Borstar PE film product portfolio

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Borstar® PE film product portfolio

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Content

• PE market overview

• PE4 project

• Borstar® products

• New Borstar® products

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Market overview LD / LLDPE

Film & Fibre83%

Moulding7%

Wire & Cable4%

Pipe2%

Others4%

2003

Total WE LD / LLDPE market: 6,967 kt

Pipe2%

Other5%

Moulding7%

Wire & Cable4%

Film & Fibre82%

2008

Total WE LD / LLDPE market: 7,729 ktAv. annual growth rates LD / LLDPE: 2.1 %

Source: PMRG July 2004

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Market overview WE Film & FibrePolyethylene LD/LLDPE - segment split

Other film33%

Stretch15% Light shrink

9%

Garbage Sacks5%

Carrrier bags7%

Heavy duty shrink7%

Extrusion Coating8% Agriculture

7%

Heavy Duty Sacks7%

Building & Construction

2%

Total LD / LLDPE WE FilmMarket Volume: 5,813 kt

2003Building &

Construction2%

Heavy Duty Sacks7%

Agriculture7%

Extrusion Coating7%

Heavy duty shrink7%

Carrrier bags7%

Garbage Sacks5%

Light shrink8%

Stretch17%

Other film33%

Total LD / LLDPE WE Film Market Volume: 6,419 ktAv. annual growth rate:LDPE: 0.57%, LLDPE 4.48 %

2008


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Market overview HDPE

Other3%

Film & Fibre24%

Pipe17%

Wire & Cable1%

Moulding55%

2003

Total WE HDPE market: 5,102 kt

Other3%

Film & Fibre23%

Pipe18%

Wire & Cable2%

Moulding54%

2008

Total WE HDPE market: 5,838 ktAv. annual growth rates HDPE: 2.73 %


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Market overview WE Film & FibrePolyethylene HDPE - segment split

Sheet > 100 µ12%

Mono-filament

7%

Split Yarn4%

Films < 100 µ77%

2003

Total HDPE WE Film & FibreMarket volume: 1,286 kt

Total HDPE WE Film & FibreMarket volume: 1,448 kt

Split Yarn4%

Mono-filament

7%

Sheet > 100 µ12%

Films < 100 µ77%

2008


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LDPE remains important –LLDPE takes the growth

~ 2,300 kt additional LLDdemand 2002-2012

12

10

8

6

4

2

004 06 08 10 1202009694 98

European LLD/LD demand (Mt)

LLD

LDAAGR:LLDPE 6-7%LDPE 0-1%

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LLDPE growth in film

LLD substitutes LD• Toughness

(higher tear strength)• Impact• Better sealability• Stiffness• Higher melt index

(reduced processing time)• Downgauging

(stronger, thinner structures)

Moulding7%Wire & Cable

4%Pipe2%

Film83%

Others4%

W.E. LD/LLD market overview

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Catalyst Loop reactor

Compressor

Flash

Diluentrecycle Polymer

EthyleneComonomerHydrogen

Gas phasereactor

Productoutlet

EthyleneComonomerHydrogen

The Borstar® process

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Illustration of Bimodal MWD

1. To be avoided2. Necessary to bring down pro-cessing forces (extrusion) and to protect fraction (4) from being

degraded. To avoid melt fracture (poor surface properties). This fraction is, however, mechani-cally weak and has to be rein-forced by (4).

4. Necessary to get high enough tie chain concentrations for toughness and strength.5. Impact melt strength and modify rheological behaviour of the polymer melt.

Fraction %

Taste, Odour, Smoke, Migration

Bimodal

Conventional

Processabilitylubricant

Mechanicalstrengthtie molecules

Processability, melt strength, swell, orientation development

Molecular weight

1 2 3 4 5

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Borstar® - MWD comparison

Diagram show actual MWD for FB2230 and a unimodal C4-LLDPE.

Log Mol Wt3.00 3.50 4.00 4.50 5.00 5.50 6.00 6.50

Borstar® FB2230C4-LLDPE

dwt /d(logM)

0.00

0.05

0.10

0.15

0.20

0.25

0.30

0.35

0.40

0.45

0.50

0.55

0.60

0.65

0.70

0.75

0.80

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What is different ?

