First Quarter 2020 | Volume 39 | Number 1

A Journal of the Thermoforming Division of SPE

IN THIS ISSUE: • Barrier Packaging Materials • Using Rheological Tools in Thermoforming • University RC Car Race Competition EXTRUSION SYSTEMS

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SPE QUARTERLY 2 SPE Thermoforming Quarterly A JOURNAL PUBLISHED EACH First Quarter 2020 | Volume 39 | Number 1 CALENDAR QUARTER BY THE THERMOFORMING DIVISION n Departments OF THE SOCIETY OF Chairman’s Corner | 4 PLASTICS ENGINEERS

Thermoforming in the News | 6-7 www.thermoformingdivision.com

University News | 8-9 Editor Conor Carlin Innovation Brief | 32 (617) 771-3321 Thermoforming & Sustainability | 34-35 [email protected]

Sponsorships n Features Lesley Kyle From the Vaults: Old Wives Tales | 10 (914) 671-9524 [email protected] Rheological Method Development: Using Rheological Tools To Predict Conference Coordinator Thermoformability | 12-22 Lesley Kyle (914) 671-9524 Barrier Packaging Materials & Processing | 24-29

n In This Issue SPE Thermoforming Quarterly® is published four times annually as an European Thermoforming Division | 33 informational and educational bulletin to ANTEC 2020 Dates | 39 the members of the Society of Plastics Engineers, Thermoforming Division, and the thermoforming industry. The name, “SPE Thermoforming Quarterly®” and its logotype, are registered trademarks of the Thermoforming Division of the Society of Plastics Engineers, Inc. No part of this publication may be reproduced in any form or by any means without prior written permission of the publisher, copyright holder. Opinions of the authors are their own, and the publishers cannot be held responsible for opinions or representations of the authors. Printed in the U.S.A.

SPE Thermoforming Quarterly® is reg- istered in the U.S. Patent and Trademark Office (Registration no. 2,229,747).|

SPE Thermoforming Quarterly 3 Chairman’s Corner

implies normal vision, not perfect “20/20” vision, as many of us may think. According to the American Academy of Ophthalmology, a person with 20/20 vision “can see what an average individual can see on Eric Short an eye chart when they are standing 20 feet away.” 20/15 vision, therefore, is sharper vision, meaning that you can see a line in the eye chart from 20 feet that others can only see from 15 feet. Only about 35% of us have 20/20 vision, which means those of us in plastics involved with lenses should have a recession-proof Further upstream in the value chain, scientists are still working business! on predictive modeling tools to improve the thermoforming process – more science, less black art. Researchers from The Dow We often try to forecast the future in business. We talk about Chemical company present findings from a study that was “… crystal balls and seeing around the corner, but more often than undertaken to define new rheological tests that were capable of not we get it wrong. Many financial analysts say that trying to defining the molecular design required to avoid excessive sage in forecast beyond 12 months is a fool’s errand, yet we see plenty the heating stage of thermoforming.” The complete report and of market reports with CAGR estimates for a 5-year period, e.g. supporting data are found on pp. 12-22. “bioplastics set to grow 18% from 2017-2022”. In recent months, we’ve heard a lot about “uncertainty” – tariffs, global threats, In events news, our colleagues in the European Thermoforming Brexit, coronavirus, etc. This doesn’t instill confidence in anyone’s Conference will be hosting around 150 people in Geneva, plans. Switzerland next month (March 18-20). In keeping with the global zeitgeist, the key topic is recycling / circular economy. Speakers This year promises more in the way of change, though how it from Danone and Nissan will headline the event. I encourage will play out remains to be seen. New regulatory regimes across you to review the technical program and consider attending this different US states, and all EU countries, will impact how plastics impressive conference. It’s not too late to register. is manufactured, converted, taxed, and recycled. We are all familiar with the groundswell of support among citizens for Signing off, action against plastics pollution, but solutions are proving to be difficult. Paradoxically, plastics are proven to be environmentally Eric sound when compared to other materials. Sometimes we have to go back to the beginning to understand some foundational questions. In recycling, for instance, do we even know why the triangles and numbers are there? We explore this on p.38. Results from new recycling-focused collaboration in Europe are presented in pp. 34-35. 12 th EUROPEAN THERMO- THERMOFORMING Despite the uncertainty, our industry continues to advance.FORMING In our lead technical article in this issue, we explore barrier materialsFOR A GREEN CONFERENCE in-depth (pp.24-29). Consumer tastes have always been a driverFUTURE for plastics packaging, with several major macro-level trends 2020 playing out around the world: mass customization; new delivery methods; single-serve or portion-based packs; extended shelf- life. What the average consumer uses and discards in the matter of minutes most certainly went through a lengthy and costly process of design, production, and quality control. Manufacturers and converters continue to invest in new technologies that reduce waste, error, and, in the case of automation, labor. 18—20 MARCH 2020 | GENEVA 18–20 MARCH 2020 | GENEVA | Switzerland

4 SPE Thermoforming Quarterly MARK YOUR CALENDARS AND DO NOT MISS THE ONLY EVENT THAT IS DEDICATED TO EUROPE’S CONFERENCE HIGHLIGHTS THERMOFORMING INDUSTRY. n Keynote Presentations n Technical Sessions The European Thermoforming Division Thin & Heavy Gauge invites you to the n Workshops 12th European Thermoforming n Exhibition Conference to be held in n Networking Events Geneva from 18th to 20th March 2020. n Parts Exhibition

Who should attend? Thermoformers, OEM’s, Machinery & Tooling Producers, Film and Sheet Suppliers, Resin Producers, Recyclers … Venue: Starling Hotel in Geneva welcomes you.

Further information about this event may be obtained from Yetty Pauwels at Society of Plastics Engineers, Thermoforming Europe Division Tel. +32 3 541 77 55, [email protected] www.e-t-d.org SHIFT INTO A HIGHER GEAR WITH ILLIG AND SAVE YOURSELF AN ENTIRE SHIFT!

THERMOFORMING SYSTEMS I PACKAGING SYSTEMS I TOOL SYSTEMS

ILLIG USA ILLIG Maschinenbau GmbH & Co KG Tradition forms future Regional Office I Indianapolis, IN Headquarters I Germany Phone +1 (855) 824-0004 SPE Thermoformingwww.illig-group.com Quarterly 5 Thermoforming In The News

wide range of applications, including to-go hinged food Genpak to Make Food containers, plates, bowls and platters, serving trays and Containers with Bioplastics two-piece food containers. Officials said that the GenZero biodegradable products will build on the company’s focus from Danimer Scientific for sustainable packaging options. Genpak ranked sixth in the 2019 Plastics News’ ranking of Frank Esposito, Plastics News Staff North American thermoformers, with estimated sales of February 4, 2020 − Bioplastics maker Danimer Scientific $500 million. The firm operates 20 facilities in the U.S. and will supply thermoforming giant Genpak LLC with Canada. material to make biodegradable food containers. Danimer Scientific holds 125 patents in nearly 20 countries In a Nov. 12 news release, officials with both firms said for a range of manufacturing processes and biopolymer the eco-friendly foodservice items created by the two formulations. Applications for the firm’s biopolymers companies “will help reduce the environmental impacts include additives, aqueous coatings, fibers, filaments, films, of nonbiodegradable packaging produced annually hot-melt adhesives and injection molded items. worldwide.” Over the course of the multi-year agreement, Fraunhofer IVV Developing R2R Bainbridge, Ga.-based Danimer Scientific will deliver several million pounds of biodegradable resins that components for New In-Mold, Genpak of Charlotte, N.C., will use in its new GenZero- Thermoformed Electronics brand line of food packaging products.

