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Manufacture of Plastic Films,

HDPE and Thermoset Plastics

(Bopp Films, Polyester Films, Polyolefins,

Polypropylene, Vinyls, Polyvinyl Acetate, Expanded

Films, Vinyl Ester Resins, Unsaturated Polyesters,

Thermoset Polyurethanes, Polyurethane Coatings,

Lamination, Thermoforming, Thermoplastic Polymers)

Introduction

Plastic film is a thin continuous polymeric material.

Thicker plastic material is often called a “sheet”. These

thin plastic membranes are used to separate areas or

volumes, to hold items, to act as barriers, or as printable

surfaces.

Plastic films are used in a wide variety of applications.

These include: packaging, plastic bags, labels, building

construction, landscaping, electrical fabrication,

photographic film, film stock for movies, video tape, etc.

High-density polyethylene (HDPE) or polyethylene high-

density (PEHD) is a polyethylene thermoplastic made

from petroleum. It is sometimes called "alkathene" or

"polythene" when used for pipes. With a high strength-

to-density ratio, HDPE is used in the production of

plastic bottles, corrosion-resistant piping,

geomembranes, and plastic lumber.

Thermoset, or thermosetting plastics are synthetic

materials that strengthen during being heated, but cannot

be successfully remolded or reheated after their initial heat

forming. This is in contrast to thermoplastics, which soften

when heated and harden and strengthen after cooling.

Thermoplastics can be heated, shaped and cooled as often

as necessary without causing a chemical change, while

thermosetting plastics will burn when heated after the

initial molding.

Additionally, thermoplastics tend to be easier to mold

than thermosetting plastics, which also take a longer time

to produce (due to the time it takes to cure the heated

material).

Some of the astonishing fundamentals of the book are

salient features of contemporary, technology and current

research, three basic processes: advances, modern

polyethylene, processes using high yield catalysts,

solution polymerization processes, polyolefins, low density

polyethylene, polyvinylidene chloride (PVDC),

vinyl chloride/vinyl acetate copolymers, polyvinyl acetate,

polyvinyl alcohol, physical and chemical properties,

manufacturing methods, extrusion of film, slit die

extrusion (flat film extrusion), comparison of blow and

cast film processes, water cooled polypropylene film,

calendaring, solvent, casting, casting of regenerated

cellulose film, orientation of film, expanded films, plastics

net from film,

unsaturated polyester and vinyl ester resins, thermoset

polyurethanes, guidelines and theories in compounding

polyurethane elastomers, compounding for thermoset

polyurethane elastomers, cellulose and cellulose

derivatives, thermoplastic polymers etc.

Market Outlook

the Global Plastic Films and Sheets Packaging Market is

valued at $92.4 billion in 2015 and is expected to reach

$139.2 billion by 2022 growing at a CAGR of 6% from

2015 to 2022. Rising demand for bi-axially oriented films

and increased demand for bio plastic materials are the

key drivers of the market.

Total export of plastic and plastic products from India

stood at US$ 449.72 million in 2015. The Indian plastic

comprises of more than 2,000 exporters.

The India plastic industry has grown by 13% annually in

the last five years and a similar growth rate is expected

to continue in 2016-17.

The size of industry is expected to reach Rs. 1.7 lakh

crore from Rs. 1.20 lakh crore last year.

High Density Polyethylene (HDPE) Market size was

valued at approximately USD 60 billion in 2015 with

gains of over 4% CAGR between 2016 and 2024.

High Density Polyethylene (HDPE) Market

US demand for plastic film is expected to grow 1.9% pa to

16 billion in 2016, with a market value of US$19 billion.

The major trend driving the thermosetting plastics

market is the growing demand for Developing countries

like India, China and Brazil, and is reflected in growing

production of thermosetting plastics: in 2015 production

of thermosetting plastics amounted to 34.99 million

tonnes. Global thermosetting plastics production is

currently estimated to be 34.99 million tonnes in 2015

and is expected to reach 41.96 million tonnes by 2020

showing a compound annual growth rate of 3.7%.

