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PVC Window ProfilePVC Window ProfileFormulating for Formulating for
Export to North AmericaExport to North America
Henry WiebkingHenry Wiebking
Senior Scientist, Plastics Technology
Grace LiGrace LiBusiness Manager, China
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TopicsTopics
North American ProfilesNorth American Profiles
How They Compare with Chinese ProfilesHow They Compare with Chinese Profiles
IngredientsIngredients
ChangesChanges
Use of TorqueUse of Torque RheometerRheometer The Importance of Calcium Carbonate The Importance of Calcium Carbonate
Tuffgard Tuffgard®®
PCC for Window ProfilesPCC for Window Profiles Hints for Successful Plant TrialsHints for Successful Plant Trials
SummarySummary
DiscussionDiscussion
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North American Profiles areNorth American Profiles are
Not the Same as Chinese ProfilesNot the Same as Chinese Profiles
Physical PropertiesPhysical Properties
Thin and LightThin and Light High PerformanceHigh Performance
CompoundsCompounds
High Quality IngredientsHigh Quality Ingredients
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North American Profiles areNorth American Profiles are
Not the Same as Chinese ProfilesNot the Same as Chinese Profiles
LeadLead--FreeFree
Can not use lead stabilizersCan not use lead stabilizers
Must change stabilizer and add lubricantsMust change stabilizer and add lubricants
High DurabilityHigh Durability – – WeatherabilityWeatherability Must hold color and impact strengthMust hold color and impact strength
Impact test as per ASTM D 4726Impact test as per ASTM D 4726 Should have AAMA CertificationShould have AAMA Certification
American Architectural Manufacturers Assoc. American Architectural Manufacturers Assoc. Standards for Window ProfilesStandards for Window Profiles
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North American and ChineseNorth American and Chinese
Profiles Contain the SameProfiles Contain the SameBasic IngredientsBasic Ingredients
ResinResin
StabilizerStabilizer LubricantsLubricants
Impact ModifierImpact Modifier
Titanium Dioxide Titanium Dioxide
Calcium CarbonateCalcium Carbonate
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IngredientIngredient China USAChina USA
ResinResin Extrusion Grade PVC ResinExtrusion Grade PVC Resin
StabilizerStabilizer NonNon--LeadLeadLeadLead
CompoundsCompounds
LubricantsLubricants
CalciumCalcium StearateStearateplus Waxplus Wax
CalciumCalcium StearateStearate
plus Wax and/orplus Wax and/or
Ester LubricantsEster Lubricants
ImpactImpact
ModifierModifier
StandardStandard
CPECPE
Acrylic and/orAcrylic and/or
High Performance CPEHigh Performance CPE
Titanium Titanium
DioxideDioxide
Lower DurabilityLower Durability
Coarser GradesCoarser Grades
Low Levels (~5phr)Low Levels (~5phr)
High DurabilityHigh Durability
Finer GradesFiner Grades
Higher Levels (~10phr)Higher Levels (~10phr)
CalciumCalcium
CarbonateCarbonate22--6 Micron Active6 Micron Active
~5phr~5phr<1 Micron Active<1 Micron Active
5 to 85 to 8 phrphr
But Differ in Specifics and Levels
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Must RemoveMust Remove
Lead Based StabilizersLead Based Stabilizers
Lead Compounds Stabilize and LubricateLead Compounds Stabilize and Lubricate Are an important lubricant in local formulasAre an important lubricant in local formulas
NonNon--Lead Stabilizers Types IncludeLead Stabilizers Types Include DibutyltinDibutyltin
Barium cadmiumBarium cadmium Barium zincBarium zinc
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Issue With Switching toIssue With Switching to
LeadLead--Free StabilizerFree Stabilizer
Lead Alternatives Do Not Lubricate as WellLead Alternatives Do Not Lubricate as Well
Higher Levels of Additional Lubricants NeededHigher Levels of Additional Lubricants Needed
Internal lubricants to adjust viscosityInternal lubricants to adjust viscosity External lubricants for metal releaseExternal lubricants for metal release
Different Types of Lubricant Systems AvailableDifferent Types of Lubricant Systems Available
CalciumCalcium stearatestearate with paraffin waxwith paraffin wax
Ester lubricant packagesEster lubricant packages
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Changing the Lubricant PackageChanging the Lubricant Package
Lubricant Types and Levels Determine aLubricant Types and Levels Determine a
CompoundCompound’’s Fusion Characteristicss Fusion Characteristics
Fusion TimeFusion Time
ViscosityViscosity
Fusion Characteristics are Adjusted to Match:Fusion Characteristics are Adjusted to Match:
A compound that runs wellA compound that runs well
The requirements of the processing equipment The requirements of the processing equipment A TorqueA Torque RheometerRheometer ((BrabenderBrabender,, HaakeHaake) is) is
Used to Measure Fusion CharacteristicsUsed to Measure Fusion Characteristics
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TorqueTorque RheometerRheometer CurveCurve
TORQUELOADING PEAK
FUSION PEAK
DEGRADATION
EQUILIBRIUM
TIME
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Torque Torque RheometerRheometer Testing Testing
A Trial and Error ProcessA Trial and Error Process Continue adjusting as needed.Continue adjusting as needed.