Danimer Scientific will include Nodax-brand First published February 13, 2020 in polyhydroxyalkanoate (PHA), which officials described Converting Quarterly Magazine as the firm’s signature biopolymer, among the resins The Fraunhofer Institute for Process Engineering and that it produces for GenZero food containers. Nodax Packaging IVV will present the manufacture of 3D is a plant-based material that officials said was verified electronics using the roll-to-roll (R2R) process at the as a reliable biodegradable alternative to traditional LOPEC international fair for printed electronics being held petrochemical plastics in a 2018 study led by University in Munich on March 25-26, 2020 (Hall B0, Stand 411). A of Georgia researchers and members of the UGA New Materials Institute. “Innovation is a core foundation of our manufacturing 1-800-722-2997 philosophy, and it has driven the development of some LLC of our most durable and sustainable packaging items,” Genpak President Kevin Kelly said in the release. “Partnering with Danimer Scientific provides us with the cutting-edge material we need to take the next step in our dedication to our purpose statement of BUSHINGS HEATERS & T/C QC CLAMP FRAMES LUBRICATION advancing innovative packaging to enhance the human www.thermoformerparts.com experience.”

Danimer Scientific CEO Stephen Croskrey added in the release that plastic “is a universal material used in countless everyday products, especially in the food and beverage industries, so it’s imperative to broaden the conversation around the type of items we can make with Chain Rails Pin Chain Pins & Bushings biodegradable materials.” THERMOFORMER PARTS SUPPLIERS 3818 Terry Diane; Beaverton, MI 48612 Genpak’s line of foodservice items are designed for a [email protected]

6 SPE Thermoforming Quarterly new thermoforming process makes this possible. It allows higher degrees of forming via temperature profiling. It was developed at Fraunhofer IVV Dresden.

Thermoforming is suitable for large batches of products and is combined here with innovative technologies for temperature control to precisely regulate the forming process. Up until now the manufacture of electronic assemblies from structural and functional components has involved production, assembly, and wiring. These are costly steps in terms of time and money.

A collaborative project has now developed forming technology whereby a substrate is first processed in its planar state using established technologies for printing and assembly. Only in the last processing step is the 3D geometry generated by forming. Interactive (operating) panels can, for example, be produced at favorable cost. Applications in robotics, home products, medical technology, and the car and aircraft manufacturing industries will benefit from this. The high requirements on ergonomics, design, and functionality in these industries will hence be optimally met. The new process also offers greater design freedom and flexibility.

Customization of Forming Processes Fraunhofer IVV is developing innovative heating and forming technologies to realize novel products. Fraunhofer IVV Dresden has a specialist team supporting the development of 3D electronic components and offers assistance to companies with aspects such as product design, material selection, and process configuration. A self- developed characterization method enables process limits and relative industrial load limits to be determined. In addition, a thermoforming test rig enables the flexible manufacturing of products on a trial basis. For this work a range of forming processes and technologies are available. Using experimental and numerical simulation, manufacturing processes and product geometries can be simulated and optimized. The thermofoming test rig allows the Fraunhofer IVV Dresden to form a variety of materials with printed electronics for companies. | THE ANNUAL TECHNICAL CONFERENCE FOR PLASTICS PROFESSIONALS

ANTEC® 2020 is the largest, most respected and well-known THE ANNUALtechnical conferenceTECHNICAL in CONFERENCEthe plastics industry. It’s where classroom theory connects with real world solutions. FOR PLASTICS PROFESSIONALS

ANTEC® 2020 is the largest, most respected and well-known technical conferenceWhy in the should plastics industry. you It’s whereattend? classroomANTEC® theory 2020 connects representsSPE with Thermoforming realthe worldideas, solutions. research Quarterly and 7 trends shaping our plastics industry. A new program format will be introduced this year-includingWhy should 4 keynotes you each attend? day and 300+ concurrent sessions. Post and pre-conference workshops will also be offered! REGISTER ANTEC® 2020 represents the ideas, research and trends shaping our plastics industry. A new program format will be introduced this year-including 4 keynotes each day and 300+ concurrent sessions. Post Yourand pre-conference registration workshops fee includes will also lunch be offered! on Monday and Tuesday, REGISTER 7 coffee breaks and 3 receptions—giving you the additional Your registration feenetworking includes lunch opportunitieson Monday and Tuesday, you asked for! 7 coffee breaks and 3 receptions—giving you the additional NOW! networking opportunities you asked for! NOW!Early Registration Who Should Attend? EndsEarly February Registration 17! Who Should Attend? Ends February 17! SPE is comprised of 22,500+ members, all from diverse backgrounds SPE is comprisedand careers—ANTEC® of 22,500+ members, is all no from different. diverse backgrounds Managers, engineers, R&D and careers—ANTEC® is no different. Managers, engineers, R&D scientists,scientists, technicians, technicians, sales & marketing sales associates, & marketing executives, associates, executives, academicsacademics and students and are students all invited areto enhance all invited their careerto enhance in their career in plasticsplastics through thisthrough networking this and networking knowledge sharingand knowledge event. sharing event.

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www.4spe.org/antec University News

STUDENT FROM GEORGIA TECH TAKES HOME THE SECOND ANNUAL RC CAR RACE TROPHY Content Compiled By Ryan Fuller, Georgia Tech Last year, students were invited to compete in the 2019 Incorporating these design elements while still being SPE Thermoforming RC Car Race and Design Competition able to fit the plastic on top of the chassis would prove in Milwaukee, Wisconsin. Students were charged with challenging. Sample car designs included the Bugatti designing, thermoforming, decorating, and racing a 1/10th Grand Sport Vitesse and the Bugatti Veyron. scale RC car body or “shell.” Ryan Fuller, representing To generate the files necessary for developing and Georgia Tech, returned to compete after an outstanding manufacturing the model, Ryan began with a basic first-time outing in 2018. For the second year in a row, Ryan car shape in the CAD software, Fusion 360. By taking won first place in the Student RC Car Race! advantage of the molding workspace, he gradually broke Ryan’s car design was inspired by Georgia Tech’s down each section of the car into more complex forms. famous mascot, the Ramblin’ Wreck, a 1930 Ford Model A. Throughout the planning of the design, the team examined very distinguishable elements from the Wreck, including the side trims and the steep angular fronts. The team’s sponsor, Robert Browning of The McConnell Company, also lent his help with the design.

Car section sample

Once he arrived at a preliminary draft of the model, the next step was to take more detailed features from the inspiration and to tie the whole design together. In the end, the model came out as a cohesive mix between an RC car, The Ramblin’ Wreck, and a sporty design.

Final design submitted by Ryan Fuller, Georgia Tech

For design inspiration, they looked to develop a vehicle with features from the Wreck while giving it a modern sportscar look.

CAD design of the model car

Next, it was time to form the plastic sheet. The mold was made using a CNC mill, thanks to the gracious help of Ken Griep from PCM. The sheet was formed from a single large mold. Utilizing resources at Georgia Tech, numerous plastic bodies were formed from the mold using their large thermoformer. The Ramblin’ Wreck, Georgia Tech’s mascot

8 SPE Thermoforming Quarterly Steps in the thermoforming process

Inspired by the Wreck’s color palette, Ryan settled on the classic Georgia Tech white and gold while combining the Bugatti’s side view and form. He then added an LED kit that would work along with the car’s internal speed control system to give the car realistic lighting. Overall, the mold turned out very nicely, and showcased the design elements Ryan set out to feature.

Fuller’s winning entry

Ryan extends many thanks to Robert Browning of McConnell Co. for his support on the project, to Ken Griep for his machining time and resources, and to Paul Uphaus of Primex for his sheet material.

Team Sponsor:

With Support From:

SPE Thermoforming Quarterly 9 Industry Practice

Editor’s Note: TheThermoforming Division has built an archive for all articles and magazines produced since the inception of our division. The result was a catalog of more than 575 articles over 35 volumes going back to 1975. Though some individual issues have been lost in the mists of time, we now maintain a digital record of contributions to our society. To celebrate our past achievements, we will occasionally republish elements from the archives.

