Processing Aid masterbatch: - Output & product quality improvement.
Why we use Polymer Processing Aid Masterbatches?
Polymer Process Aids (PPA) masterbatches are specifically designed to
enhance extrusion ability of plastic s (PE Films, pipes, tubes . ..) leading to PRODUCTIVITY and /or QUALITY improvement. If you are not using polymer processing masterbatches today in your film or pipe extrusion processing, you are probably missing great opportunities in getting higher quality products at a lower cost. The use of polymer process aids has increased as polymer processors look for higher quality and better output of their finished products. Pure Polymers supplies an extensive range of polymer process aid masterbatches to the extrusion and molding market places. Specific formulations have been developed for polyolefins such as metallocene, styrenics, and polyamides. Application Examples Film, sheet, profile extrusion, injection moulding, and others.
Pure Polymer Processing Aid
They find use in a wide variety of applications from blown film to fibre, injection moulding, profile extrusion, pipe/tubing, and cabling processes. Process aids can be used with LLDPE, LOPE, HOPE, LLDPE, PP, polystyrene, polyamides, acrylics, and others. They can be particularly effective when used with metallocene grades of polymer. Mode of Action Process aids are formulated to form a microscopic dispersed phase within the polymer carrier. During processing the applied shear-field causes the process aid to phase separate from the carrier polymer and migrate to the die wall gradually forming a continuous layer. Once the coating is complete, the backpressure of the extruder decreases to a minimum as the differential between the surface energies of the polymer and the coating allows for reduced friction during extrusion.
Other additives in the system, such as pigments and anti-blocks, as well as process conditions, affect the coating and removal rates. A number of factors affect the coating equilibrium including concentration, dispersion, throughput, viscosity, shear gradient, and temperature. To achieve the coating in a reasonable time the process aid masterbatch is typically added at % l until the beneficial effects are seen. After this, the addition rate can be reduced to %05 down to even %025 as long as the effect continues to be evident. A small addition must be maintained as the coating is dynamic, with the polymer melt both abrading the coating and depositing further process aid.
Processing Aid will:
• Enhance processability and reduce production costs.
• Grades for commodity & engineering polymers.
• Suitable for film, fiber, extrusion & injection moulding applications.
• Combination products for the complete solution.
• Eliminate sharkskin effect.
• Increase your Output to up to 15%.
• Reduce or eliminate Die Build-Up.
• Reduce or eliminate Gel s and optical defects.
• Reduce Change over time The term "process aid" covers several types of material s that are used to improve the processability and handling of high molecular weight polymers.
These products are used to:
• Eliminate melt fracture and improve surface finish.
• Reduce die-drool.
• Improve throughput & minimize energy consumption.
• Reduce the incidence of gel formation.
• Improve processability of recycled or reground polymer.ies of the active ingredients.
Pure polymers Processing Aid Advantages:
Melt Fracture Reduction Process aids enable polymer to be extruded at higher shear rates without the melt fracture (surface roughness/sharkskin effect) that may occur with untreated polymer melts. The addition of process aids results in a good product produced at higher output rates. Reduced Die-drool & Gel Formation During processing, deposits of low molecular weight polymer, additives, and degradation products can build up on the die and extruder surfaces. Such deposits can create die lines and when/i f they a rereleased, defects on the extrudate. A process aid is able to reduce die build-up because as the coating layer develops any degraded material clinging to the die is displaced and also stagnation in the extrusion process is minimized reducing the production of thermal degradation products. The low energy surface provided by the coating reduces internal build-up and subsequent degradation leading to crosslinked and oxidized gels. Reducing unmelted/unmixed gels is believed to be related to the prevention of solid bed break-up and the process aid may prevent premature melting in the feed section thus helping to maintain a coherent solid bed.
Process Efficiency Improvements
The use of a process aid reduces resistance between the polymer melt and the die, resulting in die pressure and motor torque to fall. If process temperature and outputs are kept constant process aids can reduce motor energy consumption, while if process temperature and extrusion pressures are kept constant higher outputs can be achieved. As a result of process aids reducing die build up the extruder does not need to be stopped as frequently during production to clean such deposits, thus limiting downtime. Industrial trials have also found reductions in the time for color or resin changes to be completed.
Process aids can help reduce extruder pressure when processing blends of polymers such as LLOPE with LOPE and LOPE with HOPE. While this does not solve incompatibility issues it can increase processing flexibility/options.
Durability and longevity
Processing aid Applications
Blown & Cast Film
Using a process aid can enable LLDPE to be run on narrow die gaps resulting in improved impact strength without effecting other physical properties as caused by blending with LDPE. By reducing the stress and elongation of the polymer chains in the flow direction, a process aid can also improve impact property balance, machine vs. cross-section. In cast film, the use of a process aid has been shown to improve control over thickness. Process aids are used to reduce melt fracture, increase surface gloss, and enable lower extrusion temperatures to be used resulting in higher melt strength.
Processing aid Applications
Cable & Tubing Extrusion
Here the process aid can lower apparent viscosity of the polymer, reduce die build UP, or produce a smoother, glossier surface. Blow Moulding& Injection Moulding
Excellent thermal and electrical insulation properties
Blow Moulding & Injection Moulding