Cw November 2012

November 2012

SELECTING THE RIGHT CARBON BLACK

STIR IT UP WITH THE LATEST MIXERS

PUTTING COMPOUNDS TO THE TEST

KEEP IT CLEAN FOR MEDICAL MARKETS

Having led the way with high-quality digital-only magazines for the global plastics industry, AMI is now also making its titles available free-of-charge on the iPad, iPhone and a wide range of Android-based smartphones and tablet computers.

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www.compoundingworld.com November 2012 | COMPOUNDING WORLD 3

04 Industry news The latest compounding industry news including international acquisitions and

alliances, plus new investments and plant openings.

15 Keep it clean Clean compounding lines are being commissioned to meet the stringent demands

of medical and other markets. Jennifer Markarian reports.

25 Stir it up with the latest mixers Mikell Knights reviews recent developments in batch and continuous mixers for

use in the production of compounds and masterbatches.

41 Building new benefi ts for carbon black Carbon black suppliers are tuning morphologies to improve processability and

performance. Pat Toensmeier reports.

49 Comparing conductive carbon blacks in HDPE Dr Daniele Bonacchi and Ing Christine Van Bellingen of Timcal compare the

performance of conductive and extra-conductive carbon blacks.

59 New materials testing and analysis equipment We review the latest materials testing equipment designed to check that your

new formulations meet performance and quality requirements.

64 Compounder of the month: Phon Tech

66 Dates for your diary

coming next issue� Lab compounders � Compounding high-performance plastics � Flame retardants

� Click here to make sure you get your copy

contents

PAG

E 4

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E 15

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E 25

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Applied Market Information LtdAMI House, 45-47 Stokes Croft, Bristol, BS1 3QP, United KingdomTel:+44 (0)117 924 9442Fax:+44 (0)117 989 2128www.amiplastics.com

contact usHead of business publishing: Andy Beevers E-mail: [email protected] editor: Chris Smith E-mail: [email protected] editor: Jennifer Markarian E-mail: [email protected]: Nicola CraneAdvertisement manager: Claire Bishop E-mail: [email protected] Direct tel: +44 (0)20 8686 8139

compounding world | november 2012 www.compoundingworld.com4

news

PolyOne has entered a

definitive agreement to acquire

Spartech, a leading producer

of plastic products, including

compounds, concentrates,

custom extruded sheet, and

packaging solutions. The deal,

which is expected to be

completed in the first quarter

of 2013, represents a total

transaction value of approxi-

mately US$393 million,

including the assumption of

Spartech’s net debt of US$142

million.

Stephen Newlin, PolyOne’s

chairman, president and chief

executive officer, said:

“Spartech expands PolyOne’s

specialty portfolio with

adjacent technologies in

attractive end markets where

we already participate, as well

as new ones like aerospace

and security. By combining

Spartech’s leading market

positions in sheet, rigid barrier

packaging and specialty cast

acrylics with PolyOne’s

capabilities, we can accelerate

growth for both companies”.

Victoria Holt, Spartech’s

president and chief executive

PolyOne to buy Spartech

Spartech’s sales, and Newlin

describes the opportunity to

expand the business globally

as “huge”.

The transaction, which was

unanimously approved by the

boards of directors of both

companies, remains subject to

approval by Spartech’s

shareholders and receipt of

required regulatory approvals

as well as other customary

closing conditions.

To download PolyOne’s 22

page presentation on the

Spartech acquisition, including

detailed business analyses

and strategic plans, go to

http://bit.ly/PolyOneSpartech.

❙ www.polyone.com❙ www.spartech.com

officer, added: “PolyOne and

Spartech have complementary

growth strategies, and by

combining our resources we

expect to accelerate our shift

to specialty applications with a

more competitive cost

structure, enhanced customer

relationships, improved

market access and increas-

ingly innovative technologies”.

Spartech operates 30

facilities in the United States,

Mexico, Canada and France.

The company achieved sales

and adjusted EBITDA of

approximately US$1.2 billion

and US$53.1 million, respec-

tively in the 12 months to 4

August 2012. North America

currently accounts for 94% of

Songwon of Korea, Pan Gulf

Holdings of Saudi Arabia

and Polysys of Abu Dhabi

have formally established

their new joint venture,

Songwon Additives

Technology, for the

manufacture of Songnox

One Pack Systems (OPS).

The three companies

first announced their

intention to form the JV late

last year (Compounding World, December 2011). It

includes Songwon ATG, the

former Greiz business in

Germany, which operates

one of Europe’s largest OPS

plants. Songwon Additives

Technology says that it is at

“an advanced stage” in

establishing further

manufacturing companies

in the Middle East and in

the US.

The JV is forming a new

subsidiary to manage Middle

East sales; Songwon will

handle the rest of world.

❙ www.songwonind.com

Songwon launches OPS JV

TPEI has installed a new five-axis CNC machining centre at its

factory in Lehighton, Pennsylvania, USA. It is being used specifi-

cally for the production of rotors for continuous mixers.

The new machining centre has been installed to meet growing

demand and is able to produce rotor diameters from 1 to 12

inches (2.5 to 30.5 cm). “The addition of this new large-capacity

equipment gives us the ability to increase productivity and

accuracy as well as develop and manufacture new rotor geom-

etries,” said Harold Schafer, CEO at TPEI.

For more information on recent developments in TPEI’s

product range, see the special feature on batch and continuous

mixers which starts on page 25 of this issue.

❙ www.tpei.com

PolyOne’s Stephen Newlin and Spartech’s Victoria Holt plan to

grow specialty applications

TPEI invests in CNC centre for mixer production

www.compoundingworld.com November 2012 | compouNdiNg world 5

news

Chemtura is to acquire the

bromine assets of Solaris

ChemTech Industries,

India’s leading manufac-

turer of bromine and

bromine derivatives.

The acquisition, which is

expected to be completed

by the end of 2012, includes

two manufacturing facilities

and an R&D centre in the

State of Gujarat. The new

subsidiary will be head-

quartered in New Delhi and

will become part of

Chemtura’s Great Lakes

Solutions flame retardants

business.

“The acquisition of

Solaris ChemTech’s

bromine assets will further

strengthen our bromine

position and provide our

customers with increased

security of supply through

further diversification of our

bromine supply sources,”

said Craig Rogerson,

Chemtura’s chairman,

president and CEO.

❙ www.chemtura.com

Chemtura acquiresin India

Hillenbrand is to acquire

Coperion from the German

private equity company

Deutsche Beteiligungs for an

estimated E408 million. The

transaction is expected to

close by the end of December

2012, depending on regulatory

approvals.

Hillenbrand is publicly

listed on the New York Stock

Exchange and is a leading

supplier of funeral products,

such as burial caskets, which

it sells under the Batesville

brand in North America. It has

recently been diversifying into

the industrial sector with the

acquisition of materials

handling systems supplier

K-Tron in 2010 along with the

purchase of TerraSource

Global, a manufacturer of size

reduction, conveying and

screening machinery. Last

year it added the separation

equipment specialist Rotex.

Coperion, which includes

the former Werner & Pfleider-

er and Waeschle businesses, is

a global leader in compound-

ing, extrusion and bulk

material handling equipment.

In the 12 months to the end of

September 2012, the business

had a revenue of E520 million

and EBITDA of E38.7 million.

Günter Bachmann,

Coperion’s current CEO, will

continue as president of

Coperion reporting to Joe

Raver, president of Hillen-

brand’s Process Equipment

Group. Coperion’s headquar-

ters will remain in Stuttgart,

Germany.

“The acquisition of

Private equity firm to sell Coperion to Hillenbrand

Coperion represents a very

significant move forward for

our company,” said Hillen-

brand CEO Kenneth Camp.

“Post closing, the Process

Equipment Group will generate

revenue of more than US$1

billion and will represent about

two thirds of Hillenbrand’s

total revenue.”

Coperion’s Bachmann

added: “We are very familiar

with Hillenbrand’s Process

Equipment Group operating

companies, particularly

K-Tron. We are excited about

the growth opportunities that

now will be available to our

combined company.”

The estimated purchase

price of E408 million includes

the assumption of an estimat-

ed E76 million of net debt and

E100 million pension liabil-

ity. Deutsche Beteiligungs and

Coperion’s management

acquired Coperion for E300

million in 2007 from Lyceum, a

UK private equity firm.

❙ www.coperion.com❙ www.hillenbrandinc.com

AMI has announced the

programme for its 16th

Thermoplastics Concentrates

conference, which takes place

in Coral Springs, Florida, USA,

on 29-31 January 2013. The

line-up of speakers includes

experts from key players from

throughout the masterbatch

supply chain.

In addition to major

suppliers of pigments,

Coperion’s Günter Bachmann:

excited by the growth

opportunities for the com-

bined company

Concentrates event attracts leading playersadditives and processing

machinery, the programme

includes speakers from

leading concentrates produc-

ers such as Clariant, Plastics

Color Corporation and Accel

Color. End users are also

represented with speakers

from Graham Packaging and

MWB Toy Company.

In addition to covering the

latest technology develop-

ments, the conference has a

strong business focus. AMI’s

research director, Andrew

Reynolds will cover overall

trends and the outlook for the

NAFTA thermoplastics market

as well as analysing the

region’s concentrates market

in detail.

The annual event attracts

an influential audience of

senior executives from

throughout the global supply

chain. In 2012, more than

US$2.5 billion in concentrates

sales was represented at the

conference.

For more information on

the full conference programme

plus booking details, visit

http://bit.ly/TC2013. Book

your place by 14 December

and save US$200.

❙ www.amiconferences.com


news

Epic expands LFT capacity

tion with leading machine

builders and polymer suppli-

ers, set new standards for the

quality and possibilities of

LFTs. The classic LFT prob-

lems of bad feeding and

insufficient impregnation are

now a thing of the past.”

The LFT compounds

produced on the new line will

be marketed under the Strator,

Tribocomp and Star-Therm

tradenames, depending on the

formulation of the product.

❙ www.epicpolymers.com

Epic Polymers is increasing

production capacity for

long-fibre thermoplastics

(LFTs) at its plant in Kaisers-

lautern, Germany. A new 4,000

tonnes/year production line is

being commissioned at the site

in the fourth quarter of 2012.

The company says that the

new capacity will allow it to

meet the growing demand for

LFTs that it is seeing across all

industry segments. The new

line will use its innovative

impregnation technology to

reinforce high-performance

plastics including polyamide

and PPA with long glass,

carbon and aramid fibres. It

will also produce tribologically

modified grades as well as

electrically and thermally

conductive compounds.

Epic’s director of marketing

and technology, Fred Panhui-

zen said: “The set up of the

new production line is unique

in this market. Through the

newly developed Epic Technol-

ogy, we have, in close coopera-

Washington Penn Plastic

(WPP) has officially opened

its first polyolefins com-

pounding plant in Europe.

Audia Plastics is located in

Voderady, Slovakia, and is

producing mineral- and

glass-filled polypropylene

grades as well as TPO

compounds.

In March 2011, Com-pounding World reported

that WPP was investing

roughly E8 million in the

Slovakian facility with a

planned capacity of 66,000

tonnes/year of PP com-

pounds and 2,270 tonnes/

year of masterbatch.

The expansion into

Europe is intended to build

on the company’s success

in North America, matching

manufacturing footprints

with its global customers.

The five main target

markets are automotive,

appliances, building/

construction, consumer

products and packaging.

In addition to compound

manufacturing, the facility

houses both a development

line and a full-scale

laboratory to test and certify

materials. It is WPP’s

second new plant opening in

the past four years.

The privately-owned

company also operates four

plants in the US and one in

Monterey, Mexico.

It says that the total

annual capacity for its

plants is more than 750

million lbs (340,000 tonnes).

❙ www.washingtonpennplastic.com

Washington Penn opens in Slovakia

Group promotes PVC in healthcareA new industry organisation

has been formed to promote

the benefits of PVC in health-

care applications. Based in

Brussels, Belgium, the

PVCMed Alliance is backed by

PVC resin and plasticizer

manufacturers as well as PVC

converters.

The Alliance aims to provide

a focal point for communica-

tion with healthcare profes-

sionals and regulators about

PVC-based healthcare

applications. In particular, it

wants to highlight the role that

PVC can play in the quality,

safety and cost-efficiency of

healthcare, while also being

Epic’s new line will produce

high-performance LFTs including

Strator grades based on PPA

environmentally responsible.

PVC is widely used in

medical devices for screening,

diagnosis, treatment and care,

as well as in the building of

safe healthcare environments.

Nearly 30% of all plastic-based

medical devices are made of

PVC – the two main application

areas for medically approved

PVC compounds are flexible

containers and tubing.

Current members of the

PVCMed Alliance include

BASF, Colorite Europe,

Eastman, the European

Council of Vinyl Manufactur-

ers, Oxea, Renolit, and Tarkett.

❙ www.pvcmed.org

The PVCMed Alliance will

highlight the benefits of PVC

in medical devices


news

Baerlocher commissions Chinese stabilizers plant

of solid PVC stabilizers in the

region. It also manufactures

liquid mixed metal stabilizers

in Jiangsu Province, China

through its production joint

venture Jiangsu U&B, which it

formed with Uniwel in 2010.

❙ www.baerlocher.com

Baerlocher Plastic Additives

officially opened its new PVC

stabilizers plant in Changzhou,

Jiangsu Province, China, on

19 October.

The facility, which is wholly

owned by Baerlocher, has a

capacity of 40,000 tonnes/year

and will produce Ca-based and

Pb-based stabilizer systems.

The plant is supported by a

state-of-the-art application

laboratory.

Arne Schulle, CEO of the

German-headquartered

Baerlocher Group, said: “This

operation, which already

employs more than 50 people,

will help us to further meet the

needs of a dynamic market

utilising local talents. This will

be actively supported by our

global team and will enhance

our position as the global

leader in Ca-based stabilizer

systems.”

Baerlocher established a

local sales company in China

in 2007 and claims to have

become the leading importer

DSM has begun construc-

tion of its new materials

sciences research building

on the Chemelot Campus in

Sittard-Geleen, the

Netherlands. Scheduled to

open in 2014, the facility is

part of DSM’s E100 million

investment in three new

research facilities in the

country.

It will be the most

important R&D centre for

DSM Engineering Plastics

worldwide and it will also

support other DSM

materials divisions, such as

Dyneema, as well as

research activities in

bio-based and biomedical

materials.

❙ www.dsm.com

DSM starts work on R&D site

RTP installs new mixer at German plantRTP has completed the first

phase of the previously

announced expansion at its

compoundng plant in Laden-

burg, Germany.

Maag Automatik expands presence in ChinaMaag Automatik has opened a new 11,000 m2 facility near

Shanghai, China, along with its parent company Dover. It

more than doubles the size of its previous regional

headquarters in the country and includes a product

showroom and training facility.

The German supplier of pelletizing systems will use the

new building to provide its Asia-Pacific customers with

technical expertise, after-sales service, plus faster delivery

of machines and spare parts.

❙ www.maag.comThe new Maag and Dover building in

China will help to speed up deliveries

Baerlocher’s new plant in Changzhou produces Ca-based andPb-based stabilizers

The first of two internal

batch mixers has been

installed at the facility. It will

produce a line of conductive

compounds that RTP acquired

from Clariant in March 2012.