10 SPE Thermoforming Quarterly A NEW GENERATION 125 TON THERMOFORMER FOR SOLID SHEET The Model 45 doesn't require a 3rd motion or airbox. A smart SASH (Servo Adjust Shut Height) monitors an ac- curate measuring system to maintain the newly designed platens at +/-.002" atness. • Air cylinders operate the sheet clamp frame. • The bottom platen drives the plugs. • Option: can be ordered 52'' wide. • Max. product depth 5'' • Shut height 30'' • Sheet width 48'' • Sheet line 53.5''

SPE Thermoforming Quarterly 11 Lead Technical Article

Rheological Method Development: Using Rheological Tools To Predict Thermoformability

Mary Ann Jones, Todd Hogan, Jamie Stanley, The Dow Chemical Company, Midland, MI Paul Vantol, The Dow RHEOLOGICALChemical Company, Midland, METHOD MI - retired DEVELOPMENT: USING RHEOLOGICAL TOOLS TO PREDICT THERMOFORMABILITY Abstract Thermoforming applications require a polymer sheet to have limited sag when heated above Tg, and an ability ExtrusionMary thermoforming Ann Jones, ofTodd very largeHogan, parts Jamie such as Stanley, The Dow Chemical Company, Midland, MI to withstand the load of its own weight. Many polymer those used in the appliancePaul Vantol industry, The can exceedDow Chemicalthe Company, Midland, MI - retired families have grades that have the required rheological melt strength limits of a given polymer. This study was characteristics to perform well in extrusion/thermoforming undertaken to define new rheological tests capable of applications. However, many products do not perform well defining the molecular design required to avoid excessive in large, deep draw thermoformed parts (refrigerator liners, Abstract in large, deep draw thermoformed parts (refrigerator liners, sag in the heating step of the thermoforming process and automotive flooring, tub and shower surrounds, etc.). automotive flooring, tub and shower surrounds, etc.). toExtrusion identify thethermoforming optimum temperature of very largefor forming. parts such Damping as thosefactor used (tan in theδ = G’’/G’),appliance also industry known as can “tan exceed delta”, the can melt be TheThe thermoforming thermoforming process process consists consists of heating, of heating, part part strengthused limitsas a tool of to aidentify given fabrication polymer. conditions,This study molding was shapingshaping via vacuumvacuum or orpressure pressure forming, forming, cooling, cooling, and and undertakenwindow size,to define and the new effect rheological of added recycle tests streams.capable Inof trimming.trimming. In thethe applicationsapplications referred referred to to here, here, heavy heavy gauge gauge definingaddition, the molecular we compare design polymer required families to that avoid challenge excessive our extrudedextruded sheet sheet is is produced produced at at a a thickness thickness of ~0.100~0.100 inches. inches. Sheet is cut, clamped around the outside of the part, and sag inability the heating to thermoform step of largethe thermoforming parts. Semi-crystalline process materials and to Sheet is cut, clamped around the outside of the part, and shuttled to the oven of the thermoformer. The sheet is then identifymust the be optimumrun at or above temperature their melting for forming. point temperature Damping shuttled to the oven of the thermoformer. The sheet is heated in the oven using radiant and/or convection heating factor(Tm). (tan Tm  =is wellG’’/G’), above also the knownglass transition as “tan temperaturedelta”, can be then heated in the oven using radiant and/or convection used(Tg) as aand tool the to temperature identify fabrication delta (Tm conditions,- Tg) may exceed molding to a temperature above Tg, allowing for initial sag of the sheet.heating At to this a temperature point, the sheet above is removedTg, allowing from for the initial oven sag and windowthe widthsize, ofand any the rubber effect plateau of added region recycle in the streams. melt state. In of the sheet. At this point, the sheet is removed from the addition, we compare polymer families that challenge our formed in either a negative or positive vacuum forming These rheological characteristics are related back to the oven and1 formed in either a negative or positive vacuum ability to thermoform large parts. Semi-crystalline process. entanglement density of a given polymer and compared to forming process. materialsthe width must of thebe rubberrun at plateau.or above their melting point temperature (Tm). Tm is well above the glass transition temperatureIntroduction (Tg) and the temperature delta (Tm - Tg) may exceed the width of any rubber plateau region in the melt state.3D These plastic rheological molded parts characteristics can be produced are related through back a to the entanglementvariety of fabrication density processes, of a given including polymer thermoforming,and compared to theinjection width of molding, the rubber blow plateau. molding, rotational molding and others. Applications that call for the production of a limited number of large parts are a focus for fabricators that Introduction Figure 1. 1) Negative Vacuum Forming versus 2) Positive Vacuum thermoform, in areas such as large appliances, recreation Figure 1. 1) Negative Vacuum Forming versus 2) PositiveForming Vacuum Forming vehicle3D plastic components, molded partsdunnage can and be others.produced Thermoforming through a tooling costs are generally significantly less than those General rules of thumb for varying polymers state that the variety of fabrication processes, including thermoforming, General rules of thumb for varying polymers state that for injection molding. At low volumes, thermoforming is normal thermoforming temperature for an amorphous injection molding, blow molding, rotational molding and the normal thermoforming temperature for an amorphous more economical than injection molding. At high volumes, polymer is directly related to the glass transition others. Applications that call for the production of a limited polymer is directly related to the glass transition injection molding or blow molding are favored. The number of large parts are a focus for fabricators that temperature,temperature, Tg, Tg, and and with with crystallinecrystalline polymers, polymers, the the melting breakeven point for the cost of parts and tooling between thermoform, in areas such as large appliances, recreation point,melting Tm. point, A Tm. minimum A minimum forming forming temperaturetemperature forfor an vehicleprocessing components, operations dunnage vari0es and from others. project Thermoforming to project, amorphousan amorphous polymer polymer is is TgTg ++ 20-30˚C 20-30˚ andC and the normalthe normal toolingbased costs on arethe generallysize of the significantly part. A general less rule than of thumbthose forfor formingforming temperaturetemperature isis Tg ++ 70-10070-100 ˚C.˚C. 1 Semi-crystalline1 Semi-crystalline injectionthe optimum molding. fabrication At low mode volumes, moves thermoformingfrom thermoforming is polymerspolymers areare oftenoften formed formed at orat just or above just theabove Tm. the Tm. moreto economical injection molding than injection at an annual molding. production At high order volumes, of 2000 ThermoformingThermoforming formingforming temperatures temperatures can can be be understood understood injectionto 5000 molding parts. or blow molding are favored. The break- byby examining examining aa storagestorage modulusmodulus (G’) (G’) versus versus temperature temperature even point for the cost of parts and tooling between plot run at low shear rates. In general, amorphous polymers processing operations varies from project to project, based are thought to be best formed at temperatures occurring on the12 sizeSPE of Thermoforming the part. A general Quarterly rule of thumb for the toward the end of the rubber plateau range. Polymers that optimum fabrication mode moves from thermoforming to form well will have a characteristic rheological profile at injection molding at an annual production order of 2000 to the ideal forming temperature. 5000 parts. The rheological analysis described here was Thermoforming applications require a polymer sheet performed in the shear mode on a dynamic mechanical to have limited sag when heated above Tg, and an ability to spectrometer. As such, the deformation mode and rates do withstand the load of its own weight. Many polymer not directly apply to thermoformability. The value of this families have grades that have the required rheological dynamic data is in its ability to measure both the viscous characteristics to perform well in extrusion/thermoforming and the elastic component to the modulus, and to give a tan applications. However, many products do not perform well δ value that describes the balance between melt strength