FB2230 LDPE LLDPE m-LLDPE

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Rheology - melt viscosity

100

1000

10000

100000

1,00E-02 1,00E-01 1,00E+00 1,00E+01 1,00E+02 1,00E+03

Shear rate [rad/s]

LDPE (MFR2=0.9)

LLDPE (MFR2= 1)

FB2230 (MFR2=0.3)

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Borstar® Product mix - existing

MFR2

MFR21

5

10

15

25

30

20

1

960950940930920910 Density

High neck

FB2230 FB2310

FB1460

FB4230

Low neck andco-extrusion

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Borstar® PE film grades Basic properties

FB2230 FB2310 FB4230 FB1460

MFR2 [g/10 min] 0.25

22

923

102°C

DSC melting point 124°C 127°C 124°C 131°C

0.4 0.2

MFR21 [g/10 min]

0.2

20

931

50 6

Density [kg/m³] 923 946

Vicat softening point 102°C 125°C108°C

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Borstar film mechanical properties FB2230 FB4230 FB2310 FB1460

Film thickness [µm] 40 40 40 15

Tensile strength [MPa], MD/TD 55/45 50/40 50/40 90/70

Strain at break [%], MD/TD 450/750 500/750 500/700 350/550

Tensile modulus [MPa], MD/TD 250/300 300/350 300/400 700/800

Tear strength [N], MD/TD 3/11 4/ 9 2/10 0.15/1.0

Dartdrop [g] 300 200 300 400

Puncture force [N] 65 60 65 70

Puncture energy [J] 5 4 5 1.5

Comments FLH= Frost line height DD = Die diameter

W&H, BUR=3

FLH=2DD Die gap 1.2mm

W&H, BUR=3 FLH=2DD

Die gap 1.2mm

W&H, BUR=3 FLH=2DD

Die gap 1.2mm

Alpine, BUR=4 neck height =8DD Die gap 1.5 mm

Internal d.s. test runs, without IBC

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• FB2230, FB4230 and FB2310 can be processed in most blown film lines including LDPE, LLDPE and HDPE extruders. The balance of draw down, bubble stability and properties are superior to conventional LLDPE and LLDPE rich blends. Today our materials are processed with good stability (commercial applications) from 12 µm to 2,5 mm. All three products are recommended for blown film co-extrusion.

• Recommended melt temperature is 190-210°C. Conventional narrow die gaps is recommended and should give film free of shark skin and draw down problems. Die gaps of 1,0 - 1,5 mm will normally give the best balance between extruder output and film properties. FB4230 will give somewhat lower melt pressure than FB2230.

• All three materials are sensitive to extrusion orientation and its recommended to use higher FLH (frost line height) 2-4 DD or a small neck and with BUR >2.

Processing recommendationsFB2230, FB4230 and FB2310

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250

260

270

280

290

300

310

320

330

340

350

FB2230 FB4230 FA322060

65

70

75

80

85

90

95

100

Pressure

Amperage

FB4230 compared to FB2230 and FA3220*- Film blown on a Reifenhauser KK2 extruder

Screw diameter: 70 mm. Die diameter: 250 mm. Die gap 1,0 mm., Output: 85 kg/h. FA3220: Screw diameter: 70 UC, Die diameter 250 mm, Die gap: 0,8 mm, Output: 80 kg/h.

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Screw and Die design

ScrewMost screws are suitable: LD/LLD/HDBarrier screws gives less friction heating

DieMost die gaps can be used but:

Narrow gap may give high pressureWide gap will reduce impact/tear balance

Bubble shape influence on Dart ImpactConditions for optimum result:

Film thickness BUR Frostline< 40 µm 2-3.5 3-4 xDD> 40 µm 2-3.5 2-3 xDD

RECOMMENDEDPOSSIBLE

AVOID

FLH 2 - 4 x DD< 2 x DD> 4 x DD

SCREW Barrier screwLD/HD

High friction heat

BUR 1 : 2 - 3,51 : 1,5 - 2< 1 : 1,5

DIE 1,0 - 1,5mm0,8 - 1,8mm

> 1,8 mm

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Conventional LDPE

Conventional LLDPE

Borstar FB2230FB4230, FB2310

Extruder temp. < 200°C 220°C 190 – 210°C

Die gap 0,8 - 1,5 mm Narrow

1,8 - 2,3 mm Wide

1,0-1,5 Narrow

Cooling ring Monolip Dual lip Monolip

BUR 2:1 - 3:1 1,5:1 – 2,5:1 2:1 - 4:1

FLH Low - medium Low Medium - higher

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Typical LDPE/LLDPE Borstar® bubble shape Typical HDPE shape

Processing recommendationsFB2230 and FB2310

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Film thickness rangeBorstar® LLDPE cover the full thickness range, commercially used up to 2.5mm thickness

LDPE 0,3

LDPE 1,0

LDPE 2,0

LDPE 4,0

LLDPE

LDPE/LLDPE Blends

FB2230/FB2310

0 25 50 75 100

2.5mm

(µm) Film thickness

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Dart Impact (g)

0

100

200

1,7 2,4 2,7

40µm LDPE type bubble

1.2mm die gap

2.0mm die gap

Blow Up Ratio (BUR)

Borstar® FB2230 –die gap effect on dart impact

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Borstar® FB2230 –bubble shape effect on dart impact

Dart Impact (g)