The second line will be

installed in the first half of

next year.

In addition, RTP is doubling

its capacity to produce

very-long-fibre composites at

Ladenburg with the installation

of extra pultrusion lines.

❙ www.rtpcompany.com

BU

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Hohenrainstrasse 104133 PrattelnSwitzerland

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quantec® 96 EV-10C


news

BYK starts American expansionBYK Additives & Instru-

ments has begun construc-

tion of a new three-storey

production building on

newly acquired grounds at

its site in Wallingford,

Connecticut, USA. It is

investing E36 million in the

facility which is due to be

completed in 2014.

“This investment in

Wallingford underlines once

again our aspiration to grow

on the North American

market and to produce as

many products as possible

locally,” said Dr Roland

Peter, president of BYK

Additives & Instruments.

BYK produces a range of

additives including wetting

and dispersing agents for

masterbatches, plus

modifiers for plastics.

❙ www.byk.com

IPC meets ISO medical standardInnovative Polymer Com-

pounds (IPC) of Kilbeggan in

County Westmeath, Ireland,

has achieved the ISO 13485

quality standard for medical

manufacturing.

IPC focuses on producing

compounds for medical device

manufacturers at its plant

which was established in 2008.

It says that achieving ISO

13485 will help it to grow its

European customer base.

Compounding is carried out

using a Leistritz ZSE 27 Maxx

twin-screw extruder in a Class

100,000 clean room (pictured).

pounded at the plant include

polyamides, TPEs, TPUs and

fluoropolymers.

The ISO 13485 standard is

primarily aimed at medical

device manufacturers, but a

growing number of compound-

ers and masterbatch makers

that supply such companies

are implementing the standard

themselves. Other examples

include Clariant, PolyOne,

Teknor Apex and Elasto. For

more information, see the

article on clean compounding

which starts on page 15.

❙ www.ipcpolymers.ie

TPEs compounder Star

Thermoplastic Alloys &

Rubbers has opened its a new

process development labora-

tory at its headquarters in

Broadview, Illinois, USA. The

new purpose-built 8,000 ft2

(740 m2) facility is equipped

with four extruders with

outputs ranging from 60 to 500

lbs/hr (27 to 230 kg/hr).

It is the fifth laboratory at

Star adds new extrusion labthe site – the others are used for wet chemistry, polymer research and characterisation, physical testing and sample production.

Star’s R&D manager, Dr Prakash Sanjeevaiah said: “The addition of this new lab gives us and those customers we serve a greater capability for providing more samples and in larger quantities. We are now

offering as many as 200

extrusion grade samples, argu-

ably the most in the industry.”

Star reports that it has

achieved a 50% year-on-year

increase in sales. In addition to

the new lab, it has expanded

its sales and service office

space and increased its

number of employees in

production, sales and service.

❙ www.starthermoplastics.com

The line is fed by K-Tron

gravimetric dosing units, while

pelletizing is carried out at the

plant using a Gala underwater

system or an Automatik strand

pelletizer. Materials com-

ICL Industrial Products is

ending the sale of Tris(1,3-

dichloro-2-propyl)phosphate

(TDCP or “Tris”) flame

retardants for home furnishing

applications, including chairs,

sofas and nursery products,

with effect from 1 January

2013. At the same time, it is

expanding production of its

Fyrol HF-5 polymeric flame

retardant for flexible polyure-

thane foam applications at its

ICL advances with TDCP replacementGallipolis Ferry plant in West

Virginia, USA.

“By expanding the produc-

tion of Fyrol HF-5, ICL-IP is

positioned to serve the

changing needs of the uphol-

stered furniture industry,” said

Greg Symes, ICL-IP’s global

business manager for polyure-

thane products.

The company is also

developing a new flame

retardant to replace TDCP in

automotive and other trans-

portation industry applications.

It plans to have this available

in 2013, which will allow

customers in transport-related

segments adequate time to

qualify the replacement

through the Production Part

Approval Process system.

ICL-IP says that it will cease

all production of TDCP by the

end of 2015.

❙ www.icl-group.com

www.compoundingworld.com

news

Toray is to establish a new PA

and PBT compounding plant at

its Indonesia Toray Synthetics

(ITS) subsidiary, located at

Tangerang, Banten Province,

Indonesia. It is investing

approximately ¥600 million

(E6 million) in the 6,000

tonnes/year facility which is

expected to start production in

November 2013.

ITS already polymerizes

nylon and polyester at the

Tangerang site, as well as

producing filament yarns using

these materials. Toray claims

that its new resin compound-

ing plant will be the first to be

established by an engineering

plastics manufacturer in

Indonesia.

The Japanese-headquar-

tered company says that

Indonesia’s annual demand for

engineering plastics is

expected to grow at around 9%

per annum from 21,000 tonnes

in 2011 to 45,000 tonnes in

2020. This growth is being

driven by the expansion of

Indonesia economy and in

particular increased produc-

tion of vehicles and electrical

and electronic products in the

country.

Indonesia’s automobile

production is estimated to

grow from 840,000 units in

2011 to more than 2 million

units in 2020, making it a

major automobile production

base in the region alongside

Thailand. In addition, the grow-

ing wealth of the country’s

huge population of 240 million

people is encouraging

increased local manufacture of

electrical and electronic

products.

❙ www.toray.com

Toray invests in Indonesian plant

RePin Masterbatches of India

has formed a joint venture with

Al Ahli Holding Group (AAHG)

to manufacture masterbatches

in the United Arab Emirates

(UAE) for the Middle East and

African markets. Called

AlwanRePin, the JV is 51%

owned by AAHG and 49%

owned by RePin.

AAHG is a large group with

interests in a broad range of

markets including real estate,

construction, engineering and

retail malls. Its existing

plastics activities are focused

on flexible packaging and bags

which are produced by its Al

Ahli Plastic Industries

subsidiary. Its plant at

Fujairah, UAE, includes a

five-layer blown film line for

making barrier films.

RePin is part of RP

Industries and produces a

range of black, white, colour

and additive masterbatches at

its two plants in northern

India. It has also recently

opened an office in Colombia

to grow sales in Latin America.

❙ www.alwanrepin.com

Indian and UAE groups form masterbatch JV

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news

combines high-end perfor-

mance and a low environmen-

tal footprint, that’s a winning

proposition for players and

planet.”

Merquinsa, a Spanish

subsidiary of Lubrizol, supplies

Pearlthane ECO grades of TPU

with a bio-based content of 32

to 46% and with 82 to 95 Shore

A hardness. The materials has

been developed for the sports

and recreation market and is

claimed to deliver excellent

abrasion resistance and cold

fl exibility combined with

improved hydrolysis resistance

and good adhesion to other

non-TPU shoe components.

� www.merquinsa.com

Nike saves weight withbio-based TPUNike has selected a bio-based

thermoplastic polyurethane

from Merquinsa for the sole

plate of its new light-weight GS

football boot. The Pearlthane

ECO TPU grade has a lower

density then its petroleum-

based counterparts, helping to

deliver a 15% overall weight

saving compared to traditional

sole plate designs.

“The Nike GS is the lightest

and fastest football boot we’ve

ever made and really defi nes a

new era in how we create,

design and produce elite

football boots,” said Andy

Caine, global design director

for Nike Football. “When you

can deliver a boot that

Nike saves weight with

Nike is using bio-based TPU from Merquinsa in its new

GS football boot

Evonik has commissioned a

new compounding line at its

plant in Caojing, Shanghai,

China. This second line triples

the German company’s existing

production capacity for

polyamide compounds in China.

The turn-key compounding

line was supplied from

Germany and will support the

rapid growth in demand that

Evonik is experiencing in Asia

and particularly China from

markets such as automotive,

sports and electronics.

� www.evonik.com

Evonik commissions compounding line

Clean compounding lines and plants are being commissioned to meet the

increasingly stringent demandsof the medical, pharmaceutical,

electronics and food sectors.Jennifer Markarian reports


Clean compounding | processing feature

Compounding plants are generally busy and effi cient

facilities, but they are not well known for being

particularly clean. However, an emerging trend in the

compounding industry is changing this stereotype, and

a growing number of companies are now operating

“clean compounding” facilities.

Although the processes used in clean compounding

have been used for at least 15 years in applications like

optical-quality compounds and medical compounds, the

last fi ve years have seen an increase in demand for

clean compounding and the emergence of new and

more exacting customer stipulations in a broader range

of applications.

One driver for the clean-compounding trend is the

growing industry focus on medical compounding, which

has stringent requirements for eliminating contamina-

tion. Another driver is the need for compounding

high-purity materials that will be used in a cleanroom

or used to produce cleanroom devices or equipment.

The electronics market, for example, has cleanliness

requirements that include specifi cations for outgassing,

non-volatiles, and ionics content, comments Lai Chang

Fong, technical director for Engineered Materials Asia

at PolyOne.

In addition, the trend to smaller, thinner parts makes

fl aws more apparent and creates a need for reduced

contamination. Electronics and medical devices are

good examples of this requirement, but it is also seen in

automotive and lighting as innovation produces smaller,

thinner part designs, notes Susan Brate, general

manager for manufacturing and supply chain at Sabic

Innovative Plastics.

Yet another aspect is the increase in restrictions on

the types of additives going into certain products and the

accompanying requirement to avoid cross-contamination

with the restricted additives, for example heavy-metal

containing colours or phthalate-based plasticizers.

“Customer and OEM demands for more stringent

and formalized manufacturing methods, process

control, and dedicated facilities have defi nitely in-

creased over time,” notes Will Taber, business manager

for emerging technologies at RTP Company.

Medical, food, and electronics applications are key

markets, but others can benefi t as well. “If you carry the

Keep it clean


processing feature | Clean compounding

PolyOne sees

growing

demand for

high-purity

materials used

in cleanrooms

in the electron-

ics sector

RTP’s Ultra

Clean Com-

pounding

Center is

designed to

minimize

environmental

pollutants

clean-compounding model into other applications, you’ll

be way ahead on compliance,” points out Doug Borgs-

dorf, president of Plastics Color Corporation (PCC).

From dedicated lines to complete plantsSome compounders have chosen to dedicate specific

lines or sections of their plant to clean compounding,

which helps efforts to more tightly control incoming raw

materials and reduce contamination. PCC, for example,

runs a 7,000 ft2 (650 m2) “plant within a plant” at its North

Carolina facility, in which the dedicated clean compound-

ing lines produce only FDA-approved materials.

Teknor Apex’s Vinyl Division also runs dedicated,

high-purity facilities for the production of medical

compounds in. In 2008, the company further separated

production of medical-grade PVC compounds contain-

ing phthalate plasticizers from that of medical com-

pounds plasticized with non-phthalate alternatives at

two of its plants in the United States.

RTP established an Ultra Clean Compounding Center

(UCC) in 2009 at its headquarters site in Winona,

Minnesota, USA. It is a 3,300 ft2 (300 m2), self-contained,

controlled manufacturing environment that is designed

to minimize and control the presence of environmental

pollutants such as dust, aerosol particles, and chemical

vapours.

Particles can come in the form of airborne dust from

outside a plant or from materials used within the plant.

“It is important to control not only the contaminants in

the air, but also those on material processing and

handling equipment,” says Taber.

To control contaminants, the UCC has dedicated

extruders and auxiliary equipment, positive pressure

ventilation, high-speed interlocking doors to control

access, and deionised, filtered cooling water. The UCC

also physically separates the feeding and compounding

lines, which is critical in reducing the potential for

cross-contamination due to airborne particles that can

be generated in weighing, mixing, metering, and

feeding. Compounding, cooling, pelletizing, classifying,

and packaging all take place within the contained

environment.

Operators, who have been specifically trained to

work in the UCC, follow good manufacturing practices

for operating and maintaining the equipment, such as a

complete extruder tear-down and clean-out between

every run. The UCC is used to produce compounds to

meet strict cleanliness specifications that cannot be

met in standard facilities.

For example, compounds produced in the facility can

meet requirements such as those for outgassing,

particle generation, and ionic purity (i.e., no anions or

cations that can contaminate a cleanroom) that are

demanded by applications such as some electronics

packaging. RTP also produces compounds in the UCC

for applications in food handling, medical products, and

some industrial applications where customers are

concerned with visible contaminants affecting the

perceived quality of their goods.

Clean compounding can also encompass an entire

plant. In 2010, PCC built a clean compounding facility in

California that is dedicated to medical compounds and

runs under the FDA’s current good manufacturing

processes (cGMP) quality system guidelines. For

example, in this facility, air and water are filtered, and

water baths are drained and UV-sterilized between

runs. All PCC’s facilities have ISO-9001 certification.

Teknor Apex has a clean-compounding plant at St.

Albans in Vermont that runs its Medalist range of

thermoplastic elastomers (TPEs) used in medical

devices. The plant is certified under the ISO-13485

standard for quality management in medical manufac-

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Clean compounding | processing feature

Leistritz says

compounders

can learn about

best practises

from pharma-

ceutical

manufacturers

turing, while company’s Oldbury plant in the UK is in the

process of being certified to the same standard. The

company’s TPE plant in Singapore runs with the same

processes and quality management as the other two

plants and has ISO-9000 certification.

ISO-13485 is a requirement for medical-device

manufacturers, not compounders, but Teknor sought

the certification to provide its medical-device customers

with an extra dimension of quality assurance. “The

comprehensive implementation program required for

ISO-13485 certification has focused our entire St.

Albans operation on processes and procedures that

maximize the safety and reliability of the compounds we

supply to medical device manufacturers,” said Paul

Burke, now vice-president of manufacturing at Teknor

Apex, in a press statement last year.

In a recent interview with Compounding World,

Burke noted that, from the perspective of the com-

pounder’s customers, one of the most important

aspects of ISO-13485 is the management of change,

which gives assurance that a change in the process or

materials will not affect the end product. Testing of

incoming materials, as well as the more standard

testing of the finished compound, is important in

maintaining tight process control. In addition, quality-

control checks during the production run of properties

like viscosity and durometer allow increased control

over the process and product quality, adds Burke.

Clariant has also implemented ISO 13485 standards

at selected plants in Asia, Europe and America. These

include its facilities in Malmö, Sweden, as well as in

Lewiston, Maine, USA, and in Singapore. These three

locations have dedicated lines for medical materials

and can produce “harmonised products” in all three

regions, according to Steve Duckworth, Clariant’s head

of Global Segment Medical & Pharmaceutical.

The three plants produce Clariant’s Mevopur lines of

colour masterbatches and performance compounds for

the medical and pharmaceutical markets. All Mevopur

grades are manufactured using raw materials that

comply with USP parts 87 and 88 (Class VI devices) and/

or ISO 10993 and are produced on segregated com-

pounding lines to reduce the risk of cross contamination

The IS0 13485 standard includes evaluation of risk

potential within the manufacturing process and

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establishing controls to address this. For Clariant, this

covers the formulation of a masterbatch, incoming raw

materials, production processes and the finished

product. Duckworth says that implementing ISO 13485

has taught the company lessons that are also useful in

other markets such as packaging and toys. “It is much

more rigorous that ISO 9001,” he adds.

