TECHNOLOGY OF PVC COMPOUNDING AND ITS APPLICATIONS

PVC RESINS MANUFACTURING & PROPERTIES

Introduction

Manufacture of PVCSuspension Polymerization Process

Clean Reactor TechnologyLarge Reactor Technology

VCM Containment

Mass Polymerization Process

Emulsion Polymerization Process

PVC Mass Polymerization

Comparative of PVC Produced using Different Processes

Copolymers, Chemical Modification & Blends/Alloys of PVC

Introduction

Reactivity Rations for VCM Copolymerizations

PVC Copolymers

Vinyl Acetate Copolymers

Recipe for VCM-VAC Copolymerization

Effect of VAC on Properties of PVC Copolymer

Copolymers with Olefins

Effect of Ethylene or Propylene on PVC properties

Copolymer with Vinyldene Chloride

Copolymers with Acrylates

Chemically Modified PVC

Introduction

Syndiotactic PVC

Effect of PVC Polymerization Temperature on Crystallinity

Chlorinated PVC

Comparative Properties of PVC & CPVC

PVC Grafts

Acrylic Graft

Properties of PVC Grafts

EVA grafted PVC

Cross linked PVC

Monomer for X-PVC Preparation

PVC Blends & Alloys

PVC/NBR Blend

Properties of PVC/NBR Blends

Powered NBR

PVC/NBR

Dynamically Vulcanized PVC/NBR

Comparative Properties of PVC/NBR Blends and Thermoplastic Rubbers

Typical Properties of Elvaloy Resins

Comparative Properties of PVC/EVA Blends

PVC/ABS Alloy

Dynamic Thermal Stability of PVC/ABS Alloys

Comparative Properties of PVC Alloys

PVC/Acrylic & Miscellaneous Alloys

Properties of PVC/Acrylic Alloys

Properties of PVC/Gadds Alloys

Heat Deflection under Load for PVC Alloy

Effect of processing Temp. on Rheological properties of PVC/Gadds Alloy

Effect of PVC:Gadds Composition on Torque

PROCESSING OF PVC

PVC Resins

Molecular Weight

Injection Moulding

Extrusion

Additives for Improving Processing

Heat Stabilizers

Processing Aids

Lubricants

Impact Modifiers

Compounding

Low Shear Horizontal Mixers (Ribbon Blenders)

Higher Shear Vertical Nonfluxing Mixers

Dry Blend Properties

Low Shear and High Shear Mixing in Horizontal, Jacketed Cylindrical Blenders

Hot Melt Compounding

Two Stage (Farrel) Continous High Intensity Fluxing Mixers

Compounding Lines-Batch Type

Suggested K-Value of PVC Resins

Influence of Formulations on processing behavious

The Polymer

Relation of Polymer K-Values with Threshold Temperature

Lubricants

Heat Stabilizers

Processing Aids

Impact Modifiers

Plasticized PVC

Extrusion

PVC Compounds-Some Routes and Processing

Calendering

Injection Moulding

Unplasticized PVC

Typical Formulation of Rigid and Flexible PVC Films and Functions of various components there-in

General Types of Industrial PVC Compounding Operations

Equipments for Compounding of PVC

Calendar Products and their Products

Processing of Rigid PVC

Injection Moulding -Rigid PVC

Injection Blow Moulding (IBM)