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SPE Thermoforming Quarterly 13 Lead Technical Article

plot run at low shear rates. In general, amorphous semi-crystalline materials just above Tm, simple frequency polymers are thought to be best formed at temperatures sweeps are run from 0.01 to 100 rad/sec. occurring toward the end of the rubber plateau range. Our third mode of analysis was used to a limited extent Polymers that form well will have a characteristic to examine the effect of molecular weight on the width rheological profile at the ideal forming temperature. of the rubber plateau, plotting storage modulus versus The rheological analysis described here was performed in temperature. A temperature ramp was performed in the shear mode on a dynamic mechanical spectrometer. torsion up through Tg. Ten degrees was added to the As such, the deformation mode and rates do not directly final temperature and data collection was continued using apply to thermoformability. The value of this dynamic data the parallel plate geometry. Testing was performed at a is in its ability to measure both the viscous and the elastic frequency of 1.0 rad/sec. component to the modulus, and to give a tan δ value that Data were collected on commercial extrusion resins. describes the balance between melt strength and viscous A variety of materials were collected that represented flow. That balance, at a given shear rate and temperature, differing processing ease in the field. Amorphous resins is what can best define a thermoformable material and included both high impact polystyrene (HIPS) and can also provide insight into the size of the thermoforming acrylonitrile-butadiene styrene (ABS) that had been or were temperature window. Melt strength is required, as the currently in use in refrigeration applications, as shown in extruded sheetand is viscous heated flow. and Thatsags balance, under itsat owna given weight. shear rate and in Table 1. Semi-crystalline resins including and viscous flow. That balance, at a given shear rate and in Table 1. Semi-crystalline resins including temperature, is what can best define a thermoformable Tablepolypropylene 1. Semi-crystalline (PP) and resinshigh density including polyethylene polypropylene (HDPE) A defined viscoustemperature, component is what is canrequired best define as some a thermoformable ease of polypropylene (PP) and high density polyethylene (HDPE) material and can also provide insight into the size of the (PP) resinsand high are shown density in Tablepolyethylene 2. (HDPE) resins are shown material and can also provide insight into the size of the resins are shown in Table 2. flow is neededthermoforming to uniformly temperature draw down window. around theMelt tool. strength is thermoforming temperature window. Melt strength is in Table 2. Rheological analysisrequired, can as the be extruded used to sheet define is heated the suitabilityand sags under its Table 1. Amorphous Polymers required, as the extruded sheet is heated and sags under its Table 1. Amorphous Polymers own weight. A defined viscous component is required as of a polymer ownfor large weight. part A thermoforming,defined viscous component to define is therequired as some ease of flow is needed to uniformly draw down optimum temperaturesome ease range,of flow and is neededas a quality to uniformly control drawtool. down around the tool. Rheological analysis can be used to define around the tool. Rheological analysis can be used to define the suitability of a polymer for large part thermoforming, Experimentalthe suitability of a polymer for large part thermoforming, to define the optimum temperature range, and as a quality to define the optimum temperature range, and as a quality control tool. Samples werecontrol compression tool. molded to a thickness of 1.5 mm. Samples were tested in dynamic mode on an Experimental RDSII Rheometrics Dynamic Spectrometer.Experimental Samples were analyzed in threeSamples ways. First, were a compression Frequency/Temperature molded to a thickness of Samples were compression molded to a thickness of sweep approach1.5 mm.was used Samples to define were tested the suitabilityin dynamic of mode on an 1.5 mm. Samples were tested in dynamic mode on an RDSII Rheometrics Dynamic Spectrometer. Samples were a material designRDSII and Rheometrics the associated Dynamic thermoforming Spectrometer. Samples were analyzed in three ways. First, a Frequency/Temperature temperature, analyzedusing parallel in three plate ways. fixtures First, a underFrequency/Temperature nitrogen, sweep approach was used to define the suitability of a sweep approach was used to define the suitability of a keeping the strainmaterial as lowdesign as possibleand the throughout associated thethermoforming material design and the associated thermoforming TableTable 1. Amorphous 2. Semi-crystalline Polymers Polymers temperature, using parallel plate fixtures under nitrogen, Table 2. Semi-crystalline Polymers test while stilltemperature, generating using sufficient parallel torque. plate fixtures The data under was nitrogen, keeping the strain as low as possible throughout the test used to createkeeping a master the curvestrain asusing low time-temperatureas possible throughout the test while still generating sufficient torque. The data was used while still generating sufficient torque. The data was used superpositionto principals. create a Polymermaster fabricationcurve using operating time-temperature to create a master curve using time-temperature windows weresuperposition defined through principals. examination Polymer fabricationof the master operating superposition principals. Polymer fabrication operating windows were defined through examination of the master curves, understandingwindows were the definedsize of thethrough rubber examination plateau of and the master curves, understanding the size of the rubber plateau and the the slope of thecurves, elastic understanding modulus theand size tan of δ the curves rubber in plateau the and the slope of the elastic modulus and tan δ curves in the viscous slope of the elastic modulus and tan δ curves in the viscous viscous flow flowregion region of theof the curve. curve. The The slope slope ofof thesethese curves curves provide flow region of the curve. The slope of these curves provide provide informationinformation as to as how to howwell thewell processability the processability can can be information as to how well the processability can be changed through changes in processing temperature or be changed throughchanged changesthrough changes in processing in processing temperature temperature or or shear rate. These tests are designed specifically to define shear rate. These tests are designed specifically to define shear rate. Thesethe melt tests strength are designed of the sheet specifically after heating to definebut prior to the melt strength of the sheet after heating but prior to the melt strengthforming, of the balancing sheet after this heatingagainst butthe priorability to to form forming, balancing this against the ability to form uniformly in a deep draw part. forming, balancinguniformly this in against a deep draw the abilitypart. to form uniformly in a deep draw part. Our second mode of analysis was used when Our second mode of analysis was used when comparing materials where a processing temperature has Our second modecomparing of analysis materials was where used a whenprocessing comparing temperature has already been defined. In cases of quality control or when already been defined. In cases of quality control or when materials wheretesting a processing semi-crystalline temperature materials hasjust alreadyabove Tm, simple testing semi-crystalline materials just above Tm, simple Table 2. Semi-crystallineProcessing data werePolymers gathered to define the successful been defined.frequency In cases sweeps of quality are run control from 0.01 or towhen 100 testing rad/sec. Processing data were gathered to define the successful frequency sweeps are run from 0.01 to 100 rad/sec. temperature window for thermoforming by measuring the temperature window for thermoforming by measuring the sheet surface temperature immediately before forming. Our third mode of analysis was used to a limited extent sheet surface temperature immediately before forming. Our third mode of analysis was used to a limited extent The frequency/temperature sweep data sets were then to examine the effect of molecular weight on the width of The frequency/temperature sweep data sets were then 14 SPE Thermoformingto examine the effectQuarterly of molecular weight on the width of shifted to the temperature defined as the ideal the rubber plateau, plotting storage modulus versus shifted to the temperature defined as the ideal the rubber plateau, plotting storage modulus versus thermoforming temperature for that particular product and temperature. A temperature ramp was performed in torsion thermoforming temperature for that particular product and temperature. A temperature ramp was performed in torsion compared. up through Tg. Ten degrees was added to the final compared. up through Tg. Ten degrees was added to the final temperature and data collection was continued using the temperature and data collection was continued using the parallel plate geometry. Testing was performed at a Results and Discussion parallel plate geometry. Testing was performed at a Results and Discussion frequency of 1.0 rad/sec. frequency of 1.0 rad/sec. The rubber plateau width provides us with an The rubber plateau width provides us with an Data were collected on commercial extrusion resins. understanding of the size of the molding window for a Data were collected on commercial extrusion resins. understanding of the size of the molding window for a A variety of materials were collected that represented given polymer and the ideal molding temperature. The A variety of materials were collected that represented given polymer and the ideal molding temperature. The differing processing ease in the field. Amorphous resins rubber plateau region occurs in higher molecular weight differing processing ease in the field. Amorphous resins rubber plateau region occurs in higher molecular weight included both high impact polystyrene (HIPS) and polymers, existing in a temperature / frequency range included both high impact polystyrene (HIPS) and polymers, existing in a temperature / frequency range acrylonitrile-butadiene styrene (ABS) that had been or where entanglements do not have the time to relax out acrylonitrile-butadiene styrene (ABS) that had been or where entanglements2 do not have the time to relax out were currently in use in refrigeration applications, as shown stress. 2 These entanglements are acting as mechanical were currently in use in refrigeration applications, as shown stress. These entanglements are acting as mechanical

* The values presented in the table and charts represent typical properties, but should not be construed as product specifications. * The values presented in the table and charts represent typical properties, but should not be construed as product specifications. DRIVEN BY INNOVATION There is no substitute for the experience we’ve gained by

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SPE Thermoforming Quarterly 15 Lead Technical Article