Equipment designIn addition to dedicating and segregating extrusion lines,

equipment designed to minimize contamination risks

and allow easy cleaning and maintenance is critical in

clean compounding. “When we moved to clean com-

pounding, not one piece of equipment didn’t get modified

in some way,” notes Borgsdorf. While some technology

is available today, further advances in equipment and

process designs are needed, say compounders.

One aspect to consider is the design of the extruder

and the materials of construction used. It is important

to avoid materials that degrade over time and might add

contaminants, notes Sabic’s Brate. In addition, melt

filtration is a common method of reducing contaminants

in the material.

A key to clean compounding is that there is nothing

left behind when you change from one product to

another, which can involve designing equipment to

avoid hang-up points. Newer designs of both dosing

equipment and extruders that allow easier cleaning for

faster changeovers in general compounding applica-

tions also help to achieve the thorough cleaning needed

for clean compounding.

Cleaning and maintenance procedures also need to

be modified to take into account all possible contamina-

tion risks. Cleaning a pelletizer, for example, usually

involves blowing out the pellets with air. This procedure

doesn’t work in clean compounding, because it

introduces the risk of blowing a pellet somewhere it

shouldn’t be, notes Borgsdorf.

When following cGMP guidelines in compounding,

equipment must be cleaned at appropriate intervals and

detailed, written procedures must be followed, noted

Charlie Martin, president of the US operations of

Leistritz, in a presentation explaining the use of

twin-screw extruders in the pharmaceutical industry at

the recent SPE Color and Additives Division conference

(CAD RETEC). cGMP guidelines also require inspections

Cleanroom compoundingSome clean compounding operations that

cater for the most demanding applica-

tions are carried out in cleanrooms.

Examples include the production of

compounds for medical applications,

including polymers containing an active

pharmaceutical ingredient for human

use, implants for the human body, and

some drug-eluting devices (For more

details, see the medical compounding

article in Compounding World, June 2012

– http://bit.ly/MedCompounds).

Cleanrooms can be classified by the

ISO system, which ranges from the most

stringent, ISO 1, to the least stringent, ISO

9, or by a similar FDA cGMP classification.

Biomedical compounds typically must be

compounded in at least an ISO 8 clean-

room, which is equivalent to a class

100,000 cGMP cleanroom.

Foster, for example, produces

compounds for implantable and highly-

regulated polymers in its class 10,000

cleanroom facility in Connecticut, USA.

The room features quartz epoxy seamless

floors, a dedicated fume and dust

collection system, interlock pass through,

gowning room, and temperature and

humidity controls.

Compounding of polymer blends with

active pharmaceutical ingredients must

be performed under cGMP standards and

must follow 21CFR Parts 210 and 211,

explains Tony Listro, managing director

at Foster Delivery Science.

For example, any part in contact with

the drug materials, including screws and

barrels, must be either dedicated to that

drug or undergo a validated cleaning

protocol before use in other applications.

In addition, the equipment must use

FDA-approved lubricants, and the

product-contact parts must be non-reac-

tive and non-absorptive.

Foster develops and produces compounds under clean conditions in Connecticut

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for cleanliness and records of both cleaning and

inspection. Martin noted the compounding industry can

benefi t from auditing and selectively implementing

practices of pharmaceutical manufacturing companies.

Limiting human interaction with the product through

automation is another way to reduce contamination. At

PCC’s clean compounding facilities, operators are

involved in blending, but extrusion through pelletizing and

packaging are all automatic, says Borgsdorf. Automation

can also be applied to process data acquisition. RTP, for

example, notes that its automated data acquisition

system allows detailed monitoring and traceability.

The human componentAutomation, however, cannot replace the need for

operators that are highly trained and understand the

value of running a clean compounding plant. “The

methods that you use to run processes and having

trained and disciplined managers and operators are

even more important than equipment modifi cations,”

comments Burke.

“Operators need to understand the specifi cations

and the impact of correctly following procedures on

product quality. With our operating teams, an in-depth

FMEA (failure modes/effect analysis) is a good tool. This

type of risk analysis increases understanding of the

procedures, the potential points of failure, and the risk

mitigation points,” adds Brate.

“It comes down to the people in the end,” says

Borgsdorf. “You need to value your employees and their

input. As our operators got to know the system in the new

clean compounding plant, they suggested modifi cations

to make it even better. We couldn’t have been successful

without management listening to the operators and giving

them the ability to operate as was needed.” Listening to

customers is another critical aspect for success. “The

industry needs to change its old mentality that would not

want customers to come into a manufacturing plant.

Several times a month, we now have customers coming

to perform audits, and we gladly listen to their sugges-

tions to help make our process better and even involve

them in long-range planning,” says Borgsdorf.

More informationDoug Borgsdorf of PCC will be speaking about human

factors at the Thermoplastics Concentrates 2013

conference which takes place on 29-31 January at the

Fort Lauderdale Marriott Coral Springs Golf Resort in

Florida, USA, on 29-31 January. He will join an impres-

sive line-up of speakers featuring experts from

throughout the masterbatch supply chain. For full

details, visit http://bit.ly/TC2013.

Click on the links for more information:

� www.polyone.com� www.sabic-ip.com � www.rtpcompany.com � www.plasticscolor.com� www.teknorapex.com� www.leistritz-extrusion.com � www.fostercomp.com

Clean com-

pounding

depends on

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Continuous and batch mixers | processing feature

Mikell Knights reviews recent developments in batch and continuous mixers for use in the production of compounds and masterbatches

The suppliers of batch and continuous mixers are

developing new and enhanced models to meet the

changing demands created by the latest material

formulations. These include the production of

compounds and masterbatches with higher additive

loadings, as well as those containing sensitive

bio-based ingredients or nano-scale fi llers and

reinforcements.

New mixer developments are also addressing

the growing demand for processing smaller

batches that use more expensive ingredients. Other

drivers for change include demands for greater

processing versatility, machine modularity, higher

throughputs, simplifi ed cleaning, quicker changeo-

vers, faster heating, enhanced cooling and energy

savings.

Over the following pages we review recent mixer

developments from Ross, Marion, Mixaco, Plas Mec,

Henschel, HF Mixing Group and TPEI. These include:

multiple agitators in a single planetary mixer for

enhanced processing; the use of microwave heating

elements for faster ingredient heating without shear;

pressurized water cooling circuits for unprecedented cool

down; mixer chamber bag liners that cut cleaning

requirements; new mixing tool designs that improve

productivity; and, more powerful motors that

raise output.

Better batchesRoss Mixers has expanded its line

of hybrid planetary mixers that

process high-viscosity and

high-solids formulations. Its

Planetary Dual Dispenser Mixers

(PDDM) feature two planetary

stirrers and two high-speed

dispersers that rotate on their own

axes while revolving around the mix

vessel. The stirrers continually turnover

the batch of material, feeding product to the high-speed

dispersers, and promoting heat transfer throughout the

different areas of the mixing zone. Stirrers can either

be rectangular-shaped paddles or helical high-viscosity

blades.

Each disperser shaft is equipped with saw-tooth

blades that provide an intensive shearing action which

is ideal for rapid solids dispersion and particle size

reduction. Sidewall and bottom scrapers eliminate

material build-up and ensure formulation and tempera-

ture uniformity.

“This unit, our newest offering, has the high-speed

mixing power of a stand-alone disperser, but the

planetary design allows it to process highly viscous

formulations and not only materials that are fl owable,”

says Christine Banaszek, application engineer at Ross.

In addition, the PDDM offers precise control over shear

Stir it up with the latest mixers


processing feature | Continuous and batch mixers

levels and flow patterns because the agitators are

independently driven and controlled.

Shear-sensitive materials such as syntactic foams

and other microsphere-filled composites, as well as

abrasive and extremely viscous compounds would

typically be run on a more traditional planetary mixer

which does not feature the dispersers. These applica-

tions can be run on the PDDM since the disperser

shafts are easily removable, allowing the unit to

function as a classic Double Planetary Mixer, says

Banaszek. The PDDM line comes in a wide range of

sizes from 2 to 750 gallons (8 to 2,800 litres).

Ross also offers a new ultra-high-shear inline mixer,

called the MegaShear, which is designed for very

aggressive particle size reduction, homogenization and

emulsification. Typical applications of the MegaShear

include specialty coatings, polymers, lubricants, inks and

adhesives. “In plastics production, the MegaShear is very

effective for soft polymer disintegration, wherein you

reduce the particle size of a solid polymer suspended in

liquid or dissolve the polymer entirely,” says Banaszek.

The MegaShear rotor turns at tip speeds over 11,000

ft/min (3,400 m/min), within a close-tolerance stator, and

subjects the material to thousands of intense mechanical

and hydraulic shearing events in a single pass.

The stainless steel mixing chamber is designed for

150 psig (11 bar) internal pressure at 250oF (120oC).

Being an inline device, the MegaShear can be operated

continuously in a true single-pass configuration or

piped to a batch tank for recirculation.

Ross has also introduced a new unit ideal for

laboratory and pilot-scale requirements. With a

maximum working capacity of one cubic foot (28,000

cm3), the new 42NSD-1S model is a multi-purpose

blender equipped with interchangeable double ribbon

and paddle agitators.

The unit is commonly used for blending dry powders,

granules, pellets and other solid forms, but it can also

handle wet materials such as pastes and slurries. The

standard agitator features inner and outer helical

ribbons that are pitched to move material axially, in

opposing directions, as well as radially. The double

ribbon agitator is used in most applications for fast and

thorough blending while a paddle agitator is utilized for

lower impact mixing of friable and shear-sensitive

materials. Either agitator design is suitable for coating

a liquid or very fine solid component throughout the

surfaces of larger particle ingredients.

The 42NSD-1S vacuum-rated blender comes with a

discharge extruder assembly (auger) installed along the

bottom of the trough to enhance mixing, eliminate dead

zones, and ensure complete discharge of material.

❙ www.mixers.com

Marion Mixers is a supplier of custom-designed mixing

and drying equipment. For more than 75 years it has

been designing and manufacturing equipment for

plastic processors involving many different applications.

There is growing interest in designs that feature paddle,

ribbon and hybrid style agitators, says Scott Jones,

marketing manager.

The company’s paddle style agitators, which are

offered in either sanitary-welded or easily removable

bolted-blade styles, provide a great deal of versatility,

says Jones. The paddle agitators mix materials of

dissimilar size, shape or density in a gentle lift-scoop-

tumble figure-of-eight pattern inside the vessel. This

design can be used with batch sizes that fill the

chamber from 20% to the full mixing capacity of the

unit. A 0.20 inch (5.1 mm) blade clearance to the inner

trough wall is said to deliver excellent clean-out

between batches regardless of batch volume.

This design pulls material to the middle of the

agitator for more intensive mixing, which is ideal for

blending fragile, friable or oversized ingredients, or for

mixing solids of various particle sizes, densities and

Above left:

Ross designed

this double

agitator mixer

for lab-scale

processing of

dry powders,

granules and

pellets

Above right:

The PDDM

mixer from

Ross features

newly designed

stirrers,

dispersers and

sidewall

scrapers



viscosities. This design can be used in Marion’s batch or

continuous mixers, says Jones.

The company also offers ribbon style mixers for use

with low-density free-flowing plastics materials. It is a

double-ribbon style design, which includes two sets of

flights on both the inner and outer mixing tool spirals.

The inner ribbons push product towards the end plates,

while the outer ribbons move material towards the

centre. The company also offers a hybrid mixer

featuring paddle- and ribbon-style mixing elements,

suitable for coating ingredients and for free-flowing

particles with similar particle, density and shape. The

additional flights are said to provide twice the mixing

action of a single ribbon mixer.

Marion is also bringing a novel microwave heating

approach as an option for its plastics and pigments mix-

ing unit. The microwave technology, which the company

offers through a licensing agreement with the Univer-

sity of Northern Iowa, can deliver faster and more

uniform heating and drying to ingredients.

This approach, initially developed as a solution to turn

oil into grease, may allow plastics processors to trim

batch processing times, saving money and also attaining

better heat control versus conventional thermal

temperature approaches. Jones says several tests with

plastics ingredients are ongoing in its lab and the

company would welcome additional industry suggestions

for application testing.

The microwave mixer features a transmitter, mixing

vessel, waveguide system and controls. Transmitters

typically range from 30-100 kW in power operating at

915 MHz. The stainless steel microwave mixing vessel is

ideal for compounds and powders.

❙ www.marionmixers.com

Mixaco Maschinenbau developed its Speedy SD line of

sack/drum mixers for small batch mixing between

15-55 lb (7-25 kg) of dry solids and additives, and now

they can also be used for liquids. Material formulations

are secured in a double-walled sack that is placed in

the mixing container which serves as the transport-,

mixer- and storage-container for the material. The

mixer and mixing sack do not have to be cleaned since

the mixed material is not transferred, saving cleaning

time. A standard mixing barrel can also be used in place

of the mixing sack, although cleaning will be required.

Round containers eliminate dead space, allowing for

full low- and high-intensive mixing in the mixing sack,

says Markus Frantzen, general manager at Mixaco’s US

subsidiary in Greer, SC.

A multiple winged-blade mixing tool is lowered

pneumatically into the drum for intensive mixing and is

retracted after mixing. Speedy SD 50 (50 litre) and SD

100 (100 litre) models have been added to a line-up that

includes the Speedy S50 and S100 sack models plus the

Speedy D60 drum version. The main advantage is the

quick change-over time for different formulations.

Mixaco has also improved the efficiency of its

Multi-Tool (MT) container mixer, which is designed for

the processing of temperature- or shear-sensitive

materials with little to no heating. The Container Mixer

MT uses a modular mixing tool arrangement that creates

two material flow ‘currents’ in the mixer. The primary

current continually transports material in a conveying

action from the outer section of the chamber into the

active secondary current that contains a chopper-style

drive. The combination of both mixing currents ensures

fast mixing and excellent dispersion, says Frantzen.

The Container Mixer MT only increases the product

temperature at a rate of 0.5 to 1˚C per minute, which is

far less than conventional mixing tools. The mixer is

suitable for powder coating premixes with low melt

temperatures, producing masterbatch and PTFE

premixes, and for mixing additives in powder and

granulate form. The main advantages are said to be

higher machine availability, better dispersion, quicker

changeovers, and very low energy consumption

compared to conventional mixing systems. In addition,

the MT tool system allows customers to produce a

wider range of batch sizes in the same mixer model.

Container Mixer models range from 15 to 4,000 litre.

Mixaco has also renamed its Heating-Cooling Mixer as

the Heating Mixer Cooling Mixer EC-Revolution (HM-KM-

EC Rev) unit to reflect the improved energy savings gained

Marion Mixers

offers a wide

range of

agitators

including

easy-to-clean

welded blades

COMPOUNDING WORLD | November 2012 www.compoundingworld.com30


The TRR series is designed to cold mix polymers in

powder or granule form with pigments or additives. It

can process ingredients for colour masterbatches,

powder coatings and pre-mix powder formulations. It is

said to be an ideal alternative to conventional turbomix-

ers, when production conditions require a wide range of

different products to be mixed with the same machine,

according to Plas Mec CEO Marco Marinello.