Table of Contents

CHAPTER 1

BOPP FILMS

Background

Structural Development of Plastics in India

History of films

Film Properties

Applications of Films

Process of Manufacture

Tenter Process

Comparison of the processes

Polyester Films

Raw materials

Capital equipment

General

CHAPTER 2

SALIENT FEATURES OF

CONTEMPORARY TECHNOLOGY AND

CURRENT RESEARCH

• Introduction

• Three basic processes: Advances

• Modern polyethylene processes using high yield

catalysts

• Solution polymerization processes

• Slurry processes

• Gas phase processes

• Processing

• Comparative evaluation of contemporary technology

• Process selection based on capability

• Latest development

CHAPTER 3

POLYOLEFINS

• Low density polyethylene

• Properties

• Uses 120

• Irradiated Polyethylene

• High density polyethylene

• Properties

• Uses 123

• Polypropylene

• Properties

• Poly (Methyl pentene) (TPX)

• Ethylene/vinyl acetate copolymers (EVA)

• Properties

• Poly (BUTENE-1)

• Properties

• Uses 129

• Melt flow index (MFI)

CHAPTER 4

VINYLS

• Polyvinyl Chloride (PVC)

• Properties

• Polyvinylidene chloride (PVDC)

• Vinyl chloride/Vinyl acetate copolymers

• Polyvinyl acetate

• Polyvinyl alcohol

CHAPTER 5

MECHANICAL PROPERTIES•

Tensile and yield strength elongation and young's

modulus

Test Methods

Burst strength

Impact strength

Impact Fatigue

Tear strength

Puncture penetration test

Stiffness

Flex resistance

Coefficient of friction

Blocking

CHAPTER 6

PHYSICAL AND CHEMICAL

PROPERTIES

• Optical properties

• Light transmission

• 'See-Through' Clarity

• Haze

• Gloss

• Permeability

• Water vapour premeability

• Gas Permeability

• Odour Premeability

• Density

• Heat sealabiliy

• Dimensional stability

• Water absorption

• Effect of chemicals

• Effect of Light

• Effect of Temperature

• High Temperature

• Low Temperature

• Flammability

CHAPTER 7

MANUFACTURING METHODS

• Extrusion of Film

• Slit Die Extrusion (Flat Film Extrusion)

• Comparison of Blow and Cast Film Processes

• Water Cooled Polypropylene Film

• Calendering

• Solvent Casting

• Casting of regenerated cellulose film

• Orientation of film

• Expanded films

• Plastics Net From Film

CHAPTER 8

HEALTH SAFETY OF PLASTICS FILMS

• Overall system

• Base Lines for Evaluation

• Food Spoilage

• Toxicity and Adulteration

• Interactions

• Safety evaluation Mass transfer

• Law

• Licensing Type Systems

• International trade

• Individual countries

• United Kingdom

• USA

CHAPTER 9

ODOUR AND TAINT IN PLASTICS FILMS

• Intrroduction to organolepsis and tainting

• Causes of tainting

• Loss of Volatile Material From Food to Environment

• Diffusion of Volatilies, additives, and Volatile

Residual Reactants from Plastics to Food

• Vapour From Environment t to Food

• Micro-organisms to Food

• Marco-Organisms to Food

• Radiation from Environment to Food Stuff

• Assessment

• Samples

• Food

• Tests Methodology

• Remedies

• Masking and Counteraction

• Conclusions

CHAPTER 10

SEALING OF FILMS

Mechanical methods

Heat sealing

Sealing of oriented film

High frequency heating

Ultrasonic sealing

Adhesives

Choice of method

CHAPTER 11

PRINTING ON PASTICS FILMS

• Pre treatment

• Solvent treatment

• Chemical treatments

• Flame treatment

• Electrical treatment

• Tests for efficiency of pre- treatment

• Method of Printing

• Screen printing

• Letterpress

• Flexographic printing

• Photogravure printing

• Hot stamping

• Electrostatic printing

• Printing inks

• Vaccum metallisation

CHAPTER 12

WRAPPING EQUIPMENT

• Wrapping with thermoplastics films

• Feeding the Wrapping Material

• Forming the pack

• Closing the pack

• Continuous wrapping machines

• Pouch making equipment

• Sachet making machines

• Vaccum and gas packaging

• Shrink wrapping

• Scope of Process

• Types of Shrink Wrap

• Shrink wrapping equipment

• Tray Erection

• Film Wrapping and Sealing

• Shrink Tunnels

• Properties of heat shrinkable films

• Shrink Temperature

• Degree of Shrinkage

• Shrink Tension

• Pallet overwrapping

• General advantages and problems

CHAPTER 13

UNSATURATED POLYESTER AND VINYL

ESTER RESINS•

Unsaturated polyesters

Vinyl ester resins

Compounding of unsaturated polyester and vinyl

ester resins

Applicable manufacturing processes

Recent Developments

CHAPTER 14

THERMOSET POLYURETHANES

• Introduction

• Polyurethane Chemistry

• What are Polyurethanes ?