0

400

800

1200

25 40 70Film Thickness (µm)

1.2mm die gap

Neck Height=4DD, BUR=3

LDPE Bubble, BUR=3

LDPE Bubble, BUR=2

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A unique balance of properties

MDPE / HDPELDPE

BorstarFB2230 / FB4230 / FB2310

C6 / C8 LLDPE

YIELD STRESSTENSILE STRENGTHSECANT MODULUS

PROCESSABILITYBUBBLE STABILITY HOT TACK FORCE

DRAWDOWNELONGATIONDART IMPACT

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FB2230 Comparison –a unique balance of properties FB2230

LLDPE LDPE MFR2=1,0

C4-LLDPEMFR2=0,9

C8-LLDPEMFR2=1,0

Processing details LN= Low neck / BUR

40µm LN/3:1

40µm LN/2,5:1

40µm LN/3:1

40µm LN/2,5:1

Dart Impact [F50] 300 140 140 400

Elmendorf Tear [N] MD 3 4,0 2,6 3,7

Yield strength [MPa] TD 13 12 10 9

Secant modulus [MPa] MD/TD

250/300 180/220 190/200 180/190

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FB2310 Comparison -a unique balance of properties

Material type (density) FB2310 MDPE(931)

Bimodal

LDPE (928)

MFR2=0.3

MDPE (939)

Unimodal

MDPE (939)

Unimodal Processing details LN-HN =high - low neck / BUR

40µm LN/3:1

40µm LN/2,5:1

40µm LN/3:1

25µm HN/4:1

Dart Impact [F50] 300 120 70 180

Elmendorf Tear [N] MD 2 2 0,3 0,3

Yield strength [MPa] MD/TD

-/17 -/14 -/25 -/27

Secant modulus [MPa] MD/TD

350/450 300/350 500/640 460/670

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Secant Modulus Comparison

050

100150200250300350400450500

C8-LLD FG5190 FA5225 FB2230 FB4230 FB2310

Seca

nt m

odou

lus

[MPa

]

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Dart Impact Properties, 40µm

0

50

100

150

200

250

300

350

400

450

C8-LLD C6-LLD FB2230 FB2310 FB4230 FG5190 FA5225 FL1390

Dar

t dro

p [g

/50]

Borstar Borstar Borstar C4 LLD LDPE 0,9 MD (939)

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MD tear strength properties at 40 microns

0

0,5

1

1,5

2

2,5

3

3,5

4

4,5

FB2230 FB4230 FB2310

MD

Elm

endo

rf Te

ar [N

]

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Tensile strength at break

0

10

20

30

40

50

60

FB2310 FB2230 FB4230 C8-LLD FG5190 FA5225

Tens

ile s

treng

th a

t bre

ak [M

Pa]

MDTD

Borstar Borstar Borstar C4-LLDPE LDPE

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Dart drop testing at -20°C for 70µm films

0 100 200 300 400 500

40µm FB2230

FB2230

7% EBA

3% EBA

C8-LLDPE

C4-LLDPE

LDPE (0.3)

Borstar LLDPE has outstanding low temperature performance

(g)

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Borstar® hot-tack comparison

00,5

11,5

22,5

33,5

44,5

90 95 100 105 110 115 120 125 130 135 140 145 150

3% EBA0.9 LDPEFB2230FB2310C8 LLD

Sealing temperature (°C)

N/15mm

Borstar has higher hot tack force than LDPE, C4-LLDPE and copolymers.

Borstar has a broad sealing window that will support sealing in Borstar mono films and blends, and also in coex combination with other materials.

With down-gauged film thickness it is important to reduce sealing time or temperature.

Sealing time: 0,5 sec, Delay time: 0,1 sec, Sealing pressure: 90N. Specimen 15 mm width / 40 µ

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WVTR for FB2230 / FB2310g/m²/24h/+38°C/90%RH (ASTM F 372)

02468

10121416

25 40 70 125 150 200

LDPEFB2230FB2310

Film thickness [µm]

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O2- Transmission rate FB2230 / FB2310cc/m²/24h, 2% humid O2, 23°C

(except for FB2310, 40 and 70µm: 21% humid O2)

0

1000

2000

3000

4000

5000

6000

7000

8000FB2230FB2310

25µm 40µm 70µm 125µm

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ORGANOLEPTICS –FB2230 vs. conventional LLDPE

0

0,5

1

1,5

2

2,5

FB2230 C4-LLD C8-LLD

TASTE ODOUR

ODOUR

VOLATILES

TASTE

EXTRACTABLES

OLIVE MIGRATION

0102030405060708090

100

Maximum Tolerance

FB2230

FB2230 / FB2310 have excellent organoleptic properties

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Borstar® FB2310 - shrinkage at 160°C, 2 min.

Borstar has interesting shrink properties and especially cold shrink force is very good.