The TRR models now features a simplifi ed, more

user-friendly interface, while mixer cleaning has been

rethought to be more effective. The machine’s design

divides the mixer and storage container into two

separate units, which helps to reduce contamination

and improve cleaning time. Stainless steel is used in the

mixing head chamber, mixing hopper, and the tooling.

Plas Mec offers seven models in the line ranging from

150 to 2,000 litres of capacity, and able to handle 60 to

1,000 kg of material.

Plas Mec’s TRM line of high-speed mixers for PVC

dry-blending (either rigid or plasticized) features new

mixing tools, a special hard stainless steel, and the use

of the latest variable frequency drive technology. The

new mixing tool type provides optimum mixing with a

large variety of clear, non-clear, soft, semi-soft and

rigid materials. Plas Mec says the vessel lid can be

supplied in different confi gurations for horizontal or

vertical opening.

The models can also be used for densifi cation or heat

agglomeration of other thermoplastics, such as ABS, PE

and PP. In addition, they can be used for the drying or

Batch mixing of

dry solids,

additives or

liquids from

15-55 lbs with

fast change

over between

formulations

are benefi ts of

Mixaco’s

Speedy Sack/

Drum (SD)

mixer

The TRR mixer

series from

Plas Mec is a

more versatile

alternative to

conventional

turbo mixers

from a tool-less type cooing mixer. Designed primarily for

PVC compounding, the unit incorporates Mixaco’s EC

Revolution Cooling mixer technology that cools without

any tooling in the mixing chamber.

The mixing bodies are in the shell of the chamber

and rotate around their own axis, therefore increasing

the available cooling surface for quicker cooling, says

Frantzen. A conventional cooling mixer typically

features a horizontal shaft with plough tools on them. In

this approach, water-cooled modular cooling elements

cool without introducing mechanical energy into the

product, which adds no additional heat. The tool-less

cooling mixer has a cooling jacket, large internal

cooling elements, and optimized water supply that

creates an enlarged cooling surface while reducing

design size and drive power requirements.

The mixer is said to be maintenance friendly and

reduces energy consumption signifi cantly, as the design

requires no tooling, no mixing drive, and no mixing

shaft seals. The novel discharging feature of the mixer

ensures complete material discharge. Frantzen says

customers experience shorter cooling times compared

to traditional cooling mixers. The HM-KM-EC-Rev

design features a high-intensity hot mixer with

improved high-intensity wear-coated tooling as well as

several vessel lid and discharge valve options.

� www.mixaco.com

Plas Mec expects that recent upgrades to its TRR and

TRM series of batch mixers will deliver 20% higher

productivity, 15% lower energy consumption, and 50%

more fl exibility. The company has designed a new type

of mixing tool for both models, and has also introduced

other upgrades to improve performance.

>>The advance into a new performance dimension of compounding technology. The new ZSK Mc18 twin screw extruder of Coperion, formerly Werner & Pfl eiderer, is the most pro-ductive high performance ZSK of all time. With a specifi c torque of 18 Nm/cm3 it stands for considerable throughput increases with improved product quality and the widest processing window on the market – to provide you with a unique technology advantage. That’s what we mean when we say “confi dence through partnership”. >>www.coperion.com

>compounding & extrusion >materials handling >service

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the hot or cold distribution of pigments. The TRM is

offered in 12 models ranging in size from 200 to 2,500

litres, and formulation weights from 85 to 1,050 kg.

❙ www.plasmec.it

Henschel, a division of Zeppelin Reimelt, has launched

a new cooler mixer for rigid PVC compounding. It is

claimed to deliver very short cooling times together

with fast feeding and discharging times. The Horizontal

Cooler Efficiency (HCE) series relies on newly developed

mixing container geometry, redesigned mixing tools,

and a reconfigured discharge unit that makes it possible

to increase the throughput by 30-40% for the same

machine size or to shorten mixing times when process-

ing similar volumes. A throughput of 11 batches per

hour can be achieved.

The extremely effective cooling of the HCE line is

achieved through the use of a newly designed water

jacket installed in the body of the cooling mixer. Cooling

water chambers and pipes in the mixer body achieve a

higher degree of turbulent flow because the cooling

medium is delivered under high pressure, says

Christian Tittensor, Henschel’s sales and marketing

manager, North and South America, rubber and plastic.

The system can handle operating pressures up to

7 bar, which allows for very large flows of cooling water

and a higher heat exchange rate. Conventional systems

using cooling channels deliver the water under

0.5-1.0 bar typically, says Tittensor. In addition, the

mixing bowl and other components of the HCE line are

made entirely out of non-corrosive stainless steel, and

product contact surfaces are highly polished to prevent

material build-up. Integration of the mixer to the water

supply system is easy and not expensive.

The mixing tools used in the HCE are of a new design

to provide excellent mixing, and the tools themselves

also feature a cooling circuit running through them. The

helical structure of the new tools allows for extremely

close contact of the mixture to the cooled mixing bowl.

Cooling water is supplied to the tools through the

mixer’s drive shaft.

The charge/discharge opening has been completely

redesigned as a large lid that is easier to open and close.

The overall height of the mixer has also been reduced

due to the lower height of the discharge housing.

The HCE, shown at this year’s NPE show in Orlando,

is currently offered in five sizes that handle from 1,700

to 6,000 litres. Zeppelin Reimelt’s Henschel division

also offers the HC line featuring the same develop-

ments shown on the HCE, but without a water cooling

circuit in the helical tools.

A new small batch mixer offering superior mixing in

a short time, along with rapid product changeover and

short clean up times is also new from the company.

The Container Mixer Inliner (CMI) features a thick

plastic liner placed inside the vessel that contains the

formulation during mixing and becomes the transporta-

tion device for the mixed material after processing. The

mixing container is designed with a basket structure

that keeps the liner in place by fixing the liner in the

square openings (golf-ball effect). Users can tie the bag

up and store the mixture for future use or bring it to a

compounding extruder or downstream unit for further

processing.

CMI is designed for the production of pre-mixed

powder coatings, mixing of colour concentrates and

masterbatches, and for the homogenizing of free-flow-

ing bulk materials. Mixing is achieved using a rotating

mixing tool that is supported by a counter-rotating

mixing drum.

When the mixing drum and liner are attached, the

drum swivels 120o on a horizontal axis, so the material

comes into contact with the mixing tool. Container

clamping and rotation are electronically monitored. The

Above left: The

Henschel HCE

Cooler mixer

from Zeppelin

Reimelt can

boost PVC

compounding

productivity

Above right:

The Container

Mixer Inliner

from Zeppelin

Reimelt is

suitable for

small batch

mixing

applications

Images courtesy of: Dow Chemical Company * + 19% German VAT

Organised by:Applied Market Information Ltd.

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material is homogenized solely by the rotation of the

container.

Users can remove the liner with the mixed material

and install the next liner and formulation quickly. A

Tool-Click feature allows users to remove and replace the

mixer drum tool with a clean tool in minutes. Three sizes

from 75 to 450 litres are available with additional sizes

planned for introduction over the next several months.

❙ www.zeppelin-systems.com

Continuous improvementsHF Mixing Group is implementing a range of enhance-

ments to its Compact Processor series including a new

icon-based control interface and higher rotational

speeds for increased throughput. The CP Series II is

comprised of an independently controlled FCM

non-intermeshing dual-rotor continuous mixer

integrated with a single-screw extruder. It will be

upgraded with an easier to use icon-based control

panel mounted on a swing-arm.

At the same time, the company is upgrading its

motors to extend the throughput of the line. Launched

last year, the CP 550 model produced 500 kg/h (227

lb/h), but thanks to more powerful motors is now

capable of up to 700 kg/h (318 lb/h), says Steve

Peterson, vice president and business unit director.

New, harder surface liners are also being developed to

improve the handling of highly abrasive materials, such

as PE formulations with 80% calcium carbonate.

The CP line is designed specifically for the disper-

sion of polymer compounds with high levels of mineral

fillers, additives and pigments, polymer-elastomer

blends and for applications requiring high intensity

mixing at low processing temperatures. The mixing

chamber features a segmented construction for

processing flexibility, and zoned heating and water

cooling across its short 3.5:1 L/D for controlled heat

transfer. It also has a hinged clamshell design for easy

access to the mixing chamber and for straight-forward

cleaning and part replacement tasks. A replaceable

tool-steel liner is resistant to abrasive materials.

Harburg-Freudenberger (HF) Maschinenbau, a

German manufacturer of batch mixers for rubber

processing and continuous mixing technologies,

acquired Farrel as well as the batch mixer business of

Italy-based Pomini Rubber & Plastics, then renamed the

overall entity HF Mixing Group-Farrel/Pomini. The firm

recently reshuffled its assets into business units. All of

the continuous mixing activities are centred in Ansonia,

Connecticut, USA, with development and testing

laboratories in the USA and England, while the batch

mixing assets from Farrel and Pomini (including the

Banbury and tangential mixer) will be based in England.

Farrel says that it has added the latest rotor

technology to its Banbury mixer. The NST rotor

performs better than the proven ST design, utilising a

novel helical four-wing geometry that enhances

material circulation axially within the chamber and

results in higher material flow and shear intensity.

The new distributive rotor design is said to improve

product uniformity by up to 70% compared to two-wing

rotors, or 65% better than other four-wing rotors.

Productivity is said to be up by 14% compared to

two-wing rotors, and 6% higher than four-wing designs.

The physical properties of the product are also said to

be significantly improved when mixed using the NST

style rotors.

Farrel has also upgraded its F305 and F440 Banbury

mixers to provide 5% and 8% more free volume in the

same footprint compared to its F270 and F370 units

respectively. Combined with the NST rotors, the new

chambers can mix additional volume of a formulation

using less power.

❙ www.farrel.com

Technical Process & Engineering (TPEI) has introduced

a new continuous mixer scaled down for laboratory

trials. “We used to use our two inch [5 cm] rotor

diameter line as a scale-up model, but that requires a

minimum of 50 lb [23 kg] of material to run. Customers

looking to test very expensive engineering or medical

grades are looking to run a pound or two of material,”

says CEO Harold Schafer.

The company’s latest models, the 1FR and 1FRE, can

process 1-50 lb (0.45-23 kg) of material using two

non-intermeshing rotors with a diameter of 1 inch (2.5

cm). TPEI’s continuous mixers employ a ‘free rotor’ con-

cept, unlike more conventional designs where the rotors

are integral with the bearing housing. With a conven-

tional rotor, a user must open the bearing housing in

order to remove the rotor. With a free rotor, opening the

bearing housing is not required. The rotor is free from

HF Mixing

Group is

upgrading the

Farrel CP550

Compact

Processor to

deliver higher

throughputs

Germany

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the drive bearing block and is held with couplings.

The new lab line joins a product line-up ranging from

2 inch (5 cm) diameter rotors (2FR) through 9 inch (23

cm) rotors (9FR). Output ranges from several lb up to

15,000 lb/hr (68,000 kg/h) depending on model. Each

model in the line has a 5:1 L/D and features two heating

zones and three cooling zones for extremely tight

temperature control.

The new lab model features a brand new rotor

design, which will eventually be scaled up for larger

machines. They will join the two standard No. 7 or No.

15 rotor styles that TPEI offers for processing a wide

range of materials, especially formulations with

loadings up to 80%.

The rotor designs, temperature zones, and variable

rpm control allow processors to put a little or a large

amount of energy into the product without having to

change rotor elements, allowing the unit to process PE,

PP, PVC and other materials.

Protecting pigments“We ran trials using aluminium pigments where the

customer did not want the aluminium scuffed,” says

Schafer. “A continuous mixer like ours can process

without scuffing, because this mixer type works with a

fairly large clearance between the wall and rotor itself.

With an intermeshing twin-screw, the tolerance

between screw and chamber wall is tighter,” he adds.

These rotor styles are offered for all rotor diameters in

its Free Rotor line.

The No. 7 and No. 15 rotors can run the same

materials, but the rotor selection depends on the model

size it is used with, and what you want to do with the

material. “If you have a PE and you want to put a

foaming agent in that kicks off at a certain temperature,

you’ll want the material to stay as cool as possible when

processing. A No. 7 would lower the output, but yield a

better quality for that specific product. If you were

running a green PE masterbatch or colour concentrate,

you would put in the No. 15 for maximum output. Trials

would determine the best rotor design,” says Schafer.

TPEI also offers the Free Rotor models in an

‘extended’ version (FRE) where two additional flights

are added for conveying, and the feed-throat is opened

up to better facilitate the flow of materials into the

machine. The enhancements speed up the compound-

ing process in the mixer and raise throughput by 20%

while extending the unit to 9:1 L/D.

TPEI is considering lines with even larger diameter

rotors, and has a 15 inch (38 cm) line (15FR) in develop-

ment. Applications will vary depending on customer

demand, but the initial targets include large automotive

or recycling applications where there are really high

volumes of material using mineral fillers, glass fillers,

and even low-bulk density materials. TPEI is also

looking into new rotor geometries for bioplastics and

nano-compounds.

The company offers custom material feeding

solutions for its continuous mixer. Its special J-Block

unit transfers discharge from the mixer into an

extruder, and it offers its own extruder design. The

continuous mixer can be included as part of a turn-key

system designed for a wide range of thermoplastics.

❙ www.tpei.com

TPEI can build

complete

turn-key

compounding

lines around its

continuous

mixers

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© Plastribution Limited.

All rights reserved. 2011

On the basis of the vast range

of classifications currently used,

Plastribution has chosen to employ

simpler and clearer terminology for

greater transparency:

PrimeAs it comes from the polymerisation

plant, and within a published

specification.

Off GradeAs it comes from the polymerisation

plant, but does not conform to a

published specification.

CompoundMaterial within which additives have

been incorporated by means of a

compounding process.

Pre-consumer Waste

Thermoplastic material that is a waste

by-product of an industrial process.

Post-consumer Waste

Thermoplastic material which has

been recovered from a consumer

item that has reached the end of its

intended use.

In the event that you require further

information, or need to comply with

specific requirements in terms of

post-consumer waste concentration,

please do not hesitate to contact a

member of the Plastribution team for

further information on 0845 3454560 or

[email protected].

One of the core values of Plastribution is its expertise – something that all of its suppliers and customers know they can rely on.

Industry know-how is a series of articles from Plastribution, exclusively available to the readers of Injection World and on its website www.plastribution.co.uk, that shares this expertise to provide essential background on some of the common terminology and practices used within the plastics industry.

Whether to cover gaps in knowledge where high levels are assumed, or to provide clarity where terms of reference have become confusing, Industry know-how aims to provide clear explanations and, where appropriate, thought leadership to support industry growth.

In this first article, it addresses the wide range of terminology relating to the classification of thermoplastic raw materials that has evolved over time, and Plastribution’s approach towards transparency.

By definition, thermoplastics are

a group of materials that can be

repeatedly melted by the application

of heat (or thermal energy), shaped

into the required product, part or

component, and ‘frozen’ to retain

that shape through sufficient cooling.

This process leads to a thermoplastic

having a ‘thermal history’.

Because thermoplastics can be

reshaped upon reheating a number

of times, they are considered to be

recylcable. Yet thermoplastics also

demonstrate varying degrees of

thermal instability.

Particularly at temperatures where

they begin to melt or soften, thermal

degradation of the polymer can start

to affect its properties, with this rate

of change increasing further if shear is

also applied.