• Polyurethane raw materials and moisture

• Handling of polyurethane components

• Types of polyurethane systems

• Advantages of adduction

• Range and types of polyurethane products

• Polyurethane uses

• Neoprene Lubricant Adhesive #106

• Polyurethane Coatings

• Components for Polyurethanes

• Industrial Mathematics for Polyurethanes

• Terminology

• Guidelines and Theories in Compounding

Polyurethane Elastomers

• Compounding for Thermoset Polyurethane

Elastomers

• General consideration

• Appendix

• Method for Preparation of MDI Prepolymers

CHAPTER 15

CROSSLINKED THERMOPLASTICS

• Crosslinking of thermoplastics

• Effects of Crosslinking on Polymer

• Chemical Crosslinking

• Rotational molding

• Post irradiation effects

• Acrylates

CHAPTER 16

MISCELLANEOUS

• Nylons (Polyamides)

• Polycarbonate

• Polyethylene terephthalate (Polyester)

• Acrylic multipolymer

• Propylene/vinyl chloride copolymer

• Rubber hydrochloride

• Fluoropolymers

• Polyvinyl Fluoride

• Polyurethane

• Polyimides

CHAPTER 17

IONOMERS

• Properties

CHAPTER 18

STYRENE POLYMERS AND

COPOLYMERS

• Polystyene

• High impact polystyrene

• Expanded polystyrene

• Styrene/acrylonitrile copolymer (SAN)

• Acrylonitrile/Butadiene/Styrene (ABS)

CHAPTER 19

CELLULOSE AND CELLULOSE

DERIVATIVES

• Regenerated cellulose

• Substituted Celluloses

• Cellulose nitrate (Celluloid)

• Cellulose acetate

• Cellulose Triacetate

• Cellulose acetate/butyrate (CAB)

CHAPTER 20

THERMOPLASTIC POLYMERS

• Polymerization Concepts

• Polymerization Mechanisms

• Methods of Polymerization

CHAPTER 21

THERMOSET POLYMERS

• Cross linked Polymers

• Thermoset Polyester

• Polyurethane Elastomers

• Polyimides

• Ladder polymers

CHAPTER 22

PROCESSING AND FABRICATION

• Orientation of molecules and fibers

• Reinforced thermoset processing

• Thermoplastic processing

• Molds

• Mixing equipment

• Adhesive Application

CHAPTER 23

BAG AND SACK MANUFACTURE

• Nature of the film

• Bags made from tubular film

• Bags made from Flat Film

• Heavy duty sack manufacture

CHAPTER 24

THERMOFORMING

• Methods of thermoforming

• Vaccum forming

• Skin pachaging

• Pressure forming

• Matched mould forming

• Machine variables

• Heating

• Cooling

• Moulds

• Trimming

• Printing

• Materials and applications

• PVC

• Toughened polystyrene

• Biaxially oriented polystyrene

• ABS

• Low density polyethylene

• High density Polyethylene

• Polypropylene

• Cellulose acetate

• Cellulose acetate/butyrate

• Polycarbonate

• Cold forming

CHAPTER 25

LAMINATION

• Coating

• Predetermined systems

• Reverse roll coaters

• NIP roll coaters

• Gravure coaters

• Calender coating

• Curtain coating

• Extrusion coating

• Adhesive lamination

• Wet bonding

• Dry bonding

• Co-extrusion

• Cross laminated film

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Extrusion of Film, Water Cooled Polypropylene Film, Plastics Net From Film,

Pouch Making Equipment, Sachet Making Machines, Process for Manufacturing

Unsaturated Polyester Resins, Unsaturated Polyester Resin Manufacturing Process,

Method of Preparation of Unsaturated Polyester Resins, Manufacturing Process of

Unsaturated Polyester Resin, Unsaturated Polyester Resin Manufacturing Plant,

Method for Preparation of MDI Prepolymers, Styrene Polymers and Copolymers,

Thermoplastic Polymers, Polymerization Methods, Methods of Polymerization,

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Ladder Polymers, Reinforced Thermoset Processing, Thermoplastic Processing,

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Niir Project Consultancy Services (NPCS) can provide Process Technology Book on

Manufacture of Plastic Films, HDPE

and Thermoset Plastics(Bopp Films, Polyester Films, Polyolefins, Polypropylene,

Vinyls, Polyvinyl Acetate, Expanded Films, Vinyl Ester Resins,

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