Blow Moulding
Trends, Technology & Applications
Polypropylene & Polyethylene Polypropylene & Polyethylene
Dr U.K.SaroopReliance Industries Ltd
Parable of
Three Wise Men
Parable of Three Wise Men:The Green House Effect
other
8%
Residential
13%
Industry
18%
Transportation
20%
World energy-related CO2
emissions by sector 2004:
� The world has warmed by 0.74°C in the last century
� Will warm 0.2°C per decade
� Global temperature would increase by 3°C by the turn of this century
(Source: Financial Times / International Energy Agency )
Climate Change – sparking events, that haven't
happened in 650,000 years
18%
Power
Generation
41%
Total = 26.08 bln. mt
Parable of Three Wise Men:Zurich by Turn of the Century
Pressing the Panic Button –
Three Wise Men called for providing immediate solution
Parable of Three Wise Men:Wiseman 1: Theory of Carbon Sequestration
� Carbon Capture and Sequestration
– help ameliorate global warming
� By 2050, every year 5-10 billion
Tons of CO2 will be buried
� Saline Aquifiers – sandstone
formations evaluated for storage
High Cost and Space requirements may become limiting
factors !
� US$ 6 million project in 2004
� Compressing 3,000 tons of CO2 into a supercritical fluid
� Pumping it 1.6 km below surface into 2.3 mtr. thick sandstone layer
formations evaluated for storage
Parable of Three Wise Men:Wiseman 2: Theory of Hydrogen Fuel
• Transporting energy both in Electrical and
Chemical Form
• Two conduits - ~ 1 mtr. Dia.
• Electricity – through (red) resistance free
pipes made of super conducting materials
• Chilled Hydrogen as liquid (blue)
maintain temp. ~ absolute zero
• Simultaneously transmit
– 5 gigawatts of Electricity
– 10 gigawatts of Thermal Power
Technology development – a long way to go !!
Parable of Three Wise Men:Wiseman 3: Theory of Common Sense
….. Use
more & more more & more
Polyolefins
The question is …..
Parable of Three Wise Men:The question is ???
And the answer is ….. POLYOLEFINS
Parable of Three Wise Men: Polyolefins: Environmental Value Added (A Case)
• Avg. mid-sized car in US contains $2219 of
Chemistry (Including both Chemical Products & Processing)
• Total amount of Chemistry in Automobiles US$ 31.5 bln
• Chemical products make up ~ US$ 800 of the total value
of the car
• On an avg. contains 150 kg of Plastics (8% of total wt)• On an avg. contains 150 kg of Plastics (8% of total wt)
• Enhancing Efficiency (West Europe Case)
• Each 4.5 kg of plastics substituted improves fuel
efficiency by 0.11 to 0.14%
• Annual fuel savings of over 2.3m t – equivalent to 9.2 m t
CO2 emissions
Polyolefins – offering hygienic, environmentally safe
products
PolyolefinsPolyolefinsin Rigid Packaging
Rigid Plastic Packaging
Rigid Plastic Packaging
Injection Moulding ThermoformingBlow Molding
Pails, Closures, Boxes Bottles, Jars Disposable Cups, Glasses, Punnets
Blow MouldingBlow Moulding
Processing
Blow
Moulding
ExtrusionExtrusion
Blow Moulding – Diverse Process Technologies
Injection Stretch Injection–Stretch Blow Moulding
(EBM)
InjectionInjection
Blow Moulding
(IBM)
Injection–Stretch
Blow Moulding
(ISBM)
Commonly used Plastics are : PP, HDPE, PVC, PC, LDPE, LLDPE, EVA,
Polystyrene, HIPS, ABS, SAN, PVC & PET
P O L Y P R O P Y L E NE
Versatile Polymer : Designer’s
Choice
Global PP Demand
MMTMMTMMTMMT
5353535340404040
60606060
PP - CARG 5.4%
Source Source Source Source –––– CMAI 2006CMAI 2006CMAI 2006CMAI 2006
41414141 53535353
0000
20202020
2005200520052005 2010201020102010
PlantPlantPlantPlant LocationLocationLocationLocation TechnologyTechnologyTechnologyTechnology ProcessProcessProcessProcess CapacityCapacityCapacityCapacity