A Typical Injection Moulding Screw Design for Rigid PVC Material

Three Station Horizontal Indexing Injection Blow Process

Biaxial Orientation

Conclusions

Typical High-Flow PVC Formulation

Blow Moulded Bottles and Containers

Reheat Stretch Blow

PET Vis-A-Vis PVC Stretched Bottles

PVC Heat Shrinkable Bands

Blow Moulding of PVC Bottles

Injection Blow Moulding

Orientation

Cushioned Vinyl Flooring

Wide Choice of Different Substrates

Streen Coating System

Way ahead in Flexibility

Versatility in Coating

One Pass Production

Unique Process Improvements

Principle of Operation

Embossing problems a thing of the past

Double sided Coating of Openweave Fabrics

Single screen coating process

Screen to screen coating process

Principle of application

Recycling

Description of the Process

Compounding Internal Mixers

Internal Mixers

Schematic View of Compounding Operations

Unit Operations to Produce Glass Filled Polymers

Post Compounding Operations

Schematic of Banbury Mixer

Schematic of a Grnulator

Schematic of a strand pelletizer

ADDITIVES FOR PVC

Introduction

Plasticizers

Plasticizer usage for PVC Compound

Typical Properties of Plasticizer

Physical Properties of Phthalate Plasticizers

Physical Properties of less common Phthalates

Properties of Specially Plasticizers

Physical Properties of Miscellaneous Plasticizers

Plasticizer Efficiency and Properties of Flexible PVC

Plasticizer Efficiency

Dry Blending Time for Plasticizers

Effect of Plasticizers on Plastisol Gelation Temperature

Effect of Structure of Plasticizer on PVC Properties

Properties of Flexible PVC compounds at 50 PHR Phthalate Plasticizer Level

Physical Properties of Flexible PVC using specially plasticizers

Requirements for PVC Plasticizers

General Relationships between the structure of Plasticizers and their behaviour in PVC

Characteristics of the Major Types of Plasticizer

Polymeric Modifiers for PVC

Modifiers for Flow Improvement

Flow Promoter for PVC

Haake Rheogram for Rigid PVC Pipe Compound

Standard PVC Pipe Compound 2 PHR Modifier

Effect of Level of Flow Promoters on UPVC Rheological Properties

Effect of Low Molecular Weight Polymers

Typical Properties of Flow Promoters

Modifiers for Impact Enhancement

Mechanism of Impact Resistance

Effect of Modifier Quantity

Effect of EVA

Effect of Processing Time on Impact Strength

Systems with Honeycomb Network

Effect of Processing Conditions

Effect of Processing Conditions of UPVC

Effect of MBS/Acrylic Quantity on UPVC Impact Strength

Effect of Composition on Impact Resistance

Effect of Temperature of UPVC

Impact

Applications for Impact Modifiers

Heat Stabilizers for PVC

HCI Absorption

Elimination of Labile chlorine

Prevention of Autoxidation

Addition to polyene secuence

Carbenium ion elimination

Lead Stabilizers

Structure of Lead Stabilizers

Tin Based Stabilizers

Structure of Tin stabilizers

Barium Cadmium Stabilizers

Stabilization by Barium and Cadmium Stabilizers

Calcium-Zinc Stabilizers

Non Metallic Stabilizers

Epoxy Based Stabilizers

Effect of Epoxy and Phosphite on PVC Static Thermal Stability

Organic Phosphites

Polyhydric Alcohols

Antioxidants

Light Stabilizers

Lubricants

Appearance and Melting Point of Lubricants

Calcium Carbonate

Physical Properties of CaCO3 Fillers

Clay & Talc

Silicas & Glass Fibres

Properties of Glass Fibre Reinforced PVC

Flame Retardant Agents

LOI for Various Plastics

Chlorinated Flame Retardants

Brominated Compounds Metal Oxides

Chemicals and Additives-A Review of Future Outlook

Colourants

Blowing Agents

Heat Stabilizers

Plasticizers

UV Stabilizers

Antimicrobials

Flame Retardants

Phosphate Ester Flame

Retardants/Plasticizers for Polyvinyl Chloride (PVC)

Effect of Various Flame Retardants in Plasticized

Polyvinyl Chloride

Plasticized PVC with High Oxygen Index Use of Brominated Phosphate

Typical High emperature Wire Cable Polyvinyl Chloride Flame Retardant

COMPOUNDING

Introduction

Mixing Theory

Limitations of Mixing Theory

Mixing Evaluation

Fillers

Common Fillers and their uses

Plasticizers

Colorants

Heat Stabilisers

Antioxidants

Ultraviolet Light Absorbers

Antistatic Agents

Flame Retardants

Blowing Agents

Lubricants

Methods of Compounding

Intensive Dry Mixers

Internal Intensive Batch Mixers

Continous Mixer

Two Roll Mills and Pelletisers

Underwater Pelletiser

Single Screw Extruders

Compounder Extruder

Twin Screw Extruder

Compounding Lines

COMPOUNDING OF PVC

Selection & Characterization of PVC

Major Types of PVC Resins

Processing & Applications of PVC

PVC Resins Properties

Relation of PVC K-Value, Viscosity & Mole Wt.