Processing data were gathered to define the successful Anionic polystyrene has a molecular weight distribution of temperature window for thermoforming by measuring 1.0 and is available at a broad range of molecular weights. the sheet surface temperature immediately before Polystyrene (PS) grades were compression molded and forming. The frequency/temperature sweep data sets tested via dynamic testing, ramping the temperature from were then shifted to the temperature defined as the ideal 50 to 300˚C, testing first in torsion for solid state data and thermoforming temperature for that particular product and then testing using parallel plate fixtures for the melt state. compared. These PS homopolymer grades have not been previously described. All molecular weight information can be found Results and Discussion in the legend of the chart. Commercial grades STYRON The rubber plateau width provides us with an 665 and 680 are not anionically produced and have a understanding of the size of the molding window for a molecular weight distribution of 2.0 to 3.0. Figures 3 and 4 given polymer and the ideal molding temperature. The illustrate the effect of molecular weight and the resulting rubber plateau region occurs in higher molecular weight entanglement density on the width of the rubber plateau polymers, existing in a temperature / frequency range (˚C). where entanglements do not have the time to relax out stress. 2 Thesecrosslinks entanglements and provide are both acting strength as mechanicalin the solid state and We are Weassuming are assuming that we mustthat thermoformwe must thermoform at at crosslinks and provide both strength in the solid state and We are assuming that we must thermoform at crosslinkscrosslinks andmelt and provide strength provide both aboveboth strengthstrength Tg. The in in the molecularthe solid solid state stateweight and and between We temperaturesaretemperatures assuming withinthat within we the themust rubber rubber thermoform plateau region atregion as as tested at melt strengthentanglements,melt strengthabove Tg. aboveMe, The is molecularTg.based The on theweightmolecular rigidity between ofweight the polymer betweentemperatures low withintemperatures frequencies the rubber within to plateau withstand the regionrubber the as temperaturesplateau tested atregion experienced as tested at melt strength above Tg. The molecular weight between tested at low frequencies to withstand the temperatures crosslinksentanglements,chainentanglements, and asprovide Me, is theis basedboth Tg. Me, strength onEntanglement is the based rigidity in theon thesolidof molecular the rigidity state polymer and of weights the polymerlow and Wefrequencies areduring lowassuming to frequencieswithstand the heatingthat the weto process.temperatures withstandmust Figurethermoform the experienced temperatures 3 also atcontains experienced PS with entanglements,meltchain strength asthermal chainis the aboveMe, as Tg.transitions is is Tg.Entanglement thebased Tg.The for on molecularEntanglement varying the molecular rigidity polymers weight weights molecularof between theare andlistedpolymer weights in Tabletemperaturesduring and theexperienced heatinga withinduringbroader process. the the duringmolecularrubber heatingFigure plateau the process. 3weight alsoheating region contains Figuredistribution asprocess. testedPS 3 withalso at Figurefor contains comparison 3 PSalso with chainentanglements,thermal as is the1. transitionsthermal FigureTg. Me, Entanglement transitions 2foris illustratesbased varying on for polymersthe the varying molecularrigidity effect are polymers ofof listed the entanglementweights polymer in areTable listedand density, inlow aTablebroader frequencies contains molecularpurposes.a tobroader withstandPS weight with molecular a thedistribution broader temperatures weight molecular for experienceddistributioncomparison weight for distribution comparison chain1. Figure as is1. the2 Figureillustrates Tg. Entanglement2 illustrates the effect ofthe molecular entanglement effect ofweights entanglement density, and density,duringpurposes. the heatingpurposes. process. Figure 3 also contains PS with thermal transitionsMw/Me, foron varyingthe strength polymers of an are amorphous listed in Tablepolymer as for comparison purposes. thermalMw/Me, transitionsreflectedMw/Me, on the in strengthforon a varyingtensile the ofstrength test.polymersan amorphous of are an listed amorphouspolymer in Table as polymera broader as molecular weight distribution for comparison 1. Figure1.reflected Figure 2 illustratesreflected in2 illustratesa tensile in the test.a the tensile effect effect test. ofof entanglemententanglement density, density, purposes. Mw/Me, on the strength of an amorphous polymer as Mw/Me, onTable the strength 3. Entanglement of an amorphous Molecular polymer Weight and as Thermal reflectedTable 3. in Entanglement a tensile test.3, 4, 5,Molecular 6 Weight and Thermal reflected inTransitionsTable a tensile3, 4, 3. 5, 6Entanglement test. Molecular Weight and Thermal TransitionsTransitions 3, 4, 5, 6 Table 3. Entanglement Molecular Weight and Thermal Transitions 3, 4, 5, 6

Figure 3. Figure 3. Rubber PlateauRubberFigure Width 3Plateau. versus Width Polystyrene versus Molecular Polystyrene Molecular FigureWeight 3 Figure. 3. Rubber Plateau Width versus Polystyrene Molecular WeightWeightRubber Plateau Width versus Polystyrene Molecular Rubber PlateauWeight Width versus Polystyrene Molecular (The anionic polystyrene samples were obtained from Table 3. Entanglement Molecular Weight and Thermal TransitionsWeight Fisher Scientific.)(The(The anionic anionic polystyrene polystyrene samples samples were obtainedobtained from from 3, 4, 5, 6 Fisher(The anionicScientific.) polystyrene samples were obtained from (The anionicFisher polystyrene Scientific.) samples were obtained from Fisher Scientific.)Fisher Scientific.)

Figure 4. Approximate Rubber Plateau Width versus Figure 2. Polystyrene Tensile Strength versus Entanglement Density, Anionic Polystyrene Entanglement Density Figure 4.Figure ApproximateFigure 4. Approximate 4. Approximate Rubber Rubber Plateau Rubber Plateau Width PlateauWidth versus versus Width versus Figure 2. Polystyrene Tensile Strength versus FigureFigure 2. Polystyrene 2. Polystyrene Tensile Strength Tensile versus Strength Entanglement versus DensityEntanglement EntanglementEntanglementFigure Density, 4. Density, Anionic Approximate Density, AnionicPolystyrene Anionic PolystyreneRubber Polystyrene Plateau Width versus EntanglementAnionicEntanglementFigure Densitypolystyrene 2. Density Polystyrene has a molecularTensile weightStrength versusTable 4. EffectEntanglement of Entanglement Density, Density Anionic on RubberPolystyrene distributionEntanglement of 1.0 and isDensity available at a broad range of Plateau Width and Maximum Thermoforming molecularAnionic Anionicweights.polystyrene polystyrenePolystyrene has a molecular(PS)has gradesa molecularweight were weightTableTemperature, 4. EffectTable Anionic of 4. Entanglement PolystyreneEffect of Entanglement Density on Rubber Density on Rubber 16 distributioncompressionSPE Thermoformingdistribution of Anionic molded1.0 and of andis1.0polystyrene availableQuarterly testedand is viaavailableat ahasdynamic broad aat range molecularatesting, broad of range weightPlateau of WidthPlateauTable and 4. Width EffectMaximum ofand Entanglement ThermoformingMaximum DensityThermoforming on Rubber ramping the temperature from 50 to 300˚C, testing first in molecularmoleculardistribution weights. weights. ofPolystyrene 1.0 and Polystyrene is (PS)available grades (PS)at awere broadgrades range Temperature,were of Temperature,Plateau Anionic PolystyreneWidth Anionic and Polystyrene Maximum Thermoforming torsion for solid state data and then testing using parallel compressioncompressionmolecular molded weights.andmolded tested and Polystyrenevia tested dynamic via (PS)testing,dynamic grades testing, were Temperature, Anionic Polystyrene rampingplate fixturesramping thecompression temperature for the the temperaturemelt moldedfrom state. 50 to andThesefrom 300˚C, tested 50PS testingtohomopolymer 300˚C,via firstdynamic testing in firsttesting, in torsiongrades forhave solid not statebeen datapreviously and then described. testing usingAll molecular parallel weight torsioninformationramping for the solidcan temperature be state found data in thefrom and legend then50 to oftesting 300˚C, the chart. using testing parallel first in plate fixturesplatetorsion forfixtures forthe solidmelt for state.thestate melt dataThese state. and PS thenhomopolymerThese testing PS homopolymer using parallel gradesCommercial have not grades been previouslySTYRON described. 665 and All680 molecular are not anionicallygradesplate produced fixtureshave not for andbeen the have previously melt a state.molecular described.These weight PS All homopolymer molecular weight informationweightgrades information have can not be foundbeen can previously inbe the found legend in described. theof the legend chart. All of themolecular chart.This information is provided to establish a clear Commercialdistribution ofgrades 2.0 to STYRON 3.0. Figures 665 3 and 4680 illustrate are notthe Commercialweight information grades canSTYRON be found 665in the and legend 680 of arethe understandingchart.not of the importance of molecular weight and anionicallyeffect of molecular produced weight and andhave the resultinga molecular entanglement weight density anionicallyonCommercial the width ofproduced thegrades rubber STYRONand plateau have (˚C). 665a molecularand 680 weightare notThis information is provided to establish a clear distribution of 2.0 to 3.0. Figures 3 and 4 illustrate the This information is provided to establish a clear distributionanionically ofproduced 2.0 to 3.0. and Figures have 3a and molecular 4 illustrate weightunderstanding the of the importance of molecular weight and effect of molecular weight and the resulting entanglement understandingThis information of the importance is provided of molecular to establish weight a andclear * The valueseffectdistribution presented of molecular in theof table 2.0 and weightto charts 3.0. andrepresent Figures the typical resulting 3 properties,and 4entanglement illustrate but should notthe be construed as product specifications. density on the width of the rubber plateau (˚C). understanding of the importance of molecular weight and densityeffect ofon molecularthe width ofweight the rubber and the plateau resulting (˚C). entanglement * The valuesdensity presented on in thethe table width and chartsof the represent rubber typical plateau properties, (˚C). but should not be construed as product specifications. * The values presented in the table and charts represent typical properties, but should not be construed as product specifications. * The values presented in the table and charts represent typical properties, but should not be construed as product specifications. 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SPE Thermoforming Quarterly 17 crosslinks and provide both strength in the solid state and We are assuming that we must thermoform at melt strength above Tg. The molecular weight between temperatures within the rubber plateau region as tested at entanglements, Me, is based on the rigidity of the polymer low frequencies to withstand the temperatures experienced chain as is the Tg. Entanglement molecular weights and during the heating process. Figure 3 also contains PS with thermal transitions for varying polymers are listed in Table a broader molecular weight distribution for comparison 1. Figure 2 illustrates the effect of entanglement density, purposes. Mw/Me, on the strength of an amorphous polymer as reflected in a tensile test.