IPCLIPCLIPCLIPCL BarodaBarodaBarodaBaroda MONTEDITION, ItalyMONTEDITION, ItalyMONTEDITION, ItalyMONTEDITION, Italy Slurry Slurry Slurry Slurry –––– HYHA HYHA HYHA HYHA IPCLIPCLIPCLIPCL NagothaneNagothaneNagothaneNagothane HIMONT, ItalyHIMONT, ItalyHIMONT, ItalyHIMONT, Italy SpheripolSpheripolSpheripolSpheripol 70,00070,00070,00070,000IPCL IPCL IPCL IPCL BarodaBarodaBarodaBaroda MONTELL, ItalyMONTELL, ItalyMONTELL, ItalyMONTELL, Italy AdipolAdipolAdipolAdipol 1,00,0001,00,0001,00,0001,00,000RIL HaziraRIL HaziraRIL HaziraRIL Hazira UNIPOL, USAUNIPOL, USAUNIPOL, USAUNIPOL, USA Gas PhaseGas PhaseGas PhaseGas Phase 4,00,0004,00,0004,00,0004,00,000
PP Producers in IndiaPP Producers in IndiaPP Producers in IndiaPP Producers in India
RIL HaziraRIL HaziraRIL HaziraRIL Hazira UNIPOL, USAUNIPOL, USAUNIPOL, USAUNIPOL, USA Gas PhaseGas PhaseGas PhaseGas Phase 4,00,0004,00,0004,00,0004,00,000RILRILRILRIL JamnagarJamnagarJamnagarJamnagar UNIPOL, USAUNIPOL, USAUNIPOL, USAUNIPOL, USA Gas PhaseGas PhaseGas PhaseGas Phase 6,50,0006,50,0006,50,0006,50,000HPL HaldiaHPL HaldiaHPL HaldiaHPL Haldia MontellMontellMontellMontell SpheripolSpheripolSpheripolSpheripol 2,10,0002,10,0002,10,0002,10,000
Total 1.43 Million MTATotal 1.43 Million MTATotal 1.43 Million MTATotal 1.43 Million MTA
RIL + IPCL Contribute 85% of Total PP in India
Polypropylene …
� Lightest Commodity Plastics – Density of 0.90
� High strength : weight ratio
� Excellent moisture barrier
� Very High Filling & Service Temperature (98 deg C)
PP : Versatile Polymer……
� Very High Filling & Service Temperature (98 deg C)
� Excellent chemical , fungal resistance & ESCR
� Integral hinge property
� Autoclavable and can potentially be steam sterilized
� PP has excellent chemical resistance & ESCR Properties.
� Easily recyclable
PP - A Versatile Polymer
…With the widest Performance Envelope
Optimum impactOptimum impactOptimum impactOptimum impact----stiffness balancestiffness balancestiffness balancestiffness balance
400400400400
600600600600Izod impact at RT, J/m2Izod impact at RT, J/m2Izod impact at RT, J/m2Izod impact at RT, J/m2
Flexural modulus, MPaFlexural modulus, MPaFlexural modulus, MPaFlexural modulus, MPa0000 1000100010001000 2000200020002000
200
Polypropylene…
• Reliance Manufactures & Markets three main types of
Polypropylene under the Brand Name “REPOL”
� Homopolymers : Have high heat resistance and good rigidity,
making them suitable for a vast range of applications;
� Copolymers: which are made by incorporating different� Copolymers: which are made by incorporating different
monomers, are extremely resilient materials and have wide
uses in automotive and industrial applications.
� Random copolymers : which are made by introducing ethylene
links into the polymer chain, tend to have improved optical
properties, making them ideal for applications such as
packaging where transparency is required.
Polypropylene…..
PP – Material of Choice for Blow Moulding Apllications
� Very low density
� High stiffness
� High surface hardness
� Very good chemical resistance & ESCR� Very good chemical resistance & ESCR
� Very Good Contact clarity & gloss
� Very low water absorption & transmission
� Good resistance to high temperature
� Elastomer modified grades for low temperatures toughness
� Ideal for smaller containers
Guidelines for Processing PP : Blow Moulds
� Material of Construction :
�Mild Steel
�Aluminium
�Beryllium Copper
� Essential requirements on the mould :
� Adequate cooling, preferably along the contours of the cavity
� Cooling of thicker areas of the article like neck, top and � Cooling of thicker areas of the article like neck, top and
bottom pinch-offs
� Proper alignment of the two halves
� Typical Construction of a EBM Moulds
– Venting : air vents & sand blasted mould surface to be
provided on mould to allow air to escape
� Pinch Off Design
– Pinch off land of 1.2mm recommended for PP as compared to
2.4mm for PE.
