.face-kyowa.com/en/img/learning/learning_img05.jpg
• How antifogs work: – Migration of additive, surface orientation
Antifogs - 2
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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
• How migratory antistats work: – Migration of additive, surface orientation
Antistats - 2
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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 (C6 – C18)
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
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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