For the moulder this means that great

care should be taken in selecting

the correct quality of material for

a specific application, where, for

instance, a prime grade of material

may be preferred to ensure the

delivery of properties as specified on

data sheets.

This particularly applies to plastic

components that are exposed

to hostile environments including

contact with chemicals and at

elevated temperatures.

Care should also be taken with

materials containing additives such as

fillers (see separate Industry know-how

fact sheet on ‘Regrind Guidelines’)

For various reasons a wide range of

terminology has evolved to describe

the quality of the original polymer and

materials that have been recovered

or recycled. As can be seen from the

table, this can lead to confusion.

Moreover, an increase in both

consumer pressure and government

legislation has promoted the use

of recycled plastics, and more

specifically recycled post-consumer

waste, thereby adding to the list of

materials available to choose from.

Plastribution is the UK’s leading distributor of plastics raw materials, delivering reliability, know-how and true business partnership to the world’s best polymer suppliers and our UK customers.

PLASTRIBUTION TERMINOLOGY INDUSTRY TERMINOLOGY

Prime Virgin, Prime

Prime Compound Compound

Off GradeWide-spec, Off Grade, Near to Prime, Second Quality, Second Choice

Off Grade Compound Industrial

Post-consumer wasteRepro, Reprocesses, Recycled, Reclaimed, Re-engineered

Pre-consumer wasteIndustrial, Repro, Recycled, Re-engineered

Prime + Post-consumer WasteRepro, Blended, Industrial, Recycled Content

Prime + Pre-consumer WasteRepro, Industrial, Blended, Recycled Content

Off-Grade + Post-consumer WasteRepro, Blended, Industrial, Recycled Content

Off-Grade + Pre-consumer WasteRepro, Industrial, Blended, Recycled Content

PLA0031_Industry know-how.indd 1-2 28/12/2011 14:37

Global conference on minerals as additives, pigments and fi llers in polymers

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Carbon black | additives feature

Carbon black suppliers aretuning morphologies to improve processability and performance.

Pat Toensmeier reports

Thermoplastics account for only 5% of the global

market for carbon black, but these applications are

powering innovations in formulations.

Despite the economic slowdown in many regions, the

use of carbon black in thermoplastics should increase

by 4.6% this year over 2011, and maintain average

annual growth of 4.5% through 2015, according to

fi gures from Notch Consulting Group’s 2012 Workbook,

which were cited by Birla Carbon.

This means that in 2012, the carbon black market for

thermoplastics is expected to top out at 552,000 tonnes.

If growth continues as projected, demand could account

for 630,000 tonnes in three years.

The markets driving consumption in thermoplastics

are mostly conventional end-uses: pipe, wire and cable,

automotive applications, industrial parts with conduc-

tivity requirements, food packaging, agricultural fi lm

and electronics.

The real demand driver, however, is geography,

notably the build-up of industry and markets in Asia and

South America, as investments continue to grow in

infrastructure and manufacturing. Another growth area

is the Middle East where sales of plastic pipes to the oil

and gas industry remain strong and could be buoyed by

recent offshore oil and natural gas fi nds in the eastern

Mediterranean.

In Asia, China has become the world’s second-larg-

est plastics producer after the US, and is a major

consumer of carbon black as it develops its automotive

industry, invests in infrastructure (pipe, wire and cable)

and upgrades agriculture (fi lm and irrigation pipe).

Elsewhere in the region, India’s plastics industry is

growing at a rate of 15%/yr., according to reports,

creating signifi cant demand for similar reasons.

Add to this market growth in Eastern and Central

Europe, along with improving demand in North America,

and it’s little wonder that carbon black producers are

optimistic about the near-term outlook for business.

Some of this optimism is refl ected in capacity

expansions. Cabot, considered to be the world’s largest

supplier of carbon black and masterbatches, has been

building up operations in China for several years. The

company is already expanding a newly opened (2012)

research laboratory in Shanghai, and in 2011 added

45,000 tonnes of masterbatch manufacturing in Tianjin,

where an undisclosed amount of additional capacity is

planned.

“Our recent focus has been supporting the develop-

ment of the plastics industry in China,” says George

Haines, global segment product manager for plastics.

Much of the work that Cabot is undertaking in China is,

Building new benefi ts for carbon black


additives feature | Carbon black

from a technical standpoint, critical to the country’s

success as a global supplier of manufactured goods, he

adds. “Providing the latest carbon black technologies

and capabilities is important, particularly since China is

adopting many international standards — ISO among

them — but also because many of the products it makes

end up in Europe or the US.”

Timcal, which specializes in conductive carbon

blacks, is investing in its Willebroek, Belgium, plant to

“significantly increase” production capacity, according

to Christine Van Bellingen, product manager of carbon

black and graphite for polymers. Timcal isn’t releasing

expansion numbers, but Van Bellingen says the move is

in response to growing demand from polymer and

battery markets.

Discussing the US market, Jan Kozma, vice president

of black masterbatch supplier Modern Dispersions,

says: “We are seeing more demand as the economy

recovers from its recession. Automotive is coming back,

along with pipe, food packaging, geomembranes and

agricultural applications such as irrigation tubing.”

Modern Dispersions is encouraged enough by growth

in the US and elsewhere that it recently completed an

expansion of production at its Fitzgerald plant in the

state of Georgia. Amit Dani, the company’s technical

director, doesn’t reveal numbers but says the increase

is in the range of 10-20%.

New product developmentsMost of what is emerging from new and upgraded

formulations, or being covered by capacity expansions,

is not only for targeted markets, but increasingly

specific product needs within those markets. Require-

ments here include regulations from Europe and North

America that cover product use in critical and hazard-

ous environments, better performance under dynamic

operating conditions, and greater shielding of sensitive

electronic components in a variety of applications.

“The key driver [in our product development] is

providing customers solutions and a competitive

advantage in their applications,” says Natalie Harris,

who is North American technical service manager for

Birla Carbon, a unit of India’s Aditya Birla Group.

Recent developments at Birla include products that

increase UV protection in pipe and cable jacketing, and

conductive grades that meet growing standards for

insulation, electrostatic discharge and antistatic

properties.

Harris says that features of these carbon blacks

include greater dispersibility through tailored morphol-

ogy, process enhancements, and improvements in

product cleanliness.

Most suppliers continue to focus on morphology and

other material development techniques to improve the

process efficiency of their grades while maintaining or

increasing performance.

One way of doing this is by fine-tuning cleanliness and

dispersibility, which have, of course, always been key

properties of carbon black formulations, especially in

conductive compounds. They are particularly important

when it comes to meeting the performance, productivity

and cost needs of compounders and end-users.

Van Bellingen, for example, says that Timcal’s

process routinely produces the company’s Ensaco

grades with low sulphur and ash content, thus enhanc-

ing cleanliness. The materials also achieve surface

smoothness and dispersibility, and retain mechanical

and flow properties through compounding.

This means that the materials can rival the perfor-

mance of more costly specialty grades such as extra-

conductive carbon blacks, including those made by

Timcal. The latter are engineered to meet conductivity

requirements at up to half of a usual loading, which is

important when additional properties such as weldabil-

ity or foaming are necessary. With a very high structure

and surface area, these specialty grades meet conduc-

Cabot’s new

carbon black

plant in Tianjin,

China, is

helping to meet

growing

demand in Asia

Infrastructure

investments

are driving

growth in pipe

applications for

carbon black

PH

OTO

: OR

ION

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tivity requirements at lower loadings. Nevertheless, Van

Bellingen says that compounders can have process

efficiency, performance and economy at higher loadings

without using extra-conductive grades.

One example she cites to back this up is Ensaco

250G, a conductive carbon black with an “unusual

combination of high structure and low surface area,”

which stems from Timcal’s production process. As a

result of its cleanliness, dispersibility and properties

retention, the grade can be compounded efficiently and

at less cost than an extra-conductive material that is

more difficult to disperse than a lower-surface-area

carbon black.

“This clearly highlights the importance of having

good in-bulk dispersion, and the fact that working with

the lowest additive level is not necessarily giving the

best overall performance versus higher loadings of

easy-dispersible black,” Van Bellingen says. Impor-

tantly, she notes, “The in-bulk dispersion of an additive

will orient the final mechanical properties of a formula-

tion, whatever the loading of the additive.”

The Ensaco 250G grade has other benefits as well.

One is low water content (maximum 0.3% in a saturated

atmosphere), owing to its low surface area. Van

Bellingen says this means it can be readily mixed with

water-sensitive polymers and doesn’t require a drying

step before use.

The surface area also helps reduce the viscosity

increase that accompanies a high structure. “At equal

volume resistivity, a compound filled with a lower-sur-

face-area carbon black will have a higher melt-flow

index (MFI) than a compound filled with a higher-sur-

face-area black, even though the percentages of carbon

blacks might be different,” she notes.

Another supplier working to upgrade carbon black

through morphology and other process technologies is

Cabot. Citing an established trade-off concern with

additives, Haines remarks that a carbon black loading

necessary for conductivity can adversely affect a

compound’s mechanical performance. “We continue to

look at particle size, structure and surface treatments

to find the right balance to help customers achieve the

desired conductivity without sacrificing mechanical

performance,” he says. “The key factors driving this are

the need to improve the cost-performance balance of

end-use product while meeting ever-expanding

performance requirements in existing and new

applications.”

In the presentation, at AMI’s Masterbatch 2011

conference held in Vienna, Austria, in June, Cabot

stressed the importance of expanding carbon-black

performance through morphology and improving

functionality with enhanced surface treatments to

reduce trade-offs. Advances in morphology are being

pursued to avoid trade-offs in loading and viscosity, and

to improve viscosity and dilutability with minor material

reformulation. Surface treatments, meanwhile, are

being pursued to increase carbon black wetting, its

selectivity in multiphase systems, hydrophobicity and

surface smoothness.

In the presentation the company disclosed findings of

a polystyrene electronic packaging application that used

a new grade of conductive carbon black, which was

formulated to reduce the trade-off between conductivity

and mechanical performance. The new conductive black

had MFI (g/10 min) of 9.3 versus 5.6 for the old grade;

compound moisture absorption of 420 ppm compared to

3,044 ppm; flexural modulus of 2,015 MPa versus 2,361

MPa; and impact resistance of 11.7 kJ/m2 compared with

5.7 kJ/m2. Significantly, resistivity was 6.4 X 103 in the

new grade and 6.0 X 105 in the old version.

Cabot argues that besides improvements in resistiv-

ity, mechanical performance and processing, the

enhanced morphology and surface treatments mean

that compounders can buy less material to meet

specifications, ideally saving money up front, and

reducing deliveries, handling and packaging waste,

which adds to profitability on the back end.

Modern Dispersions, meanwhile, has developed

various conductive compounds and masterbatches for

polyolefins as well as engineering grades of thermo-

plastics using high-structure, high-surface-area carbon

black, says Dani, who adds, “We see very good growth

for this market.”

Pigment progressAs important as conductivity is, it’s not the only

application for which suppliers are upgrading formula-

tions. Another area of activity is colour. Modern

Modern

Dispersions is

meeting

demands for

deeper shades

of black for car

interiors

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Dispersions is among the companies working to

improve the carbon black masterbatches it provides for

colour intensity.

Kozma says the company is fine-tuning its process-

ing technology to improve cleanliness, dispersion and

processability. “We continue to optimize our production

lines as part of an ongoing evolution in this area,” he

remarks.

Modern is getting requests from customers for

deeper shades of black colour. The deep black master-

batches are popular for interior and exterior automotive

applications, due to the gloss and aesthetics they

provide and their ability to match topcoats.

The deep (or high jetness) shades of carbon black

have problems in masterbatches that are common to

other specialty grades. These include high surface area,

dispersion difficulties and viscosity increases when

compounded in high loadings. As a result, the company

is using its expertise in machinery, processing and

materials knowledge to produce grades that effectively

meet required colour and dispersion needs.

Another application for carbon black as a colouring

aid is in the UV protection of agricultural water pipes,

hoses and films. One company that specializes in

formulations for the growing market of drip irrigation

pipes is Orion Engineered Carbons. Among the

company’s developments for this market are pigment

blacks. These are described as small, high-surface-

area particles that combine multiple properties in a

package that outperforms single additives.

The foremost property of these materials is UV

protection, of course, but the pigment blacks also

contain high-purity pigments and outstanding disper-

sion properties that reportedly minimize the potential of

microscopic defects that could cause pipes to crack or

degrade prematurely.

As might be expected, irrigation is a major market in

developing countries. India, for example, is a global

leader in micro-irrigation, and according to compound-

er Spartech, it produces 7-10 times the volume of black

masterbatch resin for this application as the US.

Orion and other carbon black producers supplying

the irrigation market clearly have applications that will

account for substantial volumes of material.

Sustainable feedstocks are also gaining use in

carbon black formulations. Orion, for one, produces

Printex Nature, a pigment for polymers that is derived

from renewable materials such as plant oils. Printex

Nature offers a good balance of coloristic properties,

dispersibility and UV protection, and can be used in a

range of applications, food packaging, agricultural

films, electronics and automotive among them.

Click on the links for more information:

❙ www.notchconsulting.com ❙ www.birlacarbon.com ❙ www.cabot-corp.com ❙ www.timcal.com ❙ www.moderndispersions.com ❙ www.amiconferences.com ❙ www.orioncarbons.com ❙ www.spartech.com

Orion

Engineered

Carbons is

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growing

market for drip

irrigation pipes

with special

grades

Carbon black is

used in

UV-resistant

agricultural

films

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Trends and technical developments in the international fl ame retardant industry

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Conductive compounds | technical paper

Daniele Bonacchi and Christine Van Bellingen of Timcal compare the

overall performance of conductive and extra-conductive carbon blacks in HDPE compounds. They fi nd that the more conductive additive is not

always the best choice

In the fi eld of permanent electrically conductive

additives, conductive carbon blacks remain the most

reliable and economical choice [1].

Carbon blacks suddenly decrease the electrical

resistivity of polymer composites when added to a

certain loading, which corresponds to the percolation

threshold. In fact, the resulting decrease in electrical

volume resistivity of a polymer when increasing the

amount of added carbon black can be described by a

percolation mechanism.

At a certain carbon black loading, the critical volume

fraction (also referred to as the percolation threshold),

the electrical resistivity dramatically drops from a

domain of high electrical resistivity to one of low

electrical resistivity, reaching an ultimate level of

resistivity, the lower plateau of the percolation curve. In

that region, further increasing the amount of added

carbon black does not decrease to a signifi cant degree

the low level of electrical resistivity.

The carbon black loading at which the sudden

decrease in resistivity occurs is different from one

carbon black to the other and is primarily related to

what is called the carbon black “structure” [2]. Conduc-

tive carbon blacks all have a ‘high structure’ which

means that they are able to transfer electrical conduc-

tivity to composites at lower loadings than less

structured carbon blacks. They are made of aggregated

primary particles in three dimensional highly branched

structures (Figure 1).