• For blow moulding applications, PP with MFI between 1 to
3 dg/min. should be used.
• Screw with L/D>20 and compression ratio >2 should be used
• Melt temperature should be between 180 & 220°C
Guidelines for Processing PP : M/c Parameters
• Melt temperature should be between 180 & 220°C
• Adequate venting of mould is required for good container
surface finish
• Hot wire cutter should be used for parison transfer
• Adequate mould cooling for faster cycles and better clarity
� Processing Temperatures
� Feed Throat : 170 - 190°C
� Melt Temp. : 180 - 220°C
� Mould Temperatures
Guidelines for Processing PP : M/c Parameters
� Mould Temperatures
� Blow mould temps. : 20°C
� Adequate mould cooling for faster cycles and better clarity
Reliance PP Blow Moulding Grades :
Grade Type MFI
(dg/min) Special Characteristics
H020EG Homopolymer 2.0 Good rigidity and processability
R019MZ Random Copolymer 1.9 Low odour, contains clarifier1.9
SR20NSMedical Grade
Random Copolymer 1.9Suitable for I.V.Fluid
application
SR20NC Random Copolymer 1.9 Low odour, contains clarifier
SRM100NC Random Copolymer 10.0Suitable for Clarified PP_ISBM
application
C015EG /
MI 1530Impact Copolymer 1.5 High impact copolymer
Clarified Polypropylene (cPP)
Additivated Random Co-Polymer
Opportunity Knocking
India visIndia visIndia visIndia vis----àààà----vis Global Averagevis Global Averagevis Global Averagevis Global Average7.5 %7.5 %7.5 %7.5 %
cPP Consumption : as a Percentage of Total PPcPP Consumption : as a Percentage of Total PPcPP Consumption : as a Percentage of Total PPcPP Consumption : as a Percentage of Total PP
Strive to Meet Global AverageStrive to Meet Global AverageStrive to Meet Global AverageStrive to Meet Global Average3.1 %3.1 %3.1 %3.1 %
PP Random Copolymer
Incorporation of Ethylene in PP
• Chain regularity disturbed.
• Decrease in crystallinity and rate of crystallization.
• Restrict the size of crystalline aggregates.• Restrict the size of crystalline aggregates.
• Better clarity.
Use of Clarifier (Nucleation)
• Large number of crystallites having size less than wavelength of light.
• Effect : Better clarity and high stiffness.
Nucleated vs Clarified PP
Nucleators and clarifiers induce formation of smaller spherulites that scatter less light.
Inorganic Nucleators : Larger than the wavelength of light.
Sorbitol-based Clarifiers form a fibrous network within the resin that makes the
crystallites smaller than the wavelength of light.
(Source: Milliken Chemical)
Polypropylene MorphologyPolypropylene MorphologyPolypropylene MorphologyPolypropylene Morphology
Nucleated PPStandard PP
100 micronsPhotomicrographs - cross-polarized light
Characteristics of Clarified PP : Characteristics of Clarified PP : Characteristics of Clarified PP : Characteristics of Clarified PP : • Glass like transparency
• Excellent moisture barrier & Chemical resistance
• Higher continuous use ambient temperature
• Hot fill ( upto 98 Deg C), Retortable &
Microwaveable
• Excellent balance of stiffness , flexibility
• Live Hinge property
• Excellent ESCR property
• Cost effective
Clarified Polypropylene (cPP) ideally suited for Modern Life Style
Applications of cPP
• Cream
• Baby feeding bottle
Bottles and containers for :
• Mineral water
• Cough syrup
• Sterile fluid• Shampoo
• Face powder
• Tooth powder
• Ketchup
• Sterile fluid
• Syrup & Squash
• Mouthwash
• Lotion
Oral care products
Blow Moulded Applications of cPP
Food applicationsSkin care products
Oral care productsShampoo bottlesBaby Feeding Bottles
I.V.Fluid Bottles
HIGH DENSITY HIGH DENSITY
POLYETHYLENE
Polyethylenes : Characteristics
• Represents a family of resins prepared from the
polymerization of ethylene gas using a variety of
catalysts
• Density, melt index, crystallinity, degree of • Density, melt index, crystallinity, degree of
branching and cross-linking, molecular weight
and molecular weight distribution can be
regulated over wide ranges. Further modifications
are obtained by copolymerization, chlorination,
and compounding additives.
