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PVC 101: Overview

I. Why PVC?

II. Polyvinyl Chloride: The Basics of Raw Materials & Compounding

A. What material goes into PVC

B. PVC versus Other Polymers/Plastics

C. Environmental/Toxicity of PVC

III. Sheet Extrusion Made Practical & Simple

IV. Market Applications

Why Use PVC in Manufacturing Products?

PVC’s Key Features Benefits for Manufacturers

Inherent Flame Resistance

PVC is inherently flame resistant• Thicker material is more resistantFaster Part Approval• Material meets agency flame ratings which reduces part testing

Chemical Resistance Resists discoloration or stress cracking from cleaners, foods, oils, detergents, insecticides and many chemicals

UV Resistance Enhanced Image• Parts look newer longer because they resist discoloration due to UV

exposure

Cost Performance Reduced Manufacturing Costs By:• Rigid vinyl can replace higher cost engineered materials like FR ABS,

PC+ABS and PC• Flexible PVC can replace higher cost thermoplastic elastomers and rubber• Flexible PVC is the most versatile and cost effective plastic on the marketImprove Manufacturing Efficiency• Lower Scrap Rates• 100% recyclable

PVC Usage• Commercial Markets

• Strip Doors• Clean Rooms• Computer and Electrical

Equipment Enclosures• Sound Block• Automotive• Tank Lining• Geomembranes• Many Others

• Other Markets• Laminated Products

• Banners• Tents• Awnings

• Wallcovering and Wallboards• Swimming Pool Liners• Tapes and Labels• Advertising (signs)• Many Others

Polyvinyl Chloride

• PVC Resin

– The Building Block– Product of salt and oil/natural gas– Two primary manufacturing methods:

• suspension method• dispersion method

– Accounts for approximately 50% of content for flexible sheet

The Basics of Raw Materials

Polyvinyl ChlorideThe Basics of Raw Materials • Plasticizer

– Additive that gives flexibility and pliability– Types Include Phthalates, Adipates and

Phosphates– Accounts for 30-40% of flexible sheet

Polyvinyl Chloride

• The Remaining 10-20%

– Fillers– Stabilizers– Process Aids– Fungicides– Flame-Retardants– UV Inhibitors– Anti-Stat

The Basics of Raw Materials

Polyvinyl ChlorideThe Basics of Raw Materials • Pricing in the PVC Sheeting

Market is Driven by Two Primary Items:

– Oil and/or natural gas pricing• As oil prices increase, prices for other

polymers based on 90-100% hydrocarbon increase at a higher rate than PVC, which is 43% hydrocarbon-based

– Seasonality factors such as the construction industry

Making Polymers

Polymer Compound

Additives

PolymerIntermediate Chemicals

Hydrocarbons (Oil, Nat Gas)

PVC Compound

Additives

PVCIntermediate Chemicals

Hydrocarbons (Oil, Nat Gas)

Salt Water

Process for Making Most Polymers

Process for Making PVC

Polyvinyl ChlorideGlobal Demand (2010 figures)

Vinyl is the second largest polymer manufactured globally.• World Polymer Demand:

• 419 billion lbs.

• PVC Resin Demand:• 75 billion lbs.• 18% of total global demand

• USA & Canada PVC Demand:• 9.5 billion lbs.

• China expected to be 44% of global demand by 2020

PVC is Used in a Variety of Plastic Processing

Injection Molding

Profile Extrusion

Sheet Extrusion Calendering

Blow Molding

Polyvinyl Chloride

• Advancements in Eco-Friendly Raw Materials

– Bio-based plasticizers• Plant based• Smaller carbon footprint• Renewable resource

– Lead additives phasing out in North America and Europe

• Less VOCs than PE, PP or ABS• Vinyl chloride and chlorine gases not

released if PVC degrades• Can be safely recycled, land-filled and

incinerated• Processed at lower temperatures than

competing polymers, i.e.; requires less energy

Eco-Friendly

Polyvinyl Chloride

PVC Has Been Safely Used for Over 50 Years

• Vinyl chloride monomer (VCM) exposure well below levels that pose a threat

• FDA approved for food packaging• FDA & USP approved for medical use• CPSC allows vinyl use in children’s toys• NSF International approved for potable water

piping• UL, CSA, CFSM and NFPA approved for fire

safety• PVC has not been legislatively banned by

any country or state/province

Safe, Non-Toxic Polymer

Phthalates and Children's Toys

Consumer Product Safety Improvement Act: Phthalates Provision for Toys

CPSIA Restrictions Apply to Specified Phthalates:• Permanent Restrictions (on use in children’s toys & articles with

concentrations >0.1%)– DEHP– DBP– BBP

• Temporary Restrictions (see Appendix)– DINP– DIDP– DnOP

(See Appendix)

Polyvinyl Chloride

• Compounding basics– Mix raw materials

• Intensive vs. ribbon

– Transfer to compounding line• Single screw, twin screw, continuous or

kneader

– Pelletizer• Air-cut, underwater or strand

– Package and ship pellets

The Basics of Compounding

Sheet Extrusion Process

Sheet Extrusion Process: Equipment Basics

Sheet Extrusion Made Practical & Simple

• Compounded raw materials are moved to the manufacturing area, typically in boxes, gaylords or via silo