Effect of Polymerization Temp on % Crystallinity

Syndiotactic Structure

PVC Morphology and PVC Characteristics

Effect of PVC Morphology on Extruder Output

Rheological Properties of PVC Dry Blends

Effect of PVC Resin Bulk Density on Rheological Properties

Effect on Processing RPM on Rheological Properties

Effect of Processing Temp. on Rheological Properties

Effect of Bulk Density on DOP Absorption

Introduction

Elements of Compounding

Methods of Compounding

Intensive Dry Mixers

Internal Intensive Batch Mixers

Contionuous Mixer

Two Roll Mills

Single Screw Extruders

Compounder Extruder

Twin Screw Extruder

What are some of them ?

Custom Compounding for Special Properties

General Guidelines for PVC Formulations for Common Product

Formulating Rigid PVC Compounds

PVC Pipe Formulations

PVC Conduit Pipe Formulations

Window Profile Formulations

Interior PVC Profile Formulations

PVC Siding Formulations

Cellular PVC Profile Formulations

Extruded PVC Sheet and Film (Single -Screw)

Calendered PVC Sheet and Film Formulations-Second Alternative

PVC Injection Moulded Pipe Fitting Formulations

High Flow PVC Injection Moulding Formulations

Extrusion Blow Moulding Rigid PVC Containers

Crystal Clear Food Contact Bottles

Clear Bottles good on taint and odour

Blow Moulded Bottle Formulations

Blow Moulded PVC Bottle Formulations

CA-ZN Formulation (Mineral Water)

CA-ZN Epoxy Recipe for 1 Litre Bottle

PVC Bottle for Shampoo

Shoe Soles

Tests for Compound

Floor Coverings/Wall Coverings

Typical Light Stable Formulation

Carbon Black Properties

Comparison -Titanium Dioxide and Zinc Oxide

Portable Water Pipe (Extruded from Dry Blend)

General Purpose Vinyl Film by Calendering

Sheeting for Outdoor Upholstry

COMPOUNDING OF PVC PASTES

Plastisols

Compounding Ingredients of Plastisols

PVC Polymers

Plasticisers

Stabilisers

Fillers

Colourants

Thickeners

Other Additives

Organosols

Compounding Ingredients

Preparation of Pastes

Gelation

Applications of PVC Pastes

Rotational Casting Formulation for Dolls and Play Balls

Compounding of PVC Latices

Latex Property Modifiers

Latex Stabilisers

Surface active agent

Defoaming Agents

Thickeners

pH Modifiers and Buffers

Polymer End Properties Modifiers

Heat Stabilisers

Plasticisers

Fillers

Pigments

Antiblocking Agents

Coalescing Aids (Volatiles)