Table 3. Entanglement Molecular Weight and Thermal Transitions 3, 4, 5, 6

Figure 3. Rubber Plateau Width versus Polystyrene Molecular Weight

(The anionic polystyrene samples were obtained from Fisher Scientific.)

Figure 4. Approximate Rubber Plateau Width versus Figure 2. Polystyrene Tensile Strength versus Entanglement Density, Anionic Polystyrene Entanglement Density

Anionic polystyrene has a molecular weight LeadTable 4. Technical Effect of Entanglement Article Density on Rubber distribution of 1.0 and is available at a broad range of Plateau Width and Maximum Thermoforming molecular weights. Polystyrene (PS) grades were Temperature, Anionic Polystyrene compression molded and tested via dynamic testing, strength. A tan delta curve with a high slope indicates the ramping the temperature from 50 to 300˚C, testing first in likelihood of a narrower temperature window for forming. torsion for solid state data and then testing using parallel The thermoforming temperature needs to be at a minimum plate fixtures for the melt state. These PS homopolymer 2030˚C above Tg and the rubber plateau width estimated grades have not been previously described. All molecular weight information can be found in the legend of the chart. from this entanglement density would be 40 ˚C. Commercial grades STYRON 665 and 680 are not Table 4. Effect of Entanglement Density on Rubber Plateau Width ABS 1 can be formed across a broad temperature range. anionically produced and have a molecular weight and MaximumThis information Thermoforming is providedTemperature, to Anionicestablish Polystyrene a clear distribution of 2.0 to 3.0. Figures 3 and 4 illustrate the ABS 2 has limited sag in the thermoforming oven but understanding of the importance of molecular weight and does tend to store energy to the point that molded parts effect of molecular weight and the resulting entanglement This information is provided to establish a clear whitened sitting on the shelf as the rubber particles density on the width of the rubber plateau (˚C). understanding of the importance of molecular weight and cavitated over time. Both of these ABS products have an entanglement density to processing conditions where melt * The values presented in the table and charts represent typical properties, but should not be construed as product specifications. entanglement density of 14. The difference in performance strength is required. comes from the difference in % rubber. Both ABS grades Amorphous Polymers contain an emulsion polymerized, small particle rubber phase. Rubber phase graft interactions started to occur Our goal when designing a polymer for deep drawn parts as the rubber content increased and interparticle distance is to resist sag in the heating process while still pulling entanglement density to processing conditions where melt dropped.dropped. Elasticity Elasticity is a function is a function of the design of the of design the of the down over the tool evenly, creating parts without significant strength is required. continuouscontinuous phase. phase. In ABS In ABS2, the 2, dispersed the dispersed rubber rubber phase phase built-in stress and without areas of thinning. Ideal molding beginsbegins to tobe be involved involved in indefining defining the the elastic elastic behavior behavior of of the the temperatures can be defined using timetemperature polymer. polymer. superpositionAmorphous Polymersand plotting the tan delta curve. Rheological data gathered on thermoforming products over a number of yearsOur consistently goal when places designing the tan a deltapolymer between for deep 1 and drawn 2 atparts a shear is to rate resist of 0.01sag in rad/sec the heating when process testing whileat the stillpreferred pulling thermoformingdown over temperature.the tool evenly, creating parts without significant built-in stress and without areas of thinning. TimeIdeal temperature molding temperatures superposition can has bemultiple defined advantages using time- whentemperature screening superposition new materials. and This plotting analysis the approach tan delta curve. allowsRheological us to evaluate data gathered a range on of thermoforming temperatures and products it over allowsa number us to ofevaluate years consistently tan delta at placesvery low the shear tan delta rates. between It is important1 and 2 atto alook shear at therate low of 0.01rates rad/secas the sheet when undergoing testing at the preferred thermoforming temperature. this fabrication mode is not under shear deformation duringTime the heating temperature process. However,superposition it is difficult has tomultiple accuratelyadvantages test when at these screening low shear new rates materials. due to thermal This analysis stabilityapproach issues. allows In high us to rubber evaluate samples a range involving of temperatures ABS, and theit butadieneallows us to phase evaluate is not tan thermally delta at verystable low for shearthe time rates. It requiredis important to run to the look test at atthe these low ratesrates asand the the sheet sample undergoing is undergoingthis fabrication crosslinking mode is throughout not under shear the test. deformation This results during in a greatthe heating deal of process. scatter in However, a shifted plot.it is difficult to accurately test at these low shear rates due to thermal stability issues. FigureFigure 5. Tan 5. Delta Tan versus Delta Temperature, versus Temperature, ABS and HIPS at ABS and WeIn can high also rubber examine samples the involvingcurves to ABS,understand the butadiene how phase OptimumHIPS atThermoforming Optimum Thermoforming Temperatures Temperatures sensitiveis not thermally a material stable may befor to the temperature time required or how to run likely the test Figure 6 Figureillustrates 6 illustrates our method our ofmethod using oftan using delta tan as adelta as a theat samplethese rates is to haveand the issues sample with molded-inis undergoing stress crosslinking in the tooltool to defineto define the theoptimum optimum thermoforming thermoforming temperature temperature partthroughout (Figure 5). the The test. HIPS This tan results delta changesin a great much deal ofmore scatter in windowwindow for fora polymer. a polymer. A series A series of Temperature-Frequency of Temperature-Frequency rapidlya shifted with plot. temperature and rate than the ABS. We see sweepsweep Master Master Curves Curves each each shifted shifted to different to different reference reference a very narrow rubber plateau when comparing the Mw temperatures were plotted. This particular HIPS grade was We can also examine the curves to understand how temperatures were plotted. This particular HIPS grade of the HIPS tested to that of the polydisperse molecular evaluated on a thermoformer and formed best in the sensitive a material may be to temperature or how likely the was evaluated on a thermoformer and formed best in weight distribution PS in Figure 2. This particular HIPS temperature range of 150-160 ˚C. This is predicted by sample is to have issues with molded-in stress in the part the temperature range of 150-160 ˚C. This is predicted by product has a low entanglement density (Me/Mw = 10), identifying the associated temperatures for data sets with a (Figure 5). The HIPS tan delta changes much more rapidly identifying the associated temperatures for data sets with a thewith lowest temperature Mw that wouldand rate have than a maximized the ABS. tensile We see a very tan delta value between 1 and 2 at 0.01 rad/s. tan delta value between 1 and 2 at 0.01 rad/s. narrow rubber plateau when comparing the Mw of the HIPS tested to that of the polydisperse molecular weight 18distribution SPE Thermoforming PS in Figure Quarterly 2. This particular HIPS product has a low entanglement density (Me/Mw = 10), the lowest Mw that would have a maximized tensile strength. A tan delta curve with a high slope indicates the likelihood of a narrower temperature window for forming. The thermoforming temperature needs to be at a minimum 20- 30˚C above Tg and the rubber plateau width estimated from this entanglement density would be 40 ˚C.

