Polyolefin Additives: Advances in Performance Extension · Polyolefin Additives: Advances in...

Keith A. Keller, PhD

Research & Development Manager

Petrochemical Conclave 2016

Polyolefin Additives:

Advances in Performance Extension

©2016 Milliken & Company

Agenda

Introduction

Roadmap for the future

Recent products case studies

A glimpse inside the labs

Wrap up


Milliken & Company

H

H Headquarters

Technical center

• Founded in 1865. Headquartered in

Spartanburg, SC, USA

• 7,000+ associates

• Global presence - 45 facilities around

the world

Technical Innovation

• Community of innovators

• More than 5.000 patents

Segments served

• Floor Covering & Interiors

• Performance Materials

• Apparel & Specialty Fabrics

• Performance Solutions

• Specialty Chemicals

©2016 Milliken & Company 5

Milliken - Plastics Additives Business

• Clarity and Aesthetics

• Productivity improvement

• Energy savings

• CO2 savings

Millad Clarifying

agents

• Stiffness/impact balance

• Dimensional stability

• Productivity improvement

• Reduced cycle time

Hyperform HPN Nucleating agents

• Weight reduction

• Scratch improvement Hyperform HPR

Reinforcing agents

• Clearest and brightest colors for Clear PP

ClearTint colorants


Milliken Product/Technology Roadmap

Markets/End uses

Products/Projects

2014 2019 2016 2025

Housewares (PP; Clear)

Legacy

Millad 3988

Millad 3988i

Rigid Food Packaging (PP; Clear)

Millad

NX8000 EQ Millad

NX8000 UC

Hyperform

HPN68L

Thermoformed Disposable Packaging (PP; Nucleated)

Hyperform

HPN600ei

Automotive compounds (PP, Reinforced)

Hyperform

HPR803i Hyperform

HPN20e

High MFI, improved impact ICP

Improved

ICP

Barrier HDPE Film (PE; Nucleated)

Barrier LLDPE Film (PE; Nucleated)

Improved HDPE Rigids & Film (PE; Nucleated)

Improved Stiffness PP (PP; Nucleated)

HPN 210M

(PE) New PE

product

PO

Composites

Low

migration

AOX

Improved

cPP

Migration

Management

Improved

Stiffness PP HMS PP

PO Property

Extension


Key Definitions

Product

• Commercial and available for sale

• Production quantities of material are available

Technology

• New concepts under testing in the labs and not available for sale

• Commercialization dates are not yet determined


Millad® NX™ 8000 clearly leads the market because it is delivering value

across three overarching themes.

7

Product: Millad® Clarifying Agents

1. Substantial energy savings and cycle time improvements

2. Superior performance in higher melt flow index resins

3. Enhanced clarity and appearance



•Household Industrial Chemical Packaging Application

•Extrusion Blow Molding Process

•North America Region

•New Product Launch that historically would have been in High Density Polyethylene (HDPE)

Material Replaced

•Excellent transparency

•Design flexibility of PP

•Reduction in raw material complexity (Inventory 1 bottle & add color to formulation)

Drivers for material

replacement:

Household Cleaner

Packaging


•Disposable drinking cup

•Food storage container Applications

•Thin wall injection molded Process

•Europe Region

•Polystyrene (PS), Polyethylene Terephthalate (PET)

Material Replaced

•Excellent transparency

•Lightweight packaging

•Boost impact resistance & avoid breakage

•Economics

•Microwaveable

Drivers for material

replacement:

Food Packaging



Product – Hyperform®

- Highest Tc of any nucleation technology

- Low warpage and improved molding performance

- Maximum part production and quality

- Low isotropic shrinkage and CLTE

- Unique shrinkage for dimensional control

- Good stiffness/impact balance (material optimization)

- Excellent aesthetics in sheet and formed parts

- Excellent thermal performance for fast forming times

- Good balance of physical properties

HPN-68L

HPN-20E

HPN-600ei


Hyperform is widely adopted across injection molding and

thermoforming processes globally

11

Hyperform Global Use by Process

[CATEGORY NAME], [VALUE]