The highly branched structures are responsible not

only for the electrical conductivity at low loading, but

also for the low bulk density of conductive carbon

blacks. Primary particles are bound to one and other via

covalent bonding in such a way that carbon black

aggregates are very resistant and will not break apart

under normal compounding conditions [3]. The extent of

the aggregation of the primary particles and the

agglomeration of the aggregates is referred to as the

carbon black “structure”. The oil absorption number

(OAN), as described in ASTM D2414, is employed to

measure the average structure level [4].

Conductive carbon blacks with different OAN values

decrease the electrical resistivity at different loadings

(percolation thresholds) and can be classifi ed according

to this number. This classifi cation is present in the

market with different names such as conductive,

extra-conductive and ultra-conductive carbon blacks,

indicating their increasing structure (decreasing

percolation threshold) and usually also their increasing

related cost.

Another important carbon black property is surface

Comparing conductivecarbon blacks in HDPE

Figure 1:

Carbon black

Ensaco 250G

aggregate,

primary

particles are

visible

Another important carbon black property is surface

Surface Area

Ensaco 250G Ensaco 350G

Structure

Conductive

65BET(m2/g)

190OAN(ml/100g)

770

320

Extra-Conductive

Table 1: Surface area and structure of Ensaco 250G and Ensaco 350G


technical paper | Conductive compounds

area – an increase of structure usually is accompanied

by an increase of the carbon black surface area. This

certainly holds true for ‘extra-conductive carbon

blacks’, though it is not always the case with ‘conductive

carbon blacks’. In fact, the proprietary production

process of Timcal is able to deliver high purity, soft

fl ake conductive carbon blacks of both ‘high structure’

and ‘low surface area’. This combination is of high

importance to ensure ease of dispersion and mixing of

the carbon black in the polymer matrix, as well as an

excellent surface smoothness in the fi nal material.

There is a trend to search for the ‘highest structured

carbon blacks’ (meaning ‘the more conductive’) as a

fi rst approach, based on the assumption that a lower

carbon black loading would necessarily result in better

properties (usually mechanical properties).

In this article, we compare the performance offered

by conductive and extra-conductive carbon blacks in a

semi-crystalline polymer – high density polyethylene

(HDPE) – at the same fi nal electrical resistivity, rather

than at the same carbon black loading. We are able to

demonstrate that an easily-dispersible conductive

carbon black of ‘high structure and low surface area’

such as Ensaco 250G (E250G) can perform at least as

well as extra-conductive blacks, which are inherently

more diffi cult to disperse, despite the higher loadings

needed to achieve equivalent conductivities.

ResultsThe physico-chemical characteristics of conductive

carbon black Ensaco 250G (E250G) and extra-conductive

carbon black Ensaco 350G (E350G) are presented in

Table 1. It can be seen that the two materials differ in

OAN values (190 vs 320 ml/100g, respectively) as well as

in specifi c BET nitrogen surface area (65 vs 770 m2/g,

respectively).

The lower surface area of E250G increases its

mobility and enables easier wetting with the polymer in

comparison to higher surface area carbon blacks [5]. The

easier wetting, together with adequate de-agglomera-

tion provided by the high structure, results in increased

dispersibility (easy mixing), which ultimately produces

excellent surface smoothness; this is a clear advantage

especially in sensitive applications like fi lms and thin

sheets for electronic packaging.

With very highly structured carbon blacks, not only is

the surface area much higher, but also the many chain

entanglements upset the de-agglomeration step,

making their dispersion in polymers more diffi cult.

In this study, we present the results obtained in

general purpose injection moulding HDPE with a melt

fl ow index (MFI) at 190°C/5kg of 11 g/10min. HDPE was

chosen as it is the material used for many conductive

applications such as mining hoses, drums for explo-

sives, tools for ATEX equipment, as well as conductive

power cable jacketing.

Compounds were produced on a Thermo Fisher

Haake co-rotating twin-screw extruder (16 mm screw

diameter, L/D = 40) in which the carbon black was added

downstream via a gravimetric side feeder equipped with

twin-screw. Further processing involved compression

moulding or injection moulding (ISO:3167 mould).

Figure 2 shows the classical percolation curves,

describing the electrical volume resistivity with

increasing carbon black loading of compression

moulded HDPE compounds. As expected, with the

highly structured carbon black E350G, the percolation

threshold is achieved at a lower carbon black loading.

In most industrial plastics applications, injection

moulding is used as an effi cient processing technology.

Unfortunately, with this kind of processing, a decrease in

semi-crystalline polymer –

(

than

demonstrate that an easily-dispersible

carbon black of

such as Ensaco 250G (E250G) can perform at least as

well as extra-conductive blacks

more diffi cult to disperse, despite the higher loadings

needed to achie

ResultsThe

carbon black Ensaco 250G (E250G) and extra-conductive

carbon black Ensaco 350G (E350G) are presented in

Table 1. It can be seen that the two materials differ in


area – an increase of structure usually is accompanied

respectively).

mobility and enables easier wetting with the polymer in

comparison to higher surface area carbon blacks

easier wetting, together with adequate de-agglomera-

tion provided by the high structure, results in increased

dispersibility (easy mixing), which ultimately produces

excellent surface smoothness; this is a clear advantage

especially in sensitive applications like fi lms and thin

sheets for electronic packaging.

the surface area much higher, but also the many chain

entanglements upset the de-agglomeration step,

making their dispersion in polymers more diffi cult.

general purpose injection moulding HDPE with a melt

fl ow index (MFI) at 190°C/5kg of 11 g/10min. H

chosen as it is the material used for many conductive

applications such


in specifi c BET nitrogen surface area (65 vs 770 m

Figure 2: Percolation curves showing the electrical volume resistivity as a function of carbon black loading, for HDPE pressed plaques containing Ensaco 250G and Ensaco 350G

Figure 3: Percolation curves showing the electrical volume resistivity with increasing loadings of Ensaco 250G and Ensaco 350G for injection moulded samples and pressed plaques



conductivity is observed, especially for compounds near

the “compression moulded” percolation threshold [6].

This effect has been explained by S.C. Jana as “shear-

induced migration” [7], but also as “structure compres-

sion” by Probst et al. [8-9].

In our study, the high tendency of HDPE to crystallize

certainly also plays a role; most probably the typical

compression moulding cooling rates induce a higher

proportion of crystalline region, segregating the carbon

black in a reduced amorphous phase portion, and shifting

the percolation towards the lowest concentrations.

When comparing volume resistivity measurements

of injection moulded samples to those after compres-

sion moulding (Figure 3), we see a shift of the percola-

tion threshold towards higher carbon black loadings:

E350G percolation threshold increases from 4% to 8%

while E250G shifts from 12% to 16%. It is interesting to

note that the absolute increase in the percolation

threshold remains constant.

To get the most representative comparison, the

compound characteristics (fl uidity and mechanical

properties) were examined at equal electrical conduc-

tivities rather than at equal carbon black loadings.

Compound melt fl ow indexes as a function of

electrical resistivities are shown in Figure 4; despite the

higher content, E250G shows similar if not higher

fl uidity (especially at high loadings) when compared to

extra-conductive carbon black.

The similar behaviour of E250G and E350G carbon

blacks at the same electrical resistivity, despite having

different carbon black loading, can be understood by

similar relative proximity of the loading amount to the

respective percolation threshold. We remember that the

percolation threshold can be defi ned as the loading at

which a spanning cluster will come into existence and is

different for both compounds as it depends on the

structure of the carbon black (Table 1). In other words,

when separated aggregates contact each other at the

percolation threshold, a rise in viscosity is observed

(decrease in MFI) which is proportional to the number of

interactions present.

Figures 5 and 6 present the mechanical properties

(ISO:527 and ISO:178) of the injection moulded com-

pounds showing that we have again strong similarities

of the mechanical properties. Specifi cally, a similar

increase of the yield strength and increase of stiffness

is observed at the same electrical conductivity, despite

the large difference in carbon black loadings.

According to both tensile and fl exural modulus, E250G

based compounds appear stiffer. An increase in yield

strength often corresponds to a good interaction between

the polymer and the fi ller, as expected for two hydropho-

bic surfaces (Ensaco carbon blacks and HDPE). A similar

trend to tensile results has been found for the notched

Charpy impact properties (ISO:179/1eA); the retained

impact energy of the E250G and E350G compounds are

similar at the same volume resistivity (Figure 7).

Considering the measured properties, it is clear that

easily dispersible carbon black, such as E250G, can be

properties) were examined at equal electrical conduc-

tivities rather than at equal carbon black loadings.

electrical resistivities are shown

higher content, E250G shows similar if not higher

fl uidity (especially at high loadings) when compared to

extra-conductive carbon black.

blacks at the same electrical resistivity, despite having

different carbon black loading, can be understood by

similar relative proximity of the loading amount to the

respective percolation threshold. We remember that the

percolation threshold can be defi ned as the loading at

which a spanning cluster will come into existence and is

different for both compounds as it depends on the

structure of the carbon black (Table 1). In other words,

when separated aggregates contact each other at the

Figure 4: Melt fl ow rates of HDPE/Ensaco compounds (190°C/5kg) as a function of volume resistivity

Figure 5: Tensile moduli and yield

strengths of HDPE/Ensaco

compounds (ISO:527) as a

function of volume resistivity

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References and notes[1] “Global electroactive polymers market trends, applications and forecasts”, Electronics.ca

publications (May 2012)[2] J Donnet, RC Bansal and M Wang, “Carbon Black”, second edition, pg 271-287 [3] G Wypych, “Handbook of fi llers”, Chemtec Publishing (Toronto 2010), pg 241-243[4] Note: the void volume is a measure to compare the structure of carbon blacks. The void

volume depends on the size and shape of the aggregate, the agglomeration of aggregates and the porosity on the primary particles. Therefore the carbon black structure can be considered as the sum of a number of accessible voids by unit weight: the inter-aggregate space, the interstices within the aggregates, and the porosity of the elementary particles. The higher the structure level of the aggregate, the higher is the volume of the voids. The oil absorption number (OAN), described in ASTM D2414, is employed to measure the void volume and therefore the average structure level.

[5] C Van Bellingen, N Probst, E Grivei, “Meeting application requirements with conductive carbon blacks” Annual Conference of the Society of Plastics Engineers (ANTEC 2005), Curran Associates (April 2006)

[6] SC Jana, Polymer Engineering and Science (2003) Vol 43-3, pg 570-579[7] SC Jana, C Hong and J Kim, Polymer Engineering and Science (2004) Vol 44(11), pg

2101-2109[8] C Van Bellingen, E Grivei, N Probst, P von Hoffmann, “Addcon World 2003” Conference

Proceedings, Rapra Technologies 2003 [9] N Probst, E Grivei, Carbon 40 (2002) pg 201-205[10] C Van Bellingen, N Probst, E Grivei Polymers and Polymer Composite (2002) Vol 10, No 1

used instead of extra-conductive carbon black, since it

retains at least the same overall properties at the same

compound electrical resistivity. The same conclusion,

drawn here for semi-crystalline polymer (HDPE), had

been already reported from the comparative testing of

E250G and E350G in amorphous polymer (polycarbon-

ate) [10].

It should be noted that our conclusions are only valid

for easily dispersible and high purity conductive carbon

black such as Ensaco 250G; the use of carbon blacks

which are less pure or more diffi cult to disperse would

dramatically increase the level of impurities (chemical

and physical) and increase the amount of domains of

undispersed carbon black inside the compound. An

increase in such domains worsens not only the surface

quality but also introduces weak points which would

decrease the overall quality of the product.

The high structure and low surface area of E250G

has been especially designed to guarantee outstanding

dispersibility in polymer matrices, which minimizes

defects in the conductive compound and helps to retain

other material properties.

ConclusionFor conductive applications which do not necessarily

require extreme weight saving or any other added

property (for example, easy welding or low sloughing),

using nearly twice the amount of easily dispersible

conductive carbon black E250G, instead of inherently

more diffi cult to disperse extra-conductive carbon

black, provides both full productivity benefi ts and an

excellent price-to-performance ratio, without sacrifi c-

ing mechanical or rheological properties.

About the authorsDr Daniele Bonacchi is development scientist, R&D

polymer applications with Timcal in Switzerland

([email protected]). Ing Christine Van Bellingen

is product manager, carbon black & graphite for polymers

at Timcal, Belgium ([email protected]).

� www.timcal.com

Figure 7: Notched Charpy impact energies of HDPE/Ensaco compounds (ISO:179/1eA) as a function of volume resistivity

Figure 6: Flexural moduli and stress

at max of HDPE/Ensaco

compounds (ISO:178) as a

function of volume resistivity

Images courtesy of: Albemarle Martinswerk and LyondellBasell

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competitive rates.

Is Compounding Worldavailable in a printed version?We do not print any copies of Compounding World. It is a digital-

only magazine, which allows us to distribute it free-of-charge to

thousands of readers around the world quickly

and effi ciently. It’s also better for the environ-

ment! If you wish to print out the magazine

yourself, then you can download the magazine

as a PDF using the PDF button which is top right

in each edition’s browser.

Can I see past issues of the magazine?Each edition of Compounding World is kept on-line for at least

12 months and can be accessed from our archive page

(http://bit.ly/CWarchive). You need to be a subscriber to the

magazine to access the full archive (see below for details on

how to subscribe for free).

How can I subscribe to Compounding World and what does it involve?You can subscribe to Compounding World free-of-charge by

completing the on-line form at http://bit.ly/CWsubscribe. Once

you have been added to our mailing list you will receive an e-mail

each time a new issue is published. We also send out a reminder

e-mail a few weeks later, highlighting the most popular articles

with direct links to these. We will not give or sell your details to

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Frequently Asked Questions about


pack (http://bit.ly/CWmedia

information or being interviewed for one of these

(e.g. start of September for the

November edition).

each issue, so we still want to hear

from you even if you do not see your


How do I advertise in Compounding WorldAdvertising in

an easy and cost-effective way to

promote your products and services to

a global audience of compounders and

masterbatch makers. We can even


advertisement manager Claire Bishop

available in a printed version?Compounding World. It is a digital-


FAQs

I have subscribed, but I am not receiving e-mails. What’s happening?New subscribers are added to our mailing list individually so

that we can check for duplicated information. This process can

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our digital-only format eliminates high printing and postage costs,

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Can I link to articles in Compounding World from an e-mail or our website?Yes, we encourage people to link to our magazine and share its

contents with colleagues, customers and suppliers. You can fi nd

the URL for the whole issue or a specifi c page in the magazine by

clicking on the @ symbol in the browser and selecting “Send to a

friend”. Simply copy and paste the URL for the “fi rst page” or

“current page”, or you can send an e-mail directly.

Can I reproduce content from Compounding World?The content of Compounding World is copyright and the property

of Applied Market Information and cannot be reproduced without

the prior written permission of the publisher. However, you may

print copies of the magazine for your own use and share links to a

particular edition or article (see above).

Is Compounding World available on smartphones and tablet computers?Yes – Compounding World is now available using dedicated apps

both for iPhones/iPads and for a wide range of

Android devices. The apps are free-of-charge

and provide free access to current and past

issues of the magazine.

The iPad/iPhone app can be found in iTunes or

Apple’s App Store by searching for “AMI Plastics”.

Alternatively visit: http://bit.ly/CWiPad. For users

of Apple’s latest iOS5 operating system, the

magazines will appear in your Newsstand app

and new editions will be added automatically if

you sign up for the free subscription.