ABS 1 can be formed across a broad temperature range. ABS 2 has limited sag in the thermoforming oven but does tend to store energy to the point that molded parts whitened sitting on the shelf as the rubber particles cavitated over time. Both of these ABS products have an Figure 6. HIPS Master Curves, Defining the entanglement density of 14. The difference in performance Thermoforming Temperature Using Tan Delta comes from the difference in % rubber. Both ABS grades contain an emulsion polymerized, small particle rubber Thermoformed parts are trimmed to size and the scrap phase. Rubber phase graft interactions started to occur as is then used as regrind. It is possible to observe molecular the rubber content increased and interparticle distance weight degradation after multiple processing steps. Mw

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SPE Thermoforming Quarterly 19 entanglement density to processing conditions where melt dropped. Elasticity is a function of the design of the strength is required. continuous phase. In ABS 2, the dispersed rubber phase begins to be involved in defining the elastic behavior of the polymer. Amorphous Polymers

Our goal when designing a polymer for deep drawn parts is to resist sag in the heating process while still pulling down over the tool evenly, creating parts without significant built-in stress and without areas of thinning. Ideal molding temperatures can be defined using time- temperature superposition and plotting the tan delta curve. Rheological data gathered on thermoforming products over a number of years consistently places the tan delta between 1 and 2 at a shear rate of 0.01 rad/sec when testing at the preferred thermoforming temperature.

Time temperature superposition has multiple advantages when screening new materials. This analysis approach allows us to evaluate a range of temperatures and it allows us to evaluate tan delta at very low shear rates. It is important to look at the low rates as the sheet undergoing this fabrication mode is not under shear deformation during the heating process. However, it is difficult to accurately test at these low shear rates due to thermal stability issues. Figure 5. Tan Delta versus Temperature, ABS and In high rubber samples involving ABS, the butadiene phase HIPS at Optimum Thermoforming Temperatures is not thermally stable for the time required to run the test at these rates and the sample is undergoing crosslinking Figure 6 illustrates our method of using tan delta as a throughout the test. This results in a great deal of scatter in tool to define the optimum thermoforming temperature a shifted plot. window for a polymer. A series of Temperature-Frequency sweep Master Curves each shifted to different reference We can also examine the curves to understand how temperatures were plotted. This particular HIPS grade was sensitive a material may be to temperature or how likely the evaluated on a thermoformer and formed best in the sample is to have issues with molded-in stress in the part temperature range of 150-160 ˚C. This is predicted by (Figure 5). The HIPS tan delta changes much more rapidly identifyingLead Technical the associated temperatures Article for data sets with a with temperature and rate than the ABS. We see a very tan delta value between 1 and 2 at 0.01 rad/s. narrow rubber plateau when comparing the Mw of the HIPS tested to that of the polydisperse molecular weight or above the Tm. The melting point may be significantly distribution PS in Figure 2. This particular HIPS product higher than the Tg and would require a wider rubber has a low entanglement density (Me/Mw = 10), the lowest plateau region than is typical for a noncrosslinked polymer. Mw that would have a maximized tensile strength. A tan PP is more difficult to thermoform than amorphous resins delta curve with a high slope indicates the likelihood of a such as HIPS or ABS, even when the high molecular narrower temperature window for forming. The weight is high. Figure 8 contains the tan delta data from thermoforming temperature needs to be at a minimum 20- frequency sweeps for differing PP grades, run at the 30˚C above Tg and the rubber plateau width estimated from lowest temperature possible above Tm. Table 4 describes this entanglement density would be 40 ˚C. these varying high molecular weight grades of both ABS 1 can be formed across a broad temperature homopolymer and impact modified PP. These polymers range. ABS 2 has limited sag in the thermoforming oven have an entanglement density of close to 60, however, but does tend to store energy to the point that molded parts the only grades that are thermoformable were designed whitened sitting on the shelf as the rubber particles containing some degree of crosslinking or long chain cavitated over time. Both of these ABS products have an Figure 6. HIPS6. MasterHIPS Curves, Master Defining Curves, the Thermoforming Defining the branching. PP is typically formed 165 degrees above Tg. Thermoforming Temperature Using Tan Delta entanglement density of 14. The difference in performance Temperature Usingloss Tan can Delta vary based on stabilizer packages. Figure 7 comes from the difference in % rubber. Both ABS grades illustrates the use of tan delta measurements as a quality ThermoformedThermoformed parts parts are trimmed are trimmed to size to sizeand theand scrapthe scrap is contain an emulsion polymerized, small particle rubber controlloss cantool. vary One based of the on products stabilizer below packages. increases Figure in tan 7 phase. Rubber phase graft interactions started to occur as thenis then used used as as regrind. regrind.deltaillustrates when It is It possiblesignificant theis possibleuse of toregrindtan observeto delta observe was measurements added,molecular molecular correlating as a quality to a loss of molecular weight from the use of regrind. HIPS B the rubber content increased and interparticle distance weight degradationdegradationcontrol afterafter tool. multiplemultiple One of processing processingthe products steps. belowsteps. increases Mw in tan appears to be more thermally stable. Mw loss can vary baseddelta when on stabilizersignificant regrindpackages. was added,Figure correlating 7 to a loss of molecular weight from the use of regrind. HIPS B illustratesloss canthe vary use appearsbasedof tan on deltato bestabilizer more measurements thermally packages. stable. Figure as a quality 7 * The values presented in the table and charts represent typical properties, but should notillustrates be construed the asuse product of tan specifications.delta measurements as a quality controlcontrol tool. tool. One One of theof the products products below increases increases in tan in tan delta deltawhen when significant significant regrind regrind was was added, added, correlating correlating to a to a loss ofloss molecular of molecular weight weight from from the use use of ofregrind. regrind. HIPS HIPS B B appears to be more thermally stable. appears to be more thermally stable.