TWIM, 15%



Other, Pipe, Etc., 8%

Global Sales By Process

Global Hyper Nucleation Trends

• HPN-68L and HPN-20E growing fast for injection

molding applications

• HPN-600ei growing rapidly for clear and opaque

thermoforming applications

• Replacement of phosphate ester salts in

thermoforming and injection molding grades

• Enabling inter-material replacement of opaque

polystyrene


Hyperform is widely adopted across injection molding and

thermoforming processes globally

12

Hyperform Global Use by Process

Global Hyper Nucleation Trends

• HPN-68L and HPN-20E growing fast for injection

molding applications

• HPN-600ei growing rapidly for clear and opaque

thermoforming applications

• Replacement of phosphate ester salts in

thermoforming and injection molding grades

• Enabling inter-material replacement of opaque

polystyrene






Other, 12%

Global Sales By Markets


HPN in ICP Thermoforming

• ICP nucleated with Phosphate Ester Salt

Control

•Sealed, hot filled, microwavable rice containers

Application

•Thermoforming Process

• Isotropic shrinkage

•Reduced warpage in final parts during filling and sealing

•Reduced warpage after microwaving

• Improved part quality

•Reduced scrap rate

•Higher productivity

Polypropylene with

Hyperform® selected because:


HPN in Automotive Application

•Hyperform® HPN-20E Product

•Automotive Grill

•Automotive Door Panel Application

• Injection Molding Process

•Very low shrinkage and low CLTE for high-performance exterior automotive applications

• Allowed unpainted PP grill to match PC/ABS for shrinkage

• PP HPN-20E grill also achieved improved long-term exposure performance

•Part to part consistency

Polypropylene with

Hyperform® selected because:

20 mfr ICP

35 mfr ICP


Applying our ability to control polymer crystal orientation, we have

developed nucleator prototypes that maximize flexural modulus and

heat distortion temperature.

15

Technology – Improved Stiffness PP

12 MFR HPP 26 MFR ICP

Milliken EXP-715

Phosphate Ester


A different nucleator prototype shows improvement across multiple

dimensions of physical properties, providing a highly balanced material.

16

Technology – Improved Polypropylene

12 MFR HPP 26 MFR ICP

Milliken EXP-705

Phosphate Ester


In designing an impact copolymer, there are fundamental tradeoffs

among MFR, impact resistance, and stiffness.

18

Technology – Improved ICPs


0

50

100

150

200

250

300

350

400

0 20 40 60 80 100 120

23°C

ISO

Izod Im

pact

Mean (

J/m

)

Melt Flow Rate (dg/min)

Izod Impact at 23°C of ISO Bars vs Melt Flow Rate

Starting Resin

Commercial Resins

EXP-Milliken

Non-Breaks

Error bars are ± One Measurement Standard Deviation

This technology can significantly change the balance of properties.

19


Value Proposition

16 to 50 MFR

Same impact

Value Proposition

2X MFR

50% better impact

Value Proposition

2X MFR

Non-break



It is possible to access very different regions of performance space from

the same flake starting point, shifting the balance of what was previously

accessible.

20


Low MFR

ICP

Experimental

Additive

RO

Vis-broken

ICP

High Impact

High MFR ICP


Product – PE Nucleators

• Barrier improvement - 25 – 70% lower transmission rates in

HDPE and LLDPE (all permeants)

• Optics improvement - Reduction in LLDPE haze up to 40%

- Improvement in HDPE clarity and haze

- Higher gloss in both HDPE and LLDPE

• Increased Tc - Faster freeze-off / increased output

• Physical Properties - Higher MD and TD modulus with slight

to no loss in tear and impact

properties

• Barrier improvement - Various permeants (H2O, O2, grease,

hydrocarbons, etc.)

• Optics improvement - HDPE sheet clarity and gloss

• Increased Tc - Cycle time reduction / increased

output

• Higher Productivity

• Increased stiffness/impact

balance - Material reduction in radial/round

applications

- Stronger parts in radial/round

applications

• Improved ESCR (drums), HDT

& pigment leveling (closures)

Flexible Applications

Rigid Applications


Milliken’s expertise in controlling the crystalline orientation of polymers

has led to a new PE nucleator: HPN 210M

22


Polyethylene normally self-nucleates

into large spherulitic structures.

Molded article

Spherulites (random crystal growth)

Molded article

MD crystal growth

HPN 210M

With HPN 210M, PE crystals grow in the

machine flow direction of the polymer.



Nucleated with HPN 210M at reduced cycle

time: no warpage, original dimensions

improved mechanical properties – both

stiffness & HDT are increased

Reduced cooling time 10- 20%

Nucleated with HPN 210M at the same

cycle time: no warpage and larger parts


This long-term development arc is driven on the core of an innovation

culture.

24

Conclusion

Innovation

Opening new

applications and

material substitution

opportunities for

polypropylene &

polyethylene

Millad 3905

Millad 3988

Hyperform HPN-68L

Millad NX8000

Hyperform HPR-803i

Millad 3940

Hyperform HPN-600ei

Hyperform HPN-20E

Opening new applications and

material substitution

opportunities for polypropylene &

polyethylene

Innovation

Polyolefin Additives: Advances in Performance Extension · Polyolefin Additives: Advances in...

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