• Compound is then drawn into a system of hoppers and dryers (image on left)

• Compound then proceeds through to a single or twin screw extruder (image on right)

Sheet Extrusion Made Practical & Simple

• Material is conveyed through the screw and into a sheet die– Compound is re-melted and mixed by

both shear heat and pressure through this process

• Typical types of dies:– Coat hanger die (image)– Pipe die– Plate die

Sheet Extrusion Made Practical & Simple

• After exiting the die, the PVC is then forced through a series of chrome rolls

• The thickness of the material is set at this point in the process

• Typical types of rolls:– High polish– Frosted– Embossed

Sheet Extrusion Made Practical & Simple

• The formed sheet then goes through a cooling process, that can include:– Water bath (image on top)– Chilled rolls (not pictured)

• Light boxes can be installed for visual quality control (image on bottom)

Sheet Extrusion Made Practical & Simple

• Knives or slitting equipment such as crush cutters are set to slit wide sheet into specific roll widths (pictured)– 4”, 6”, 8” etc.

• Excess PVC is then recycled, reground and put back into the process

Sheet Extrusion Made Practical & Simple

• PVC sheet then is pulled into a wind-up where it is wound onto cores

• Typical types of wind-ups found in the plastics processing industry:– Surface winders– Turret winders

Market Applications

Strip Doors Data Centers

Market Applications

Tank Lining Enclosures

Summary

PVC 101:I. Compounding

A. Raw materials are mixed and extruded as pellets

II. ExtrudingA. Pellets go through a series of hoppers and

dryers

B. Pellets go through a single or twin screw extruder

C. Hot material winds through a three roll calender stack. Embossed at this point

D. Sheet is cooled and wound onto cores

III. PVC MarketsA. Commercial Markets

I. Strip Doors, Clean Rooms, Computer & Electrical Enclosures, Automotive, Geomembranes, etc.

B. Many Other Markets

Questions?

• Resources, Additional Questions & Information– TMI, LLC

• www.tmi-pvc.com | 1.800.888.9750

– American Chemistry Council• www.americanchemistry.com

– The Vinyl Institute• www.vinylinfo.org

– Vinyl Council of Canada• www.plastics.ca

– European Council of Vinyl Manufacturers• www.pvc.org

AppendixPhthalates and Children's Toys

Consumer Product Safety Improvement Act: Phthalates Provision for Toys

In August 2008, President Bush signed into law the Consumer Product Safety Improvement Act (CPSIA), (H.R. 4040). The CPSIA overhauled the Consumer Product Safety Act, and responded, in part, to public concerns about imported toys containing lead. Among the CPSIA’s provisions are restrictions on six phthalates in toys and children’s products. These restrictions became effective February 10, 2009.

The phthalates restrictions of the CPSIA apply to specified phthalates in particular products:• DEHP, DBP and BBP: There were permanent restrictions, effective February 10, 2009, on the sale

of children’s toys and child care articles with concentrations of more than 0.1 percent of di-(2-ethylhexyl) phthalate (DEHP), dibutyl phthalate (DBP) or benzyl butyl phthalate (BBP).

• DINP, DIDP and DnOP: CPSIA placed temporary (interim) restrictions, effective February 10, 2009, on the sale of children’s toys that can be placed in a child’s mouth, and on child care articles that contain more than 0.1 percent of diisononyl phthalate (DINP), diisodecyl phthalate (DIDP) or di-n-octyl phthalate (DnOP). Toys that can be put in the mouth are defined to include toys or parts smaller than five centimeters in one dimension. Toys that cannot be put in the mouth, but can be licked, are not included.

For the three interim-restriction phthalates (and for other phthalates and plasticizers), the Consumer Product Safety Commission (CPSC) must convene a scientific study conducted by a Chronic Hazard Advisory Panel (CHAP). After the CHAP is completed, CPSC must decide whether to lift the interim restriction or make it permanent.

AppendixPhthalates and Children's Toys, What You Need to Know

The CPSIA sets specific standards on the presence of certain phthalates in toys and child care articles. However, unlike lead, where prior to the passage of CPSIA there had been numerous, highly publicized recalls of children’s products by CPSC, there had been no equivalent activity by the CPSC with regard to phthalates. It is also important to note that:• Of the six phthalates restricted by the CPSIA, DINP had been typically used in toys in recent

years; this phthalate has not been permanently restricted by CPSIA. Instead, it has been referred for further study. DINP was found safe in a previous review by CPSC.

• A CHAP convened in 2001 to review the safety of DINP concluded that, “For the majority of children, the exposure to DINP from DINP-containing toys would be expected to pose a minimal to nonexistent risk of injury.”

• The CHAP also added there might be a risk to children who mouth DINP-plasticized toys for 75 minutes a day or more, day after day for an extended period of time; however, mouthing experiments showed that children kept toys in their mouths for less than two minutes a day.

• CPSC has never expressed immediate concerns about phthalates used in toys and child care articles, therefore, consumers should not be alarmed or concerned that some children’s products may still contain phthalates.

• The industry voluntarily removed DEHP and DINP from teethers, rattles and pacifiers and, as a result, these products are made from plastics that are not expected to contain phthalates. The CPSIA simply put this voluntary agreement into law.