CONTROLLING SHEAR TO PRODUCE BRILLIANT EFFECT Mineral Mica is a delicate, natural, inorganic...

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Transcript of CONTROLLING SHEAR TO PRODUCE BRILLIANT EFFECT Mineral Mica is a delicate, natural, inorganic...

  • CONTROLLING SHEAR TO PRODUCE BRILLIANT EFFECT PIGMENT MASTERBATCHES ADVANCED TECHNOLOGY FOR SUPERIOR EFFECT PIGMENTS WITH MINIMUM DAMAGE

    © Copyright 2015 - STEER Engineering Pvt. Ltd.

  • UNSEEN IS UNSOLD.

  • Gone are the days of just form and function. Consumers now

    look for aesthetics as well as performance. And in todays

    overcrowded market place the competition for attention is a

    fierce one. How does a packaged product stand out in a shelf

    when there are ten other brands offering the same set of

    benefits? How does a cosmetics manufacturer get millennials to

    buy the product? How does an automobile salesman convince

    his customer beyond the usual technical specifications? The

    challenge of getting noticed is, perhaps, one of the most critical

    issues that keeps manufacturers awake in todays world.

  • At STEER, we have the answer to make you sleep better. As a leader in materials

    transformation, we incorporate our in-depth knowledge of polymer sciences,

    advanced technology and technical expertise to deliver innovative solutions that

    help create the differentiation that brands and manufacturers look for. Our advanced

    technology for processing special effect and mica-based pigments, helps

    manufacturers create a new degree of visual engagement. Whether it is adding

    lustre, sheen, glitter and sparkle, creating depth and luminescence or simply playing

    with multicolour effects, our technology helps you process mica-based pigments

    without damage to the extremely sensitive platelets, ensuring effective

    colouration, brilliant appearance and the right visual impact and differentiation that

    products and brands need to get noticed.

    SPARKLE. GLITTER. SHINE. ATTRACT. AND SIMPLY DAZZLE.

  • Our technology for processing the extremely sensitive mica-

    based special effect pigments, with minimum damage, has

    helped us deliver outstanding results to leading

    manufacturers and compounders of effect pigments.

    TRUSTED BY SOME OF THE WORLD’S

    LEADING EFFECT PIGMENT MAKERS

  • Mineral Mica is a delicate, natural, inorganic pigment. Coated mica crystalline

    platelets, such as those used in effect pigments in thermoplastics (ex: for pearlescent

    appearance), are extremely sensitive. Any alteration or change in size of the structure

    will hinder effective coloration and alter the appearance of the pigments and plastics.

    The biggest cause of attrition to the structure is exposure to shear during various

    stages and unfortunately most of the technology available today does not

    account for some or all of the following; Ÿ Efficient mixing Ÿ Control over shear and elimination of shear peaks Ÿ Efficient energy transmission Ÿ Stagnation and Degradation and the resulting char formation

    Moreover, selection of the right twin-screw extruder is also critical. Key

    requirements include; Ÿ A deeper extruder flight depth Ÿ The right Screw to barrel clearance to prevent Leakage and subsequent damage due to shearing. Ÿ The ability to work with low-bulk density materials.

    PROCESSING MICA-BASED EFFECT PIGMENTS:

    UNDERSTANDING GAPS IN TODAY’S TECHNOLOGY

  • PROVEN INNOVATION ADVANCED TECHNOLOGYMEETS IN-DEPTH KNOWLEDGE OF POLYMER SCIENCES:MEETS

    STEER’S TECHNOLOGY FOR PROCESSING EFFECT PIGMENTS WITH MINIMUM DAMAGE

    Effective processing on a twin-screw extruder requires the precise implementation of different

    steps involved Wetting, Dispersion and Task Specific mixing (Distribution and Stabilisation). At

    STEER, we have mastered the art of processing mica-based pigments with minimum damage,

    allowing us to protect product quality, while ensuring an effective and economical product.

  • #1 EFFECTIVE WETTING:

    #2 EFFECTIVE DISPERSION:

    #3 EFFECTIVE DISTRIBUTION & STABILISATION:

    #4 DEEPER ROOT DEPTH

    #5 ADDRESSING ‘LEAKAGE’

    #6 LOW BULK DENSITY MATERIALS

    EFFICIENT MIXING WITH STEERS PATENTED FRACTIONAL-LOBE ELEMENTS STEERs patented Fractional-lobe mixing elements, address the gaps in todays technology by allowing for mixing through elongation and laminar means in a non-filled process section. This allows for frequent splitting and recombination of the melt pool. STEERs mixing elements have fully intermeshing and self-wiping characteristics to help with effective wetting in the intermeshing zone. Besides the shorter lead angles increase the frequency of holding.

    SOLVING THE ISSUE OF SHEAR PEAKS IN THE 65-YR OLD 2-LOBE KNEADING BLOCKS STEERs special mixing elements reduce/eliminate shear peaks and still maintain a fully intermeshing and self-wiping characteristic. This reduction/elimination of shear peaks (through the use of multiple lobes) results in controlled energy input, improving both efficiency and effectiveness. Moreover the element geometries facilitate a controlled energy input depending on task Simple shear for the reduction of cohesive aggregates and agglomerates, planar shear for high energy dispersion, low energy elongation.