The Android app can be found in the Google

Play Store by searching for “AMI Plastics” or by

visiting: http://bit.ly/AMIAndroid. It is

compatible with more than 850 different devices,

including a wide range of smartphones and tablet computers

from companies such as Samsung, HTC, Motorola, LG, Asus,

Panasonic, Sony Ericsson and Archos.

This month’s freebrochure downloadsSimply click on the brochure cover or link to download a PDF of the full publication

If you would like your brochure to be included on this page, please contact Claire Bishop. [email protected]. Tel: +44 (0)20 8686 8139

ExxonMobil: Vistamaxx case studyThis case study looks at how ExxonMobil’s Vistamaxx propylene-based elastomer helped Halsall Toys Europe improve the impact

performance of an innovative toy without the need for costly mould modifications.

➤ Click here to download

Oxea: Phthalate-free plasticizersThis 24-page technical brochure from Oxea Chemicals has full details of its phthalate-free, non-VOC plasticizers including the results of extensive

comparison tests with DOP, DINP and DIDP.


the oxo people

OXSOFT®

Phthalate-free, non-VOC plasticizerswww.phthalate-free-plasticizers.com

Plastribution: Plastic FantasticPlastribution’s new 20-page Plastic Fantastic magazine looks at the company’s award winning work on an indestructible prison chair, lists its full range of

materials, and looks in detail at a selection of new resins.


Shepherd Color: inorganic pigmentsThis 19-page brochure outlines the complex inorganic colour pigments (CICPs) produced by The Shepherd Color Company, which has offices in the USA, Europe, Japan and Australia.


Steer: EPZ screw elementsThis 20-page brochure from Steer Engineering has details of the company’s EPZ screw elements, barrels and shafts, including innovative designs that deliver higher intake, enhanced mixing and efficient conveying.


How to advertise in this magazineUse Compounding World to promote your products and services. This media pack has full details of our global coverage, forthcoming features, simple copy requirements and very competitive costs.


CW media pack new.indd 1

4/4/11 20:04:48

Timcal: carbon additivesTimcal has produced this 24-page brochure to provide technical details of its Timrex graphite and Ensaco conductive carbon black additives for polymer compounds. It covers a wide range of applications.


Who is responsible for publishing Compounding World magazine?Compounding World is published by Applied Market Information

(AMI), which is a leading supplier of information and market

intelligence to the global plastics industry. Founded in 1986, the

company has offi ces in the UK and the USA. It offers a range of

consultancy services, market studies and technical books, as well

as organising more than 30 plastics industry conferences per

year. For more information, visit www.amiplastics.com.

What other magazines do you produce?Our other digital magazines are: Injection World for the injection

moulding industry (www.injectionworld.com); Pipe and Profi le Extrusion (www.pipeandprofi le.com); Film and Sheet Extrusion

(www.fi lmandsheet.com); and our newest title, Pipeline Coating(www.pipeline-coating.com).

I have a brochure, company newsletter or customer magazine that I’d like to share with your readers. How can I do that?There are three ways of doing this.

You can link to a PDF of the

publication from an advertisement

within the magazine. Additionally,

we can include it in our Brochure

Showcase page which features six

different publications with their

covers, brief descriptions and

relevant links. The third option is

to include the full publication

alongside the magazine as a

“digital supplement” - we simply

add your pages onto the back of

the magazine. For details and

examples of all three options, contact Claire Bishop

([email protected] Tel: +44 208 686 8139).

Can you produce a digital magazine or brochure for my company?Yes - we offer contract publishing services. We can

help you to produce a customer magazine or brochure,

providing writing, editing and design services as

required. We can then turn it into a digital publication

using the same state-of-the-art on-line platform that

we use for Compounding World. Once it is produced,

we can make it available to our readers in the ways

listed above. For details, contact Claire Bishop

([email protected] Tel: +44 208 686 8139).

I have another question to ask, or a suggestion to make. Who should I contact?

Please contact Andy Beevers, our head of business publishing, at

[email protected].


SPECIAL OFFER: Save €200 if you register before 25th January 2013

WOOD-PLASTICCOMPOSITES 2013

The international business conference & exhibition for the wood-plastic composites industry

25-27 February 2013Austria Trend Savoyen Hotel, Vienna, Austria

Media supporters: Also sponsored by:

Images courtesy of: battenfeld-cincinnati Austria GmbH, Beologic, TimberTech and Trex Company

HEADLINE SPONSOR

Maud Lassara – Conference Organiser [email protected] Ph: +44 117 924 9442 Fax: +44(0)117 311 1534


www.compoundingworld.com November 2012 | compouNdiNg world 59

Materials testing | products

melt flow testing

Zwick streamlines melt index testingcontrol and force control, which

adjusts test loads up to 50 kg.

Automatic parameter

control is particularly useful

for polymers with an unknown

MFR, where operator influence

in the determination of

parameters could lead to

reductions in measurement

accuracy. Another automated

feature is push-button

pre-compacting and cleaning,

which saves additional

operator time.

Zwick says that its Mflow

extrusion plastometer is

designed for typical quality

assurance applications in

Zwick recently introduced two

new extrusion plastometers for

melt index testing. The Aflow

and Mflow are part of the

company’s Xflow series and

they both have new automated

features that streamline the

test process and improve

laboratory efficiency.

The Aflow extrusion

plastometer for determining

the melt mass flow rate (MFR)

and melt volume flow rate

(MVR) has been designed for

high throughput environments.

Automated features that

improve speed and reliability

include automatic parameter

polymer analysis

netzsch speeds up characterizationNetzsch says that its latest TG

209 F1 Libra thermobalance

enables polymer analysis to

be carried out faster, more

accurately, and across an

extended temperature range.

Its special BeFlat function

automatically compensates

for any external factors

influencing the measurement.

The calculated DTA signal,

c-DTA, yields valuable

information on a polymer’s

phase transitions. This

additional information allows

for an unknown sample to be

identified and characterized

much more easily and

precisely.

Q-Lab has opened its new,

fully-equipped contract

testing laboratory in

Saarbrücken, Germany. The

facility includes multiple QUV

weathering, Q-Sun xenon arc

and Q-Fog corrosion test

chambers. Colour, gloss and

other expert visual evaluation

services are also available.

The lab provides European

customers with many of the

same contract testing

services that are offered by

Q-Lab’s Florida facility.

❙ www.q-lab.com

Q-lab opens contract lab in germany

weather testing

The vacuum-tight design of

the TG 209 F1 Libra not only

allows for the creation of a

pure inert atmosphere via

evacuating and filling, but also

for the execution of measure-

ments under vacuum condi-

tions. The mass loss steps

from the evaporation of the

plasticizer and the decompo-

sition of the polymer can be

clearly separated. Therefore

it becomes possible to

characterize the plasticizer

content precisely.

❙ www.netzsch.com

areas such as R&D, QA and

goods inward checks. It

incorporates program-con-

trolled weight positioning and

removal, which streamlines

the testing process by

eliminating the need for an

operator to manually position

the weights required for each

individual test.

The modular design of the

Mflow enables easy upgrading

and retrofitting. For example, it

can be fitted with extrudate

cutters, a displacement

transducer for MVR measure-

ment and a weight-lifting unit.

❙ www.zwick.com

netzsch’s tg 209 f1

libra thermobalance

accelerates

polymer

analysis

putting your formulations to the test

the aflow has been

developed for high

throughput

applications

we look at some of the latest materi-als testing equipment and software developments designed to ensure that

your new formulations deliver the required levels of processability, mechanical performance, appearance

and longevity. Click on the web links at the end of each story for more information.


products | Materials testing

mechanical testing

Tinius Olsen has launched a

range of new hardness

testers that can rapidly and

accurately determine the

hardness value of a wide

variety of materials including

plastics, large parts and

small precision components.

Covering portable, bench,

and floor-mounted testers,

the range includes method-

specific units as well as

universal models. The latter

can run any popular hardness

colour monitoring

X-rite adds new hand-held spectrocolorimetersurface being measured from

three different directions while

simultaneously recording 27

colour-accurate images in 1.8

seconds. With eight different

visible illuminations and one

ultraviolet illumination, the

RM200QC is able tto accurately

define the location of a colour

in the colour space.

The instrument can give

results as a simple pass/fail

message or CIE L*a*b* values

and delta E colour differences.

It also reports results in

standard colour difference

equations and tolerances, such

as CIELAB, CMC, CIE 94, or

CIE 2000.

Its memory holds 20

standards and up to 350

measurements automatically

stamped with time and date

and saved as PDF and CSV

files. These can be downloaded

using a USB cable so the

information can be shared

throughout the supply chain.

X-Rite has launched a new

hand-held spectrocolorimeter

– the RM200QC – which it says

delivers an inexpensive yet

powerful way to record and

communicate colour differ-

ences, speeding up the

introduction of new products

and reducing scrap levels.

The instrument is designed

to simplify the comparison of

the colours of lab samples or

production parts with

reference standards, creating

reports for sharing with supply

chain partners. It boasts

advanced features that identify

colour differences

between samples and

standards, opacity,

and greyscale

assessment, as well

as highlighting how

colours may change in

appearance under D65

daylight and Illuminant A

household tungsten-filament

lighting,

tinius olsen expands its range of material hardness testers

scale test, including Vickers,

Micro-Vickers, Brinell,

Rockwell, Superficial Rockwell,

Knoop, HBT or HVT.

The testers feature the

latest designs, hardware and

firmware to deliver fast and

accurate results. According to

Tinius Olsen, they provide very

high gauge repeatability and

data reproducibility, along with

excellent accuracies and

resolutions.

The FH series of hardness

testers use load cell based

systems to ensure enhanced

test results. Most models

incorporate the latest

full-colour touch-screen

displays and controls for easy

operation. Connectivity is via

USB port and wi-fi, providing

the ability to consolidate test

results data from other Tinius

Olsen testing machines using

the company’s latest Horizon

test automation software.

❙ www.tiniusolsen.com

Target users include

masterbatch formulators,

injection moulders and

extruders, according to

Matthew Adby, product/

market manager for X-Rite.

The RM200QC is already

being used by Poppin of New

York, USA, to set colour

standards and enhance

productivity for its desk sets,

pens and pencils, which are

designed in-house for

manufacture in China.

The company’s manufac-

turing personnel use the

RM200QC as a quality control

device to monitor colour

deviation between items in

production and the Pantone

standard colour. Using

L*a*b* data generated by the

RM200QC, Poppin has been

able to reduce the difference

between what New York

designers stipulate and what

is manufactured in China.

❙ www.xrite.com

X-Rite says that the

RM200QC is inexpensive

enough for companies to

purchase multiple units that

can be stationed at individual

machines or at critical steps in

a workflow to alert quality

control personnel if a

manufacturing process is out

of control. It adds that the

instrument is particularly

suited to helping companies

that currently manage colours

by comparing incoming raw

materials or finished products

with colour swatches, fan

decks or sample products.

A proprietary camera

technology is used in

the RM200QC to

illuminate the

This month’s freebrochure downloads

Simply click on the brochure cover or link to download a PDF of the full publication

If you would like your brochure to be included on this page, please contact Claire Bishop. [email protected]. Tel: +44 (0)20 8686 8139

Plastribution: know-how

In the third edition of Plastribution’s know-how magazine you can fi nd out more about the newest additions to the company’s product portfolio , including the latest resin options for LED applications.

� Click here to download

www.plastribution.co.uk

0845 34 54 560

Issue 03 October 2012

the magazine

In this issue

The Olympic torch – Momentum 13

Joining the App revolution 14

Recycle with industry know-how 16

Nylon replaces metal in cars 32

More efficient LEDsDon’t be left in the dark, turn to page 24 and find out more.

Key Filters: KCH screen-changer

This brochure from Parkinson Technologies features the new Key Filters KCH continuous hybrid screen-changer which delivers continuous extrusion pressure, reacting rapidly to disruptions caused by varying contaminant levels.


In plastics extrusion, having the right screen changer for your material’s filtration requirements can make the difference between profit and loss. Parkinson Technologies’ line of Key Filters products offers custom engineered solutions and turnkey services to meet melt filtration needs for most thermoplastic materials.

The new KCH is a development product that joins the best features of the proven KC product with the time-tested reliability of the KCN product line.

Like the KCN, the KCH delivers the same uniform continuous extrusion pressure, varying as little as ±20 psi. However, with hydraulic puller action, the KCH can react rapidly to disruptions caused by varying contaminant levels.

No process interruption translates into increased production and decreased scrap, bringing maximum efficiency to your extrusion operation.

Introduces its new

KCH Continuous Hybrid Screen Changer

© Parkinson Technologies Inc. Dusenbery® is a registered trademark of Parkinson Technologies.

A brand from Parkinson Technologies Inc.

Shepherd: pigments for plastics

This selection guide from Shepherd Color Company has details of 20 different pigments with their properties, regulatory approvals and applications listed in an easy-to-read table.


Steer: SPL40 turn-key lines

This eight-page brochure covers Steer Engineering’s new SPL40 compounding pelletizing systems that include feeders, extruders, strand die heads, water troughs, air knives, pelletizers and classifi ers.


PlasMec TRM Turbomixers

This eight-page brochure covers PlasMec’s TRM Turbomixer, which can be used for mixing PVC dry-blends, producing wood-plastics composites (WPCs) or the hot/cold dispersion of masterbatches/additives.


Steer: EPZ screw elements

This 20-page brochure from Steer Engineering has details of the company’s EPZ screw elements, barrels and shafts, including innovative designs that deliver higher intake, enhanced mixing and effi cient conveying.


How to advertise in this magazine

Use Compounding World to promote your products and services. This updated media pack has full details of our global coverage, forthcoming features for 2013, simple copy requirements and very competitive costs.


Central and Eastern Europe 2,644

Central and South America 951

Middle East and Africa 2,392

Western Europe6,178

North America

4,902

Asia4,243

Rates and data

Advertisement manager:Claire BishopE-mail: [email protected] tel: +44 (0)20 8686 8139

contact us

Global circulation

Western Europe835

Asia556

North America822

Central and Eastern Europe 96

Central and South America 128

Middle East and Africa 66

Global app downloads

Size of email list: 21,310 names

Total downloads: 2,503

Head of Business Publishing:Andy BeeversEmail: [email protected]

Editorial: Email: [email protected]

Applied Market Information LtdAMI House, 45-47 Stokes Croft, Bristol, BS1 3QP, United KingdomTel:+44 (0)117 924 9442Fax:+44 (0)117 989 2128www.amiplastics.com

Compounding World has highly competitive advertising rates, ensuring that your marketing budget goes much further.

Advertisement copy sizes Width by height

Double-page spread: 420mm x 297mm

Full page 210mm x 297mm

Half page (horizontal): 210mm x 148mm

Half page (vertical): 100mm x 297mm

Third page (horizontal): 210mm x 99mm

Quarter page (horizontal): 210mm x 74mm

Quarter page (vertical): 100mm x 148mm

E – Euros Single 3+ 6+ 12+Double-page spread E2,550 E2,000 E1,800 E1,200

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$ – Dollars Single 3+ 6+ 12+Double-page spread $3,300 $2,600 $2,350 $1,550

Page $2,200 $1,750 $1,550 $1,100

Half page $1,500 $1,200 $1,050 $775

Third Page $1,200 $1,000 $850 $650

Quarter page $950 $775 $580 $450

Brochure Showcase entry: E200 or $260 per brochure

File formatsFinal advertisement copy should be supplied as a high resolution (300dpi) digital file in either PDF or jpg format. To supply artwork in any other format, please contact us first to discuss compatibility.