Experience plays an important role.Experience plays an important role. When the goal is achieved moveWhen the goal is achieved move
on to a plant trial.on to a plant trial.
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Adjusting Formulations Adjusting Formulations
Using the TorqueUsing the Torque RheometerRheometer
PropertyProperty
Fusion TimeFusion Time
Fusion TorqueFusion Torque
Equilibrium TorqueEquilibrium Torque
Stability TimeStability Time
Adjust With Adjust With
External Lube LevelExternal Lube Level
LubricantsLubricants
Internal Lube LevelInternal Lube Level
Stabilizer level/typeStabilizer level/type
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Torque Torque RheometerRheometer::
Key to Successful Formulation DevelopmentKey to Successful Formulation Development
IngredientSelection
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Torque Torque RheometerRheometer::
Key to Successful Formulation DevelopmentKey to Successful Formulation Development
IngredientSelection
StartingFormulation
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Torque Torque RheometerRheometer::
Key to Successful Formulation DevelopmentKey to Successful Formulation Development
IngredientSelection
StartingFormulation
Torque RheometerTesting
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Torque Torque RheometerRheometer::
Key to Successful Formulation DevelopmentKey to Successful Formulation Development
IngredientSelection
StartingFormulation
Torque RheometerTesting
FormulationModification
h
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Torque Torque RheometerRheometer::
Key to Successful Formulation DevelopmentKey to Successful Formulation Development
IngredientSelection
StartingFormulation
Torque RheometerTesting
FormulationModification
ProductionTrial
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Torque Torque RheometerRheometer::
Key to Successful Formulation DevelopmentKey to Successful Formulation Development
IngredientSelection
StartingFormulation
Torque RheometerTesting
FormulationModification
ProductionTrial
ProductTesting
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Impact ModifierImpact Modifier
One of the More Expensive IngredientsOne of the More Expensive Ingredients
AcrylicsAcrylics
Main type used in North AmericaMain type used in North America
OffenOffen used aloneused alone
Suppliers:Suppliers:
ArkemaArkema
, Rohm & Haas, Kaneka,.., Rohm & Haas, Kaneka,..
Chlorinated Polyethylene (CPE)Chlorinated Polyethylene (CPE)
Used alone or in combination with acrylicsUsed alone or in combination with acrylics
High quality product requiredHigh quality product required Suppliers: Dow, Bayer, Solvay,Suppliers: Dow, Bayer, Solvay,……..
Choice of calcium carbonate may allow reduction in impact modifier level.
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Key Change: Type and AmountKey Change: Type and Amount
of Titanium Dioxideof Titanium Dioxide Provides colorProvides color
Retards weatheringRetards weathering Color changeColor change
Loss of physical propertiesLoss of physical properties
Need Durable,Need Durable, DispersableDispersable, Plastics Grade, Plastics Grade Use at high levels: 8Use at high levels: 8--12phr12phr
Suppliers and GradesSuppliers and Grades
KronosKronos:: KronosKronos 2220, 22222220, 2222 DupontDupont:: TiPureTiPure®® R R --102, R 102, R --105105
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Calcium CarbonateCalcium Carbonate
Not Just a Cheap FillerNot Just a Cheap Filler Does Lower Formulation CostDoes Lower Formulation Cost
As a Filler As a Filler -- replacing resinreplacing resin
As a Modifier As a Modifier – – can improve impact strengthcan improve impact strength
Provides ColorProvides Color
Aids Processing Aids Processing
Die scrubDie scrub
Speeds meltingSpeeds melting
Retards Degradation:Retards Degradation: HClHCl ScavengerScavenger
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Most Important CaCO3 Properties in ProfilesMost Important CaCO3 Properties in Profiles
0 0.5 1 1.5 2 2.5 3 3.5 4
Median Particle Size (microns)
0
2
4
6
8
10
12
14
16
18
20
22
f t -
l b s / i n
0
100
200
300
400
500
600
700
800
900
1000
1100
J / m
Notched Izod Impact Strength
20 phr calcium carbonate filled rigid PVC
Small Particle SizeSmall Particle Size
Minimize oversizeMinimize oversize
Completely CoatedCompletely Coated
100% active100% active
In N.A.In N.A.