    PREVENTING STAGNATION AND DEGRADATION: STEERs distributive mixing elements with fully intermeshing and self-wiping profile prevent stagnation and degradation and the resultant char formation. They facilitate distributive mixing characteristics while generating the right pressure. Besides, they also provide the ability to facilitate melt homogenisation prior to discharge from the extruder improving strand stability or dimensional accuracy.

    1.71 DO/DI STEERs OMEGA 1.71 DO/DI (the new standard in compounding) or the deeper root depth, draws more of the resin into the screw root and away from the shear forces that occur when the melt contacts the barrel wall.

    One of the biggest causes of damage to the pigment is shearing that can occur when plastic containing the pigment, leaks back into the trailing screw channel. This occurs when the screw-to-barrel or screw-to-screw dimensions are large enough to allow leakage of the polymer. With STEERs OMEGA 1.71 DO/DI co-rotating twin-screw extruder the Barrel to Screw Gap and Screw to Screw Gap are maintained at less than 0.25mm to have fully wiping effect rather than shearing effect.

    STEERs OMEGA 1.71 DO/DI co-rotating twin-screw extruder provides manufacturers the ability to work with shear-sensitive and low-bulk density materials, making it the ideal equipment of choice for working with mica-based pigments. Moreover, the patented conveying elements increase throughput by 5x while reducing the attrition that can occur with standard conveying elements.

    STEER’S PATENTED SPECIAL ELEMENTS ARE AVAILABLE ONLY WITH STEER PLATFORMS

  • FOR FURTHER INFORMATION ON THE TRIALS OR TO WORK WITH US WRITE TO SHYAM.PANI@STEERWORLD.COM OR VISIT STEERWORLD.COM

    EQUIPMENT: Ÿ STEERs Do/Di=1.71 Technology platform

    OMEGA 40H; L/D=44 Ÿ Special Design Elements by STEER Ÿ Loss-in-Weight Feeders Ÿ Strand pelletizer

    MATERIALS: Ÿ 70% LLDPE, 30% Pigments Ÿ Iridion 305 Solar Gold Ÿ Iridion 305 WM10 (PEWax dispersion) Ÿ Iridion 305 Pearlets PO (70% MB in PE) Ÿ Antioxidant, Additives.

    PROCESSING: Ÿ Three Screw Designs; Standard Hi-Shear

    & Optimized Special Elements Ÿ Screw RPM fixed @ 600 for all trials Ÿ 170-230C

    TESTING: Ÿ Microscopic Examination at MERCK as

    per MERCK Standard Procedure

    THE PROOF IS IN THE PIGMENTS TRIALS CONDUCTED AT STEER’S APPLICATION DEVELOPMENT CENTER IN BENGALURU, INDIA

  • FOR FURTHER INFORMATION ON THE TRIALS OR TO WORK WITH US WRITE TO SHYAM.PANI@STEERWORLD.COM OR VISIT STEERWORLD.COM

    “STANDARD” HIGH SHEAR DESIGN

    “OPTIMIZED” USING STEER SPECIAL ELEMENTS – SIDE FEED

    Pigment Top Cut = 60microns, Top Cut in Compounded Masterbatch = 28microns

    Pigment Top Cut = 60microns, Top Cut in Compounded Masterbatch = 60microns,

    OVERSIZE PARTICLE DETECTED INDICATING LEAST PARTICLE DAMAGE

  • ADVANCED TECHNOLOGY FOR PROCESSING MICA-BASED PIGMENTS WITH MINIMUM DAMAGE

    DEEPER ROOT DEPTH FOR REDUCED SHEAR FORCES | BARREL TO SCREW GAP AND SCREW TO SCREW GAP’ < 0.25MM TO PREVENT LEAKAGE | ABILITY TO PROCESS LOW-BULK DENSITY & SHEAR-SENSITIVE

    MATERIALS | BETTER ENERGY DISSIPATION | HIGH VOLUME, HIGH TORQUE

    STEER’S OMEGA 1.71 DO/DI CO-ROTATING TWIN-SCREW EXTRUDER — THE NEW STANDARD IN COMPOUNDING

  • ADVANCED TECHNOLOGY FOR PROCESSING MICA-BASED PIGMENTS WITH MINIMUM DAMAGE

    EFFICIENT MIXING THROUGH LAMINAR / ELONGATION MEANS | ELIMINATION OF SHEAR PEAKS WHILE MAINTAINING A FULLY INTERMESHING AND SELF-WIPING CHARACTERISTIC | EFFECTIVE DISTRIBUTION

    & STABILISATION WITHOUT STAGNATION OR DEGRADATION

    STEER’S PATENTED SPECIAL ELEMENTS

    RFV Elements

    SFV Elements

    FME Elements

    DSE Elements

    FKB Elements

    OSE (wave) Elements

  • 5 10 GLOBAL OFFICES, SATELLITE OFFICES APPLICATION DEVELOPMENT CENTERS3

    STATE-OF-THE-ART FOUNDRY FOR SPECIAL STEEL1 COUNTRIES SERVED39

    EMPLOYEES500+ PATENTS 33

    350000 ELEMENTS SOLD EXTRUDERS INSTALLED470

    Satellite Office

    Application Development Center

    Global Office

    Countries Served

    Foundry

  • STEER AMERICA

    1525 Corporate Wood Parkway, Suite 500, Uniontown, Oh