With higher shrink temperature Borstar show even higher reactivity and can in some applications replace LDPE.

With blends of Borstar and fractional melt LDPE one can achieve improved film and shrink properties. This would enable film producers to down-gauge without compromising quality.

0

10

20

30

40

50

60

70

80

2 3 4

FB2310 - MDFB2310 -TD

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Free shrink test of 100 µ BorstarFB2310/LDPE in 3 layer coex film, all layers has same composition

0

10

20

30

40

50

60

70

150°C 160°C 170°C

MDTD

• Test show that FB2310 needhigher temperature than LDPE to achieve balanced shrink.

• With use of FB2310 cold shrink force is higher compared to use of LDPE.

• With blends of LDPE addedFB2310 producers are typically down gauging 20-30%, but maintaining filmintegrity.

Tests done in a 2 min. oven test%

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Coefficient of friction - FB2230 / FB2310

Naturally low COF due to rough surface.Normally slip additive is not needed.No anti-block needed - easy opening.

FB2230/FB2310; 40µm

LDPE 1,O mfr (with 1000ppm AB); 40µm

1

0.4

0500 Slip additive (ppm)1000

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Treating of Borstar films => less power is needed to achieve same treatment level

Dyne/cm

0

10

20

30

40

50

60

HDPE (bi) Borstar LLD HDPE (uni) LDPE

• With bi-modal PE lesspower is needed to achieve the same treatmenteffect

• Tests also show that surface tension decrease less over time than with traditional LDPE

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FB2230, FB4230 /FB2310 for blends in HDPE films

Use FB2310 (or FB2230) instead of C4-LLDPE as blending agent (15-20%) with HMW HDPE to get product and processability improvements.

Downgauging & output possibilities (processing/bubble shape)

Borstar benefits are excellent compatibility with HMW HDPE, improved film stiffness, better tear strength & dart drop versus C4-LLDPE blends.

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FB2230/FB2310 for blends in HDPE

Test result example - HMW HDPE blended with 15% of :

C4-LLDPE FB2310

Average thickness, µm 18 15

Tensile @ break MD/TD, kg/cm2 540 / 400 500 / 400

Dart impact @ 50%, grams 200 280

1% Sec. Mod. MD/TD, kg/cm2 6300 / 6600 6500 / 7000

Tensile @ yield MD/TD, kg/cm2 - / 240 - / 240

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Borstar bimodal basic properties

FB4370 FB4250T FB2230 FB2310

0.4 0.2

20

931

108°C

127°C

40

937

110°C

DSC melting point 128°C 124°C 124°C

FB4230

MFR2 [g/10 min]

124°C

0.4

40

925

102°C

0.2 0.4

MFR21 [g/10 min] 22 40

Density [kg/m³] 923 923

Vicat softening point 104°C 104°C

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Borecene™mLLDPE and Borstar® LLDPE + LDPE for Collation Shrink Films.W & H/ TRNO.: 50856. Trial 2.1 and 2.2* 230 kg/h. * 73 m/min. * BUR 2,5 and 3,5

25%

50%

25%

75% FM5270 + 25% FT5270

60% FB2310 +40% FT5270

75% FM5270 + 25% FT5270

40 µm

Haze = 4,9% / 4,7%

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Borstar LLDPE & Borecene mLLDPE for Collation Shrink Films

40 my ABC coex. films. W & H trials April 2005

Formulations:

Evaluation of key film properties in Borealis laboratory: TRNO.: 50856-3 TRNO.: 50856-4

BUR 2,5 BUR 3,5Collation shrink film key property specification W& H formulation 2.1 W& H formulation 2.2

Film thickness, µm: 40±4 40 40

2-Sigma, %: <6 2,9 3,4

TD/ Stiffness, MPa: >250 410 355

Film impact, g/50%: >150 120 190

Ball Puncture, N/J: >40/ >2,0 75/ 4,2 69/ 3,8

Sealing range, °C: min. temp. / >20 135/45 135/45

MD/ Tear resistance, N: >1,5 0,6 1,0

TD/ shrinkage, %: >15 <1 21,3

MD/TD Hot shrinkage, N: <0,1/ <0,05 0,06/ <0,01 0,044/ <0,01

MD/TD Cold shrinkage, N: >1,5/ >0,5 1,78/ <0,1 1,58/ 0,96

Haze / Gloss, %/ -: <10/ >100 4,9/ 124 4,7/ 126

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We are investing in Borstar

020000400006000080000

100000120000140000160000

199719981999200020012002200320042005

• PE2 plant in Porvoo

• PE3 plant in Stenungsund

• PE4 plant in Schwechat

• Abu Dhabi via Antwerp

• Borstar LLDPEFilm sales

Borstar PE film product portfolio

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Transcript of Borstar PE film product portfolio