Improving the sustainability of thermoformed polyolefin food packaging through UPES® interpolymer modification

Presenter: Dr. Eric VignolaASTM Committee D10Workshop on PackagingOctober 12, 2010San Antonio, TX

Outline

• Sustainability concepts

• Introduction to QINNEX® technology & UPES® interpolymer resin

• UPES resin modification of polyolefins

– HDPE

– PP

– LDPE

• Summary

• Acknowledgements

NOVA Chemicals and Sustainability

• We believe a sustainable business is a profitable and socially responsible business

• Our approach to managing health, safety, security, environmental protection and sustainability is implemented primarily through the principles of Responsible Care®

Sustainability Development

• We support the United Nations’ definition of Sustainable Development – meeting the needs of the present without compromising the ability of future generations to meet their own needs

• NOVA Chemicals is committed to the “Triple Bottom Line” approach to sustainability:

– Environmental, Social, Economic

Environmental

SocialEconomic

Sustainability

Sustainable concepts

• The 3 R’s

– Reduce

– Re-use

– Recycle

• Plus

– Renewable resources

– Recycle content

– End of life

• Lightweight• Lower Carbon Footprint• Reduced Volume• Increased Durability

A product of

The technology behind UPES resin delivers enhanced compatibility with various polymers systems and broadens the processing window of most polyolefins.

An interpolymer made from Polystyrene (PS) and Polyethylene (PE), UPES resin offers the following:

• Variable ratio of the two polymers

• Different types of polyolefins can be used

• Can add different co-monomers

• Ability to vary of amount of cross-linking

• Where the two phases are compatibilized ‘in situ’

Polyethylene Micro-pellets

Suspension Polymerization

Polyolefin pellets

Opaque / white beads

55 to 60 pellets per gram

extrusion

UPES resin Interpolymer Morphology

PE/PS Melt Blend PE/PS Interpenetrating Network

(1) Properties were determined on injection-molding specimens following the protocols of ASTM D4549 “Standard Specification for Polystyrene Molding and Extrusion Materials” unless otherwise specified.

(2) The product properties designated in this standard have been determined in accordance with the current issues of the specified testing methods. Methods of the American Society for Testing and Materials (ASTM) are used wherever applicable.

(3) Melt flow index at 230°C/2.16kg (446°F/4.76lb). a) UPES-090-EXP : Notched Izod specimen displayed partial break, un-notched specimen displayed torque and flex upon impact, but no break b) UPES-170-EXP: Notched Izod specimen displayed hinged break, un-notched specimen displayed indentation, but no break c) UPES-315: Notched Izod specimen displayed break, un-notched specimen displayed break

Properties of UPES resin are tailorable

UPES resin Interpolymer Properties

Properties(1) ASTM(2) UPES-090-EXPresin

UPES-170-EXPresin

UPES-315resin

Tensile Strain at Break (%)

D 638 54.2 5.7 2.7

Flexural Modulus (psi) D 790 89 200 169 900 300 000

Notched Izod(ft-lb/in) a,b,c D 256 11.3 2.8 0.4

Un-notched Izod(ft-lb/in)

D 256 12.2 20.2 12.5

Melt Flow Index(3)

(g/10 min)D 1238 0.32 0.23 0.24

Rheological Properties of UPES resin

Resin (Supplier) Melt Index (g/10 min)

@200°C/5 kg

Melt Index (g/10 min)

@190°C/2.16 kg

PS 1600 (INEOS-NOVA) 5.5 --

FP-120-A (NOVA Chemicals) -- 1.0

UPES-315 resin (NOVA Chemicals) 0.46 0.04

UPES -315 resin offers:

• Improved processability

• Shear thinning properties

190°C

100

1000

10000

100000

1000000

0.01 0.10 1.00 10.00 100.00

Sh

ea

r V

isc

osit

y (

Pa

-s)

Frequency (rad/s)

PS1600

FP120-A

UPES-315 resin

Collaboration throughout the Value Chain

NOVA Chemicals :: resin

PRIMEX :: sheet

Tray-Pak :: thermoformed parts

Situation

Polyolefin Thermoforming Challenges

– Warpage

– Increased sheet gauge required to deliver desired performance properties

– Poor material distribution

– Inefficient processing

– Difficulty achieving sustainable output rates

What is Thermoforming?

