CONTROLLING SHEAR TO PRODUCE BRILLIANT EFFECT PIGMENT MASTERBATCHESADVANCED 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 today�s

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 today�s 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 mixingŸ Control over shear and elimination of shear peaksŸ Efficient energy transmissionŸ 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 depthŸ 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.

#1EFFECTIVEWETTING:

#2EFFECTIVEDISPERSION:

#3EFFECTIVEDISTRIBUTION &STABILISATION:

#4DEEPER ROOTDEPTH

#5ADDRESSING‘LEAKAGE’

#6LOW BULKDENSITYMATERIALS

EFFICIENT MIXING WITH STEER�S PATENTED FRACTIONAL-LOBE ELEMENTSSTEER�s patented Fractional-lobe mixing elements, address the gaps in today�s 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. STEER�s 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 BLOCKSSTEER�s 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:STEER�s 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/DISTEER�s 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 STEER�s 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.

STEER�s 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 STEER�s Do/Di=1.71 Technology platform

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

MATERIALS:Ÿ 70% LLDPE, 30% PigmentsŸ Iridion 305 Solar GoldŸ 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 ElementsŸ Screw RPM fixed @ 600 for all trialsŸ 170-230C

TESTING:Ÿ Microscopic Examination at MERCK as

per MERCK Standard Procedure

THE PROOF IS IN THE PIGMENTSTRIALS 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 SCREWGAP’ < 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-SCREWEXTRUDER — 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 WHILEMAINTAINING 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 STEEL1COUNTRIES 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, Ohio 44685, USA

Tel: +1-866-984-1800Fax: +1-330-563-4413E-mail: info@steeramerica.comWeb: www.steeramerica.com

STEER CHINA

603,Building No.12, 3599#, Qixin Road, Minhang District , Shanghai, China 201101

Tel: +86-021-34718598Fax: +86-021-34718598 ext. 806E-mail: info.china@steerworld.comWeb: www.scg.steerworld.com

STEER EUROPE

Tel: +44 2032904949E-mail: info@steereurope.comWeb: www.steerworld.com

STEER INDIA - Bangalore

#290, 4th Main, 4th Phase, Peenya Industrial Area, Bangalore 560 058, India

Tel: +91-80-23723309/10 +91-80-42723300Fax:+91-80-28391374E-mail: info@steerworld.comWeb: www.steerworld.com

STEER JAPAN

Fukui Building 4F, P3-21-7 Higashiueno, Taito-Ku, Tokyo 110-0015 Japan

Tel: +81-3-6411-5770Fax: +81-3-3831-3230E-mail: info@steerjapan.comWeb: www.steerjapan.com

STEER INDIA - Mumbai

#317, Regus Business Centre, Level-3, Neo Vikram, New Link Road, Andheri (W) Mumbai � 400053. India

Tel: +91 22 61984900Toll Free: 1800 425 55111Fax: +91 22 61984950E-mail: info@steerworld.comWeb: www.steerworld.com

STEER is a creator of materials platform technology that effectively transforms and functionalises materials in the fields of plastics, pharmaceuticals, food & nutraceuticals, biomaterials and biorefining. Founded in 1993 by Dr. Babu Padmanabhan with a vision to steer a new world, STEER today has 5 global offices and 10 satellite offices, serving over 39 countries and employs over 500 gifted engineers, scientists and technicians across the globe. With 33 patents for breakthrough innovations, STEER is committed to the design, creation and implementation of advanced platform technologies, components, elements, peripherals and applications that help our customers, and the world at large, to move forward.

ABOUT US

STEER A NEW WORLD.STEERWORLD.COM | INFO@STEERWORLD.COM