Our full advertisement terms and conditions can be viewed at www.compoundingworld.comThe AMI magazine portfolio

Applied Market Information publishes four other digital magazines focused on specific sectors of the global plastics industry: Injection World, Pipe and Profile Extrusion, Film and Sheet Extrusion plus Pipeline Coating. If you place bookings in more than one of our five magazines, then the series bookings accumulate across all of your adverts.

It is possible to add rich media to your adverts, such as videos, flash animation, surveys and presentations. To find out what’s possible and how much it costs, contact us to discuss your ideas. We also offer banner and skyscraper adverts on compoundingworld.com. Contact us for our competitive rates and latest viewing figures.

www.injectionworld.com

www.pipeandprofile.com

www.filmandsheet.com

www.pipeline-coating.com

+Compounding World offers:n Comprehensive global coveragen Targeted editorial contentn In-depth market knowledgen Free online access for alln Highly competitive advertisement ratesn An effective and efficient route to market

For more information about advertising inCompounding World, contact Claire Bishop today:Tel: +44 (0)20 8686 8139 E-mail: [email protected]

Compounding World is a monthly magazine written

specifically for polymer compounders and masterbatch

producers around the globe. It is distributed electronically and

can be read free-of-charge online. In addition, it can be

accessed on tablet computers and smartphones using our

free apps for the iPad, iPhone or Android devices.

The magazine is published by Applied Market Information

(AMI), the leading provider of market intelligence and analysis

for the global compounding and masterbatch industries.

The company has a detailed database of senior decision

makers at compounding and masterbatch production sites

across Europe, the Americas, Asia and the Middle East. This

unique and constantly updated database provides

Compounding World with comprehensive global access to the

key purchasers of polymer additives, compounding machinery

and ancillary equipment.

The magazine delivers relevant and up-to-date information

on the most important technical developments, market

trends, business news and legislative announcements. And

unlike other general plastics magazines, Compounding World

is 100% focused on the specific information needs of

Visit www.compoundingworld.com to see the latest issue and take out a free subscription

MEDIA INFORMATION 2013

The global magazine for polymer compounders

compounders and masterbatch producers.

Adverts are very competitively priced and can include links

straight to your own website. If you are selling machinery,

ancillary equipment, materials, additives or services to

compounders or masterbatch producers, then Compounding

World provides an extremely efficient vehicle to promote your

business globally.

CW media pack October 2012.indd 5 25/09/2012 17:36


products | Materials testing

melt flow testing

Instron describes its new

Ceast MF20 and MF30

modular melt flow testers as

versatile, single-weight

measurement systems

suitable for use both in R&D

and in advanced quality

control. They provide users

with increased convenience

for easy and accurate

measurement of the flow

properties of plastics

according to ASTM D1238

and ISO 1133.

Both instruments are said

to conform to strict toler-

ances with regard to

temperature accuracy and

stability. In particular, they

comply with the stringent

requirements of the latest

ISO 1133-2 testing standard

weather testing

atlas updates entry-level instrumentviewing for the operator, while

a choice of eight languages are

now offered (English, German,

French, Spanish, Italian,

Chinese, Polish and Russian).

Two pre-programmed test

Atlas Material Testing

Technology has updated the

design of its Suntest CPS+, a

widely-used entry-level

instrument for accelerated

materials testing. It is

particularly suitable for the

ageing of smaller specimens,

including the light and weather

testing of plastics.

The new fourth generation

model provides improved

functionality and ease of

operation. Its new features

include improved quality of

light for better performance.

Control the UV output of the

xenon test chamber has been

enhanced to eliminate areas of

instron melt flow testers meet new iso 1133-2 requirements

for materials sensitive to

time-temperature history and/

or moisture.

The Ceast MF30 includes a

weight magazine and weight

lifter, which is also available

as an option for MF20. The

weight magazine contains a

complete set of eight test

masses ranging from 0.325 kg

(piston mass) up to 21.6 kg for

testing a wide spectrum of

materials, from fast-flowing

masterbatches to highly

viscous elastomers or filled

thermoplastics.

The newly developed

Manual Mass Selector enables

pre-selection of the required

test mass, thus facilitating

preparation and execution of

the tests.

when testing low MFR

materials.

The MF20 is offered as a

basic instrument to be

configured with a variety of

options, such as a manual or

motorized melt cutting device

and a high-resolution digital

encoder for MVR measure-

ments according to ASTM

D1238, methods B and C.

❙ www.instron.com

methods are also included to

help those who are new to

the use of xenon equipment.

A range of accessories are

offered, including five

interchangeable optical

filters that simulate all

relevant light conditions:

outdoor daylight, indoor

daylight, artificial supermar-

ket light, ID65 (ICH) and solar

standard. Other add-ons

include an immersion unit for

the simulation of extremely

wet, marine or acidic

environments, plus a chiller

and water-cooled specimen

table for specimen cooling.

❙ www.atlas-mts.com

UV fading, while repeatability

has been improved.

In addition, the instrument’s

ease-of-use has been

improved. Its larger four-line

display panel provides easier

atlas says its fourth

generation suntest CPs+

provides improved

functionality.

A further standard feature

of the MF30 model is a

high-resolution load cell for

controlled compacting of the

material prior to the start of

the test up to a maximum force

of 750 N. Also included in the

test system is a high-precision

encoder that permits the

controlled extrusion of the

melt to a defined height. In

addition, the supplied software

enables purging of the barrel

at the end of a test, specifically

Download the programmes for these forthcoming conferencesSimply click on the brochure cover or link to download a PDF of the full publication

To see our full line-up of more than 25 plastics industry eventsover the next 12 months, please visit www.amiconferences.com

Pipeline Coating

AMI is holding the fi fth international Pipeline Coating conference on 18-20 February in Vienna, Austria. This event, which attracts a large global audience, covers the latest developments in pipeline protection and coating technologies.

� Click here to downloadFax back to +44 (0) 117 311 1534

Pipeline Coating 2013


Sponsored by:

Media supporters:

sPECIAL OFFER: Save €110 if you register before 14th December 2012

18-20 February 2013Austria Trend Hotel Savoyen,

Vienna, Austria

Images courtesy of: Bredero shaw and shawCor, Canusa systems and Wasco Coatings Group

International conference on pipeline protection, coating technology, materials and markets

The hugely popular Wind Turbine Blade Manufacture conference returns for the third time on 27-29 November in Düsseldorf, Germany. Download the programme that covers the latest materials and processing innovations.


speCial OFFer: Save €200* if you register before 12th October 2012

* + 19% German VAT


Also sponsored by:

Image courtesy of: siemens

WIND TURBINE BLADE MANUFACTURE 2012

International conference and exhibition on wind blade composites design, manufacturing and markets

27-29 November 2012Maritim Hotel, Düsseldorf, Germany

heaDline spOnsOr

Media supporters:

TM

Companies attending the previous Polyethylene Films conference accounted for more than 3 billion lbs of PE resin usage. Don’t miss this essential industry event when it returns to Florida’s Daytona Beach on 5-6 February 2013.


The international industry conference on markets and technical aspects of waterproofi ng for roofi ng and geomembranes is being held in Düsseldorf, Ger-many, on 11-13 December. This brochure has all the details.

� Click here to downloadOrganized by:Applied Market Information LLC

Images courtesy of: Bold text for company name

The international marketing, business and technical conference for the polyethylene film industry

Polyethylene Films 2013

HEADLINE SPONSORS

SPECIAL OFFER: Save $200 if you register before December 14, 2012

February 5-6, 2013The Shores Resort & Spa,

Daytona Beach, Florida, USA

Also sponsored by: Media supporter:

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Fax back to +44 (0) 117 311 1534

International industry conference on markets and technical aspects of waterproofing for roofing and geomembranes

waterproof membranes

2012

Media Supporters: Organised by:Applied Market Information Ltd.

SPECIAL OFFER: Save €100* if you register before 9th November 2012

* + 19% German VAT

11-13 December 2012Hotel Nikko, Düsseldorf, Germany

HEADLINE SPONSOR

AMI’s seventh Thin Wall Packaging conference has attracted a great line-up of speakers from companies such as Nestlé, RPC, Linpac, General Mills and EDV Packaging. This brochure has the full programme.


Thin Wall Packaging 2012

3-5 December 2012Maritim Hotel, Cologne, Germany

speCial OFFer: Save €210* if you register before 2nd November 2012


Sponsored by: Media supporters:

International conference on market trends and developments in plastics tubs, cups and tray packaging

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* + 19% German VAT

Wind Turbine Blade Manufacture Thin Wall Packaging

Waterproof membranes Polyethylene Films 2013

Grass Yarn & Tufters Forum

The Grass Yarn & Tufters Forum is the international conference covering trends and developments in the artifi cial grass market. The seventh such event is being held in Cologne, Germany on 18-20 February and its infl uential programme includes FIFA.

� Click here to downloadfax back to +44 (0) 117 311 1534

Images courtesy of: Dow Chemical Company * + 19% German VAT


speCIaL offer: Save €210* if you register before 18th January 2013

The Grass Yarn & Tufters

Forum 2013Trends and developments

18-20 February 2013Maritim Hotel, Cologne,

Germany

heaDLIne sponsor

Media supporter:

Head offi ce location: Yunlin, Taiwan

Date founded: 2005

CEO: Antony Chang

No. of employees: 40

Sales 2011: US$3 million (estimated)

Plant locations: Yunlin, Taiwan

Production 2011: 1,500 tonnes

Profi le: Phon Tech is one of the leading manufacturers and exporters of styrene-based thermoplastic elastomers (TPEs) in Taiwan. The company was established in 2005, bringing together a team with decades of industry knowledge and experience. Phon Tech specialises in styrenic block copolymer compounds (SEBS) that are marketed under the brand name Phoenix.

Product line: Phoenix TPE compounds are available in transparent, translucent, white, black, colour and over-moulding grades. They are used in applications such as medical appliances, food/beverage closures and containers, non-slip surfaces (power tools, bike grips, knife grips), footwear, stationery, toys, electronics and so on. Phoenix compounds are suited to standard plastic processing including injection moulding, blow moulding and extrusion.

Product strengths: Phon Tech claims to produce materials with excellent anti-brittle properties, rubber-like texture, excellent UV stability and high tensile/tear strength. In addition, the materials are odourless, chemically resistant and recyclable. Ongoing innovation ensures the products keep pace with ever changing customer requirements.

Phon Tech Industrial Company

compounder of the month

Forthcoming featuresThe next issues of Compounding World magazine will have special reports on the following subjects:

DecemberLaboratory compoundersFlame retardantsCompounding high-performance plastics

JanuaryPolymer foam technologiesPelletizersDispersants and coupling agents

Editorial submissions should be sent to Andy Beevers: [email protected]

For information on advertising in these issues, please contactClaire Bishop: [email protected] Tel: +44 (0)20 8686 8139

Take out your own FREE subscriptions to any of the magazines.Click on the logos below to simply register on-line.

Catch up on our recent issues for FREE

Simply click on the cover to see the full magazine, or download the issue in the relevant iPad/iPhone app

Compounding World – SeptCompounding World’s September issue is packed with articles on developments in pigments and colorants, the North American masterbatch industry, adding value with mineral fi llers, and how to measure the weathering resistance of plastics.

� Click here to view

Injection World – OctoberInjections World’s October issue is fi lled with features on the latest trends in caps and closures, advanced medical device applications, moulding multi-layer optical parts, plus innovations in thin wall packaging.


Compounding World – OctThe October edition of

Compounding World contains special features on reinforcing fi bres, titanium dioxide trends,

extruder alignment techniques, melt fi ltration

systems plus Fakuma show highlights.


Pipeline Coating – NovemberThis new edition of Pipeline

Coating magazine boasts features on deep sea joint

testing, shale gas opportunities, the lining of

subsea hydrocarbon pipes, and delivering water in Botswana.


Pipe and Profi le – Sept/OctThe September/October issue

of Pipe and Profi le Extrusion examines the latest ideas in

co-extrusion, downstream equipment, and PE100 resins. It also looks at how trenchless

technology is reducing the cost of installing plastic pipes.


Film and Sheet – NovemberThe November edition of Film and Sheet Extrusion magazine contains special features on BOPP trends, multilayer packaging, bioplastics research, extruder innovations and additives for polyolefi ns.


dates for your diary

Don’t miss a single issueRegister now for your free subscription at:


And don’t forget to tell your colleagues, customers and suppliers about the magazine. You can use the e-mail button above

(the @ symbol in the browser) to help spread the word.

14-15 November Expoplast,Montreal,Canada www.expoplast.org

29 Nov – 2 Dec PlastEurasia,Istanbul,Turkey www.plasteurasia.com

7-10 January ArabPlast,Dubai,UAE www.arabplast.info

29 Jan - 1 Feb Interplastica,Moscow,Russia www.interplastica.de

6-7 March PlastecSouth,Orlando,FL,USA www.plastecsouth.com

12-15 March Plastimagen,MexicoCity,Mexico www.plastimagen.com.mx

12-15 March Pro-PlasExpo,Johannesburg,SouthAfrica www.proplasafrica.co.za

3-6 April Tiprex,Bangkok,Thailand www.tiprex.com

10-11 April PlastTeknik,Malmo,Sweden www.easyfairs.com

14-16 May Plast-Ex,Toronto,Canada www.plast-ex.org

20-23 May Chinaplas,Guangzhou,China www.chinaplasonline.com

20-24 May Feiplastic,SaoPaolo www.feiplastic.com.br

18-19 June PDM,Telford,UK www.pdmevent.com

18-20 June PlastecEast,Philadelphia,USA www.plasteceast.com

10-12 September PlastecMidwest,Chicago,USA www.plastecmidwest.com

16-23 October K2013,Düsseldorf,Germany www.k-online.de

Global exhibition guide

AMI conferences 27-28 November MineralsinCompounding,Atlanta,GA,USA

27-29 November FireResistanceinPlastics,Cologne,Germany

29-31 January ThermoplasticConcentrates,CoralSprings,FL,USA

18-20 February TheGrassYarn&TuftersForum,Cologne,Germany

25-27 February Wood-PlasticComposites,Vienna,Austria

5-7 March Cables,Cologne,Germany

12-14 March PVCFormulation,Düsseldorf,Germany

18-20 March MasterbatchAsia,Singapore

19-21 March GreenPolymerChemistry,Cologne,Germany

7-8 May BioplasticsCompounding&Processing,Miami,FL,USA

14-15 May PolymersinCables,Miami,FL,USA

14-16 May PolymerSourcing,Vienna,Austria

3-5 June Masterbatch,Frankfurt,Germany

For information on allthese events and other

conferences on film,sheet, pipe and

packaging applications, see

www.amiplastics.com

Cw November 2012

Documents

Transcript of Cw November 2012