Deep Draw Produce Tray

HDPE Part 60 mils

UPES resin/HDPE 50 mils

Increase in melt strength offered by UPES resin provides:

• Reduced gauge• Better material distribution

50 mils = 1.270 mm60 mils = 1.524 mm

HDPE Property Modification

0 s 15 s 30 s 45 s 60 s 75 s 90 s 105 s 120 s

HDPE/UPES resin 50 mils

HDPE 60 mils

HDPE Property Modification

44

103

0

20

40

60

80

100

120

Cru

sh s

tre

ngt

h (

psi

)

HDPE 60 mils

HDPE/UPES 50 mils

140% increase

Increase in melt strength offered by UPES resin provides:

• Increased thermoforming throughput• Improved part performance ASTM D 2659

UPES resin/HDPE blends vs. HDPE

• 20% source reduction

• 33% faster forming rates and shorter start-ups– Increased machine time availability

• > 100% increase in mechanical properties

• Enhanced part definition

• Reduced scrap rates

• Recyclable

Shallow Draw Institutional Tray

0

50

100

150

200

250

300

350

400

Flex

ura

l mo

du

lus

(psi

)

HDPE 25 mils

HDPE/UPES 20 mils

30 %

• 20% source reduction• 30% increase in flexural properties• 40% increase in throughput rates

ASTM D 790

Polypropylene-UPES resin Lidstock

• HIPS is the incumbent

• Achieved 11 mil parts, previously unattainable with 100% PP

• Enhanced ESCR properties compared to HIPS & similar mechanical properties than HIPS

• PP/UPES resin parts weigh less than HIPS or filled PP parts at the same gauge

• Processability similar to HIPS

UPES resin in LDPE based x-linked foams

Foam 1: 4.4 pcf (70 kg/m3)

Foam 2: 4.9 pcf (78 kg/m3)

Foam w/ UPES resin: 2.5 pcf (40 kg/m3)

UPES modified LDPE resin produces lower density foams with superior properties

0

40

80

120

160

200

De

nsity

Te

ns

ile

str

en

gth

Te

ar

str

en

gth

Pu

nc

ture

Co

mp

ress

ion

de

fle

ctio

n

Elo

ng

atio

n

Pro

pe

rty

% V

olt

ek

fo

am

Voltek foamYoungbo foamCellect foam w/ IP-73-U (30%)

Foam 1Foam 2

Foam w/UPES

Pro

pe

rty

% o

f Fo

am 1

resin

Summary

• UPES resin is a tailorable product that can offer increased rheological properties, melt strength, compatibility and functionality

• Documented sustainability benefits: Lightweight Lower carbon footprint Reduced volume Increased durability

• Opinion letters available for food contact applications

Questions?

UPES, QINNEX and their logos are trademarks of NOVA Brands, Ltd.; authorized use/utilisation autorisée.

The information contained herein is provided for general reference purposes only. By providing the information contained herein, NOVA Chemicals Inc. makes no guaranty or warranty and does not assume any liability, with respect to the accuracy or completeness of such information, or product results in any specific instance, and hereby expressly disclaims any implied warranties of merchantability or fitness for a particular purpose or any other warranties or representations whatsoever, expressed or implied. Nothing contained herein shall be constructed as a license to use the products of NOVA Chemicals Inc. in any manner that would infringe any patent. Nothing herein shall be copied, reproduced, distributed or otherwise used without the express written permission of NOVA Chemicals.

Acknowledgments:• Joseph B. Paolucci• Shelly A. Martel• Daniel C. Purpura• Christine B. Hetzer• H. T. Kemp

For more information visit: www.upesresin.com