• Extrusion Temperatures :– Melt temperatures in the range of 175 - 205ºC are
recommended.
– Normally, temperatures of s190 - 205ºC will result in optimum ESCR properties.
– No premium in stress crack resistance can be expected
Processing Of HDPE
– No premium in stress crack resistance can be expected by increasing melt temperatures above 215ºC.
• Mould Temperatures :– Mould temperatures should be preferably 20ºC to
minimize cycle time. The cycle time also depends upon mould design and atmospheric conditions.
– Mould temperatures should not be too low as this would lead to mould sweating.
PE Application Portfolio
0 . 9 6 0
0 . 9 5 5
0 . 9 5 0C a p s
0 . 9 4 5
0 . 9 4 0
0 . 9 3 5
<-----------------D
en
sity
IM ( In d u s t r i a l &
H o u s e h o l d )H M F & H M B M
G P B M ( P e s t i c i d e ,
C o s m e t i c s , L u b e &
E d i b l e o i l
c o n t a i n e r )
R a ff i a &
M F
H M P i p e s
W & C
0 . 9 3 5
0 . 9 3 0
0 . 9 2 5
0 . 9 2 0
0 . 9 1 5
0 . 9 1 0
0 . 0 1 0 . 1 0 . 3 0 . 5 1 3 1 0 2 0 3 0 5 0
M e l t F l o w I n d e x - - - - - - - - >
I M & M B
B l o w n F i l m ( G P ,
M i l k & L a m i n a t i o n
) & D r i p l a t e r a l s
C a s t
F i lmE C
<-----------------D
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R M
Applications of HDPE
• Edible oil
• Chemicals
• Petro Products (Lube Oil)
• Pharmaceuticals
• Pesticides
• Cosmetics
• Toys
• Automotive Parts (Arm rest, windshield
washer bottle)
Applications Of Polyethylene
Milk BottlesEdible Oil Containers
Lube Oil Containers
Bottles
Pesticide Containers
HDPE Blow Moulding Grades
Grade MFI Density Special Characteristics Typical Applications
Indothene
54GB012
1.2
(I5)0.954
Bimodal MWD, Good flow
and ESCR.
Small vol. Containers and GP
containers preferably upto 5 L
Indothene
52GB010
1.0
(I5)0.950
Broad MWD, Very good
swell and impact
5-30L containers for lube oil,
edible oil, adhesives etc.
Relene
B560030.3 0.956
Good melt strength and
rigidity
General purpose containers,
jerry cans (Upto 15L)B560030.3 0.956
rigidity jerry cans (Upto 15L)
Relene
TB50004
0.45
(I5)
0.952Good melt strength,
Swell and ESCR
Medium volume containers,
liners, sheets, air ducts etc.
Indothene
52GB003
0.45
(I5)0.952
Good melt strength and
swell, impact - stiffness
balance
Medium volume containers,
liners, sheets, air ducts etc.
Indothene
52GB001
0.40
(I5)0.952
Broad MWD, good swell,
melt strength & Impact
strengh
Large containers, L-ring drums,
liners & barrels upto 240L
RIL PartnershipRIL Partnership
Role of Business Development Group
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� Identify Modern technologyIdentify Modern technologyIdentify Modern technologyIdentify Modern technology
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� Nurturing new application / Promotion / Market extensionNurturing new application / Promotion / Market extensionNurturing new application / Promotion / Market extensionNurturing new application / Promotion / Market extension
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� Regulations / Mandation for driving GrowthRegulations / Mandation for driving GrowthRegulations / Mandation for driving GrowthRegulations / Mandation for driving Growth
• Bulk Packaging
• Rigid Packaging
• Flexible Packaging
• Automobiles
Sector Management
• Lifestyle & Appliances
• Textiles & Fibers
• Pipe & Profiles
• Downstream Development
Concept to Commercialisation
Machinery Manufacturers
Machinery Manufacturers
A Vital link amongstA Vital link amongstA Vital link amongstA Vital link amongstM/c Mfg. M/c Mfg. M/c Mfg. M/c Mfg. ---- Business Business Business Business ---- Converter Converter Converter Converter ---- End UserEnd UserEnd UserEnd User
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