Handling and Processing

Mixing

Dipping

Coating

Spraying

Compounding of PVC Solution & Adhesives

Plasticizers

Stabilisers

Fillers

Pigments

Lubricants

Methods of Application of Solutions

Applications of Solutions Adhesives

TESTING OF RESINS AND COMPOUNDS

Testing of PVC Resin

K-Value

Bulk Density

Plasticizer Absorption

Particle Size Distribution

Electrical Conductivity of Water Extract

Powder Flow

Sulfated Ash Content

Fish Eye Count

Testing of PVC Compounds

Bulk Density

Shore Hardness

Tensile Strength/Elongation

Static heat Stability

Dynamic Heat Stability

Brabender/Haake Gelation & Degradation Time

Electrical Volume Resistivity

Volatile Loss

Ageing Test

Cold Bend Temp. Test

Testing of PVC End Products

Films/Sheets/Profiles

Tensile Stress at Yield

Test for Dimentional Change at 120o C

Rigid PVC Pipes for Potable Water Supplies

Dimensions of Pipes

Visual Appearance

Opacity

Short Term Hydraulic Test

Long Term Hydraulic Test

Reversion Test

Impact Strength at oC

Methylene Dichloride Test

Flexural Strength

Wires and Cables

Thermal Stability Test

Determination of PVC Cable insulation Degradation

Comparison of Techniques to Assess FVC Degradation

Problem Solving in PVC Compounding and Processing

Resin

Lubricants

The Role of Lubricant

In PVC Compounding

Stabilizers

Additives

Material Characteristics and its effect of processing resins

Development of an Optimum Formulation

New Do's and Don'ts

Plasticizer Migration

High Purity Non-Stain Plasticizers for Floor and wall Coverings

Testing

Sample Preparation

Cure

Stain Specimen Conditioning

Stain

TGATensile Properties

Hardness

Results

Chemical Resistance

Rigid

Chemical Resistance of Vinyl Compounds: Percent Change in Weight

SPECIALITY PLASTIC COMPOUNDS & MASTERBATCHES

Introduction

Product

Coloured Masterbatches

Additive Masterbatch/Speciality Compounds

Market

Suggested Capacity

Land & Building

Raw Materials

Utilities

Manufacturing Process

Plant & Machinery

Personnels

Estimated Cost of the Project

Suggested Means of Financing

PVC COMPOUNDS

Introduction

Product

Market

Suggest Capacity

Land & Building

Raw Materials

Utilities

Manufacturing Process

For Rigid Pipes

For Bottle Blowing

For Blown Film

For Flexible Hose Pipes

For Mineral Water Bottle

Plant & Machinery

Personnels

Estimated Cost of the Project

Suggested Means of Financing

XLPE CABLE COMPOUND, JELLY FILLED TELECOMMUNICATION CABLE COMPOUND & SHEATING COMPOUND

Introduction

Product

XLPE Compound

MDPE Compound

FRLS Compounds

Land & Building

Raw Materials

Utilities

Manufacturing Process

XLPE Compound

MDPE Compound FRLS & Low Halogen

Compounds

Plant & Machinery

Personnels

Estimated cost of Project

Suggested Means of Financing

PLASTIC GRANULES FROM FRESH RESIN

Manufacturing process of LDPE Granules from LDPE Resin

Plastic Filler Granules (PP)

