Improving the sustainability of thermoformed polyolefin food packaging through UPES
Transcript of Improving the sustainability of thermoformed polyolefin food packaging through UPES
Improving the sustainability of thermoformed polyolefin food packaging through UPES® interpolymer modification
Presenter: Dr. Eric VignolaASTM Committee D10Workshop on PackagingOctober 12, 2010San Antonio, TX
Outline
• Sustainability concepts
• Introduction to QINNEX® technology & UPES® interpolymer resin
• UPES resin modification of polyolefins
– HDPE
– PP
– LDPE
• Summary
• Acknowledgements
NOVA Chemicals and Sustainability
• We believe a sustainable business is a profitable and socially responsible business
• Our approach to managing health, safety, security, environmental protection and sustainability is implemented primarily through the principles of Responsible Care®
Sustainability Development
• We support the United Nations’ definition of Sustainable Development – meeting the needs of the present without compromising the ability of future generations to meet their own needs
• NOVA Chemicals is committed to the “Triple Bottom Line” approach to sustainability:
– Environmental, Social, Economic
Environmental
SocialEconomic
Sustainability
Sustainable concepts
• The 3 R’s
– Reduce
– Re-use
– Recycle
• Plus
– Renewable resources
– Recycle content
– End of life
• Lightweight• Lower Carbon Footprint• Reduced Volume• Increased Durability
A product of
The technology behind UPES resin delivers enhanced compatibility with various polymers systems and broadens the processing window of most polyolefins.
An interpolymer made from Polystyrene (PS) and Polyethylene (PE), UPES resin offers the following:
• Variable ratio of the two polymers
• Different types of polyolefins can be used
• Can add different co-monomers
• Ability to vary of amount of cross-linking
• Where the two phases are compatibilized ‘in situ’
Polyethylene Micro-pellets
Suspension Polymerization
Polyolefin pellets
Opaque / white beads
55 to 60 pellets per gram
extrusion
UPES resin Interpolymer Morphology
PE/PS Melt Blend PE/PS Interpenetrating Network
(1) Properties were determined on injection-molding specimens following the protocols of ASTM D4549 “Standard Specification for Polystyrene Molding and Extrusion Materials” unless otherwise specified.
(2) The product properties designated in this standard have been determined in accordance with the current issues of the specified testing methods. Methods of the American Society for Testing and Materials (ASTM) are used wherever applicable.
(3) Melt flow index at 230°C/2.16kg (446°F/4.76lb). a) UPES-090-EXP : Notched Izod specimen displayed partial break, un-notched specimen displayed torque and flex upon impact, but no break b) UPES-170-EXP: Notched Izod specimen displayed hinged break, un-notched specimen displayed indentation, but no break c) UPES-315: Notched Izod specimen displayed break, un-notched specimen displayed break
Properties of UPES resin are tailorable
UPES resin Interpolymer Properties
Properties(1) ASTM(2) UPES-090-EXPresin
UPES-170-EXPresin
UPES-315resin
Tensile Strain at Break (%)
D 638 54.2 5.7 2.7
Flexural Modulus (psi) D 790 89 200 169 900 300 000
Notched Izod(ft-lb/in) a,b,c D 256 11.3 2.8 0.4
Un-notched Izod(ft-lb/in)
D 256 12.2 20.2 12.5
Melt Flow Index(3)
(g/10 min)D 1238 0.32 0.23 0.24
Rheological Properties of UPES resin
Resin (Supplier) Melt Index (g/10 min)
@200°C/5 kg
Melt Index (g/10 min)
@190°C/2.16 kg
PS 1600 (INEOS-NOVA) 5.5 --
FP-120-A (NOVA Chemicals) -- 1.0
UPES-315 resin (NOVA Chemicals) 0.46 0.04
UPES -315 resin offers:
• Improved processability
• Shear thinning properties
190°C
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1000000
0.01 0.10 1.00 10.00 100.00
Sh
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Pa
-s)
Frequency (rad/s)
PS1600
FP120-A
UPES-315 resin
Collaboration throughout the Value Chain
NOVA Chemicals :: resin
PRIMEX :: sheet
Tray-Pak :: thermoformed parts
Situation
Polyolefin Thermoforming Challenges
– Warpage
– Increased sheet gauge required to deliver desired performance properties
– Poor material distribution
– Inefficient processing
– Difficulty achieving sustainable output rates
What is Thermoforming?
Deep Draw Produce Tray
HDPE Part 60 mils
UPES resin/HDPE 50 mils
Increase in melt strength offered by UPES resin provides:
• Reduced gauge• Better material distribution
50 mils = 1.270 mm60 mils = 1.524 mm
HDPE Property Modification
0 s 15 s 30 s 45 s 60 s 75 s 90 s 105 s 120 s
HDPE/UPES resin 50 mils
HDPE 60 mils
HDPE Property Modification
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103
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HDPE 60 mils
HDPE/UPES 50 mils
140% increase
Increase in melt strength offered by UPES resin provides:
• Increased thermoforming throughput• Improved part performance ASTM D 2659
UPES resin/HDPE blends vs. HDPE
• 20% source reduction
• 33% faster forming rates and shorter start-ups– Increased machine time availability
• > 100% increase in mechanical properties
• Enhanced part definition
• Reduced scrap rates
• Recyclable
Shallow Draw Institutional Tray
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HDPE 25 mils
HDPE/UPES 20 mils
30 %
• 20% source reduction• 30% increase in flexural properties• 40% increase in throughput rates
ASTM D 790
Polypropylene-UPES resin Lidstock
• HIPS is the incumbent
• Achieved 11 mil parts, previously unattainable with 100% PP
• Enhanced ESCR properties compared to HIPS & similar mechanical properties than HIPS
• PP/UPES resin parts weigh less than HIPS or filled PP parts at the same gauge
• Processability similar to HIPS
UPES resin in LDPE based x-linked foams
Foam 1: 4.4 pcf (70 kg/m3)
Foam 2: 4.9 pcf (78 kg/m3)
Foam w/ UPES resin: 2.5 pcf (40 kg/m3)
UPES modified LDPE resin produces lower density foams with superior properties
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Voltek foamYoungbo foamCellect foam w/ IP-73-U (30%)
Foam 1Foam 2
Foam w/UPES
Pro
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% o
f Fo
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resin
Summary
• UPES resin is a tailorable product that can offer increased rheological properties, melt strength, compatibility and functionality
• Documented sustainability benefits: Lightweight Lower carbon footprint Reduced volume Increased durability
• Opinion letters available for food contact applications
Questions?
UPES, QINNEX and their logos are trademarks of NOVA Brands, Ltd.; authorized use/utilisation autorisée.
The information contained herein is provided for general reference purposes only. By providing the information contained herein, NOVA Chemicals Inc. makes no guaranty or warranty and does not assume any liability, with respect to the accuracy or completeness of such information, or product results in any specific instance, and hereby expressly disclaims any implied warranties of merchantability or fitness for a particular purpose or any other warranties or representations whatsoever, expressed or implied. Nothing contained herein shall be constructed as a license to use the products of NOVA Chemicals Inc. in any manner that would infringe any patent. Nothing herein shall be copied, reproduced, distributed or otherwise used without the express written permission of NOVA Chemicals.
Acknowledgments:• Joseph B. Paolucci• Shelly A. Martel• Daniel C. Purpura• Christine B. Hetzer• H. T. Kemp
For more information visit: www.upesresin.com