Only use one micronOnly use one micron
and finerand finer
SMI recommendsSMI recommends
TuffgardTuffgard®® PCCPCC
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TuffgardTuffgard®®
Precipitated Calcium CarbonatePrecipitated Calcium Carbonate
0.35 Microns0.35 Microns DiscreteDiscrete
100% Active100% Active
High ImpactHigh Impact
StrengthStrength
Reduce ImpactReduce ImpactModifierModifier UseageUseage
<ONE MICRON>
1 micron
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Effect of Calcium Carbonate on ProfilesEffect of Calcium Carbonate on Profiles
More Impact ModifierMore Impact Modifier
Low GlossLow Gloss
Low Carbonate PriceLow Carbonate Price
Standard Compound CostStandard Compound Cost
Less Impact ModifierLess Impact Modifier
Higher GlossHigher Gloss
Higher Carbonate PriceHigher Carbonate Price
Lower Compound CostLower Compound Cost
Standard 1Standard 1--4 micron4 micron
(coarse, agglomerated)(coarse, agglomerated)
0.35 micron0.35 micron
Tuffgard PCCTuffgard PCC
(fine, discrete)(fine, discrete)
T ff d PCCT ff d PCC
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Tuffgard PCCTuffgard PCC
Allows Impact Modifier Reduction Allows Impact Modifier Reduction
How Much ?How Much ?
Depends onDepends on Current calcium carbonate type and levelCurrent calcium carbonate type and level
Current impact modifier type and levelCurrent impact modifier type and level
Starting PointsStarting Points
If now using 2If now using 2--3 micron carbonate3 micron carbonate
Remove about 4phr of modifierRemove about 4phr of modifier
If now using 1 micron carbonateIf now using 1 micron carbonate
Remove about 2phr of modifierRemove about 2phr of modifier
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Adjust CaCOAdjust CaCO33
LevelLevel
If Increasing TiOIf Increasing TiO22
If TiO2 Then CaCO3
8 phr 8 phr
9 phr 7 phr
10 phr 6 phr
11 phr 5 phr
12 phr 4 phr
Total of CaCO3 + TiO2 = 16 phr
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Optimizing a PVC Profile FormulationOptimizing a PVC Profile Formulation
Formulation DevelopmentFormulation Development Ingredient choices and levelsIngredient choices and levels
ProcessabilityProcessability Production TrialProduction Trial
Product TestingProduct Testing
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Hints for a SuccessfulHints for a Successful
Production TrialProduction Trial
Do Only When Production LineDo Only When Production LineOperation is StableOperation is Stable
Take Control Samples at Start and EndTake Control Samples at Start and End Make One Change at a TimeMake One Change at a Time
Allow the Time to Re Allow the Time to Re--Stabilize BeforeStabilize BeforeSamplingSampling
Record All Machine ConditionsRecord All Machine Conditions
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Hits For Product TestingHits For Product Testing Test to a Number Test to a Number –– not just pass/failnot just pass/fail
Compare Production Line Conditions, NotCompare Production Line Conditions, Not
J ust Formulation Variables, With Properties J ust Formulation Variables, With Properties
Test Enough Samples for Good Accuracy Test Enough Samples for Good Accuracy
If Parts FailIf Parts Fail –– Adjust FormulationAdjust Formulation
If Parts PassIf Parts Pass –– Extended Production RunExtended Production Run
SummarSummary
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SummarySummary
Some major adjustments are needed to develop aSome major adjustments are needed to develop a
PVC window profile formulation for the NorthPVC window profile formulation for the North
American market.American market.
Choice of Calcium Carbonate is KeyChoice of Calcium Carbonate is Key
Achieving needed impact strengthAchieving needed impact strength
Minimizing costs by reducing impact modifierMinimizing costs by reducing impact modifierusageusage
0.35 micron Tuffgard PCC is recommended0.35 micron Tuffgard PCC is recommended
Use torqueUse torque rheometerrheometer to ensure formula will run onto ensure formula will run on
processing equipment.processing equipment.
Control and record machine conditions for bestControl and record machine conditions for best
information and optimization.information and optimization.