PVC Granules

Process of Manufacture

Plant Economics

Fixed Capital

Raw Materials

Total Working Capital

Total Capital Investment

Turn Over/Annum

PLASTIC GRANULES

Process of Manufacture

Concentration of Blending

Removal of Colour to obtain Transparent Granules by Activated Carbon Treatment

Filteration

Distillation

Cooling and Dehumidifying

Granulation

Weighing, Filling and Packing

Plant Economics

Fixed Capital

Raw Materials

Total Working Capital

Total Capital Investment

Turn Over/Annum

APPLICATIONS OF PVC

Review of Major Applications

Rigid PVC Pipes

Advantages of Rigid PVC Pipes

Graphical Sketch of a Twin Screw Extruder

Applications

Chemical Resistance

Resistance of PVC Pipes to Common Chemicals under use Conditions

Composition Energy Saving of PVC Pipes

Weathering

Summary of the Testing Results

Flow through Rigid PVC Pipes

Flow or Friction Losses

Surge and Water Hammer

Economics of Rigid PVC Pipes

Water Flow Velocity

Start up

Schematic of a large tube die

some Common Problems and Solutions of Pipe Extrusion

Industrial Profiles

Various Forms

Major Applications

Cellular PVC Profiles, Boards and Pipes

Introduction

Technology of Structural Foam extrusion

Foaming

Foaming Processors

Free Foaming Process

Inward Foaming Process

Machine and Die Technology

Extruders

Dies

Chemical Blowing agents

Processing aids

PVC grades

Properties of Cellular UPVC Pipes

Physical Properties of Cellular UPVC Pipe

Physical Properties of Cellular UPVC Board and Profile

Manufacturing of PVC Sheets

Calendering

Extrusion of PVC Sheets

Extrusion Blowing of PVC Sheets

Calandrette Process

Further Processing of Sheets by Forming

Requirements of PVC Sheets

Roller Film Calender

Calenders

Blister Packaging

Vacuum Formed Products

Skin Packaging

Problems and Suggested Remedies in Sheet Extrusion

Calendered Film-Typical Problems

Thickness Variation

Film Curling or Side Bending

Flatness Defects

Blister Packaging

Calendering of Rigid PVC Compounds

Advantages of Calendering Process

Blister Packaging Components

Heat Seal Coatings

Selection of Paperboard

Blister Packing Vs Skin Packaging

Blister Packaging Machinery

Advantages of Blister Packs

Blister Packaging Constraints

Blister Packaging in Pharmaceutical Industry

some Typical Applications of PVC Sheets

Typical Blister Packaging Applications

End Use Applications Chart

Non Packaging Applications

Tropicalised Blister Pack-ANew Concept

Rigid PVC Free Foam Boards

Areas of Application Overseas

Advertising

Building Sector

Electrical Industry

Miscellaneous

Typical Values of PVC

Integral Foam Sheets

PVC Integral Foam Sheets Applications

Characteristics

Advantages

Fabrication

Major Applications

Expanded PVC for Replacement of Wood

Free Foaming

Surface Treatment

Fabrication of PVC Sheets

Matchining

Rigid

Flexible

Cutting

Rigid

Flexible

Drilling

Punching and Blanking

Planning

Routing and Milling

Screwing and Tapping

Grinding and Sanding

Engraving

Adhesive Bonding

PVC to Other Materials

PVC to itself

Printing and Metallising

Laminating and Plastification of Printed Master

Welding

Ultrasonic Welding

High Frequency and Radio Frequency Welding

Shaping of PVC

Cold

Hot

Three Dimensional Shaping

Simple Forming

Injection Moulding-Rigid PVC

Injection Blow Moulding (IBM)

Biaxial Orientation

High Flow Injection Moulding Applications

Conclusions

Typical High Flow PVC Formulation

Blow Moulded Bottles and Containers

Reheat Stretch Blow

Pet vis-a-vis PVC Stretched Bottles

PVC Heat Shrinkable Bands

Blow Moulding of PVC Bottles

Injection Blow Moulding

Orientation

Cushioned Vinyl Flooring

Wide Choice of Different Substrates

Prodution of Cushio Vinyl Flooring Using glass fibre

Production using asbestos mat

Rotary screen printing system for cushion vinyl flooring

Screen Coating System

Way ahead in FlexibilityVersatility in coating

The screen coating system: Advantages

One Pass Production

Unique Process Improvements

Principle of Operation

Embossing problems a thing of the past

Double sided Coating of Open weave Fabrics

Single Screen Coating process

Screen to screen coating process

Principle of application

PVC in Medical Applications

Typical Medical Grade PVC Compound for Extrusion

Moulding of PVC Footwear

Compounding

Moulding

Machines

Moulds

PVC Uppers

Processing

Coatings

Sectional View of a coating Machine

Various types of spreader

Rotational casting and slush moulding

Dipping

Injection Moulding

Extrusion

Graphical Sketch of a twin screw extruder

Screw Temperature Control

Application Principle

Friction free Applications

Clear, simple operation

Two sided coating of openweaving fabrics

Tarpaulin Coating Line

PVC Coated Tarpaulines

Properties of Vinylidene Chloride Copolymer Films

Properties of VDC copolymer Films made

From Aqueous Latices and from Solutions

Lamination Methods

Direct lamination in cleander of two PVC Sheets

Lamination in calender of several sheets

Independent Lamination and Embossing

Laminating and Embssing Plant

Lamination and embossing of three PVC or PVC/ABS sheets

Embossing of wall paper coated with vinyl film

Roller Melt Process

Description of the Process

Application Carrier Materials

The Roller Melt Process is suitable for Recycling

Processable Raw Materials

Advantages of the Process

Process of Plasticised PVC

Processing of PVC Pastes

Dipping Process

Slush or Rotational Moulding

Blown Films

Moulding of PVC Footwear

Moulding

Flexible (Soft Plasticized) PVC Film

RECYCLING OF PVC

Plastics Waste Management Hierarchy

Coding as an aid to separation

Recycling of Short Life PVC Products

Bottles

Separation by Hydrocyclones

New Products from Recycled PVC Bottles

Prospects for Chemical Recycling of PVC

Tecoplast Bottle Plant

Service Life of PVC Products

Recyclable Vinyl

PVC Bottles, Jars and Containers

Design Considerations

Physical Properties

Marketing Consideration

Safe and Recycleable

Lower Mold Costs

SUPPLIERS OF RAW MATERIALS

PRESENT MANUFACTURERS

SUPPLIERS OF PLANT & MACHINERIES

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