Figure 8. Tan Delta Analysis via Frequency Sweep – Polypropylene Figure 8. Tan Delta Analysis via Frequency Sweep – DesignP olypropyleneversus Thermoformability Design versus Thermoformability Figure 8. Tan Delta Analysis via Frequency Sweep – Figure 7. HIPS Master Curves, Tan Delta for Quality FigureP olypropylene9 alsoFigure contains 9 also Design contains frequency versus frequency Thermoformability sweep sweep data, data, analyzing analyzing Control – Use of Regrind high densityhigh density polyethylene polyethylene (HDPE) (HDPE) grades grades commonlycommonly used used Figure 7. HIPS Master Curves, Tan Delta for Quality for deepFigure draw 9 also thermoforming. contains frequency These sweep grades data, thermoform analyzing Both HIPS and ABS can be thermoformed into deep for deep draw thermoforming. These grades thermoform Control – Use of Regrind wellhigh widensitythout thepolyethylene need for crosslinking. (HDPE) grades HDPE commonly has the usedmost draw parts without excessive sagging in the Figureheating 8. Tan Delta Analysis via Frequency Sweep – well withoutflexiblefor deep polymerthe draw need thermoforming. chain for andcrosslinking. so has These the grades lowestHDPE thermoformMe has at the 1390 most process. As amorphous polymers, they can be formedPolypropylene close Design versus3 Thermoformability Both HIPS and ABS can be thermoformed into deepflexible g/molwell polymer wi. thoutThe theentanglement chain need forand crosslinking. sodensity has the based HDPE lowest on hasMw theMe is mostatquite 1390 enough to Tg to have sufficient melt strength for this FigureFigure 7. HIPS 7. MasterHIPSdraw MasterCurves, parts Curves, Tanwithout Delta Tan excessivefor Delta Quality for saggingQuality Control in – Usethe heating highflexible for polymerthese HDPE chain products, and so has 136, the and lowest both Mehave at a1390 high fabrication mode. A desired molecular weight canFigure be g/mol. 9 also contains 3 The frequencyentanglement sweep data, density analyzing based on Mw is quite Control – Use ofprocess. Regrind As amorphous polymers, they can be formed close molecularg/mol. 3 T heweight entanglement tail (Mz > density 1,000,000 based g/mol). on Mw is quite of Regrind definedenough to produceto Tg to a sufficientlyhave sufficient wide melt rubber strength plateau.high for ABS densitythis polyethylene (HDPE) grades commonly used for deep drawhigh thermoforming. forhigh these for these HDPE HDPEThese products, gradesproducts, thermoform 136, 136, andand bothboth have have a high a high containingfabrication emulsion mode. Arubber desired particles molecular can weight be formedcan be Both HIPS and ABS can be thermoformed into deep well withoutmolecular the needmolecular for weight crosslinking. weight tail tail (Mz HDPE(Mz > >1,000,000 has1,000,000 the most g/mol). Both HIPS and ABSsuccessfullydefined can beto produce thermoformedat lower a sufficiently molecular into wide deep rubberweights draw plateau. due ABSto draw parts without excessive sagging in the heating flexible polymer chain and so has the lowest Me at 1390 contributionscontaining emulsionof rubber rubber phase particles graft interactionscan be formed to parts process.without As excessive amorphous sagging polymers, inthey the can heating be formed process. close Asg/mol . 3 The entanglement density based on Mw is quite elasticity.successfully at lower molecular weights due to amorphousenough polymers,to Tg to have they sufficient can be melt formed strength close for enoughthis high for these HDPE products, 136, and both have a high fabrication mode.contributions A desired ofmolecular rubber weightphase cangraft be interactionsmolecular to weight tail (Mz > 1,000,000 g/mol). to Tg definedto have to producesufficientelasticity. a sufficiently melt strength wide rubber for plateau.this fabrication ABS mode.containing A desired emulsionSemi-Crystalline molecular rubber weight Polymersparticles can canbe definedbe formed to successfully at lower molecular weights due to produce a sufficiently wide rubber plateau. ABS containing contributions ofSemi-Crystalline Somerubber semi-crystallinephase Polymers graft interactions polymers, to such as emulsionelasticity. rubber polypropylene particles can (PP), be areformed extremely successfully difficult to at thermoform lower molecularinto weights largeSome duedeep semi-crystalline todrawn contributions parts. These polymers,of rubbermaterials suchmust beas thermoformedpolypropylene at (PP),or above are extremelythe Tm. The difficult melting to thermoform point may phase graft interactions to elasticity. Semi-Crystallinebeinto significantlyPolymers large deep higher drawn than parts. the TgThese and materials would require must bea widerthermoformed rubber plateau at or above region the than Tm. isThe typical melting for point a non- may Semi-CrystallineSome crosslinked semi-crystallinePolymersbe significantly polymer. higherpolymers, PP thanis more thesuch Tgdifficult andas wouldto thermoform require a polypropylene (PP), are extremely difficult to thermoform Figure 9. Tan Delta Analysis via Frequency Sweep – thanwider amorphous rubber plateauresins suchregion as HIPSthan isor typicalABS, evenfor awhen non- Someinto semi-crystalline large deep drawn polymers, parts. These such materials as polypropylene must be Successful HDPE Grades Designed for thecrosslinked high molecular polymer. weight PP isis high.more difficultFigure 8to contains thermoform the thermoformed at or above the Tm. The melting point may ThermoformabilityFigure 9. Tan Delta Analysis via Frequency Sweep – (PP), are extremelytanthan difficultdelta amorphous data to from thermoform resins frequency such as into sweepsHIPS large or forABS, deepdiffering even when PP Figure 9. Tan Delta Analysis via Frequency Sweep – Successful be significantly higher than the Tg and would require a Successful HDPE Grades Designed for grades,the high run molecular at the lowest weight temperature is high. Figurepossible 8 containsabove Tm. the drawnwider parts. rubber These plateau materials region mustthan isbe typical thermoformed for a non- at HDPE ThermoformabilityGradesThe Designed rubber plateau for Thermoformability width versus molecular weight Tabletan delta4 describes data from these frequency varying sweepshigh molecular for differing weight PP crosslinked polymer.grades, PPrun is at more the lowestdifficult temperature to thermoform possible aboveFigure Tm. 9. Tan Deltacannot Analysis be measured via Frequency for these Sweepolefin polymers– as the Tm is grades of both homopolymer and impact modified PP. The rubber plateau width versus molecular weight than amorphousTable resins 4 such describes as HIPS these or ABS,varying even high when molecular Successful weight HDPEsignificantly Grades Design highered forthan Tg. We cannot know how the These polymers have an entanglement density of close to cannot be measured for these olefin polymers as the Tm is 20 SPEthe high Thermoforming moleculargrades weight of both Quarterlyis high. homopolymer Figure 8 contains and impact the modifiedThermoformability PP. relationship of plateau width to entanglement density of tan delta data60, from however, frequency the only sweeps grades for that differing are thermoformable PP were significantly higher than Tg. We cannot know how the These polymers have an entanglement density of close to polyolefins compares to that of polystyrene. However, we grades, run atdesigned the lowest containing temperature some possible degree above of crosslinking Tm. or long relationship of plateau width to entanglement density of 60, however, the only grades that are thermoformable wereThe rubbercan plateau compare width PP versus to the molecular ultra-high weight MW HDPE grades that Table 4 describeschain branching.these varying PP highis typically molecular formed weight 165 degrees above polyolefins compares to that of polystyrene. However, we designed containing some degree of crosslinkingcannot or long be measuredform for well. these olefin Table polymers 5 summarizes as the Tm the is relative thermal grades of bothTg. homopolymer and impact modified PP. can compare PP to the ultra-high MW HDPE grades that chain branching. PP is typically formed 165 degreessignificantly above highertransitions than Tg. and We thecannot entanglement know how thedensity across the These polymers have an entanglement density of close to relationship of plateaupolymerform well.width families. toTable entanglement The 5 entanglementsummarizes density the ofmolecular relative weightthermal of 60, however, theTg. only grades that are thermoformable were polyolefins comparesPPtransitions is to 5x that that ofand ofpolystyrene. PE.the PPentanglement would However, have wedensity an Mw acrossof 940,000 the designed containing some degree of crosslinking or long can compare PP g/molpolymerto the toultra-high families.be able MW toThe matchHDPE entanglement thegrades entanglement that molecular densityweight ofof chain branching. PP is typically formed 165 degrees above form well. TableHDPE.PP is5 5xsummarizes The that PP of would PE. the PPnorelative longerwould thermalbehave easily an Mwextruded. of 940,000 Other Tg. transitions and g/molthe entanglement to be able todensity match theacross entanglement the density of polymer families.HDPE. The entanglement The PP would molecular no longer weight be easily of extruded. Other * The values presented in the table and charts represent typicalPP properties, is 5x that but shouldof PE. not PPbe construed would have as product an Mw specifications. of 940,000 * The values presented in the table and charts represent typicalg/mol properties, to be but able should to not match be construed the entanglement as product specifications. density of HDPE. The PP would no longer be easily extruded. Other

* The values presented in the table and charts represent typical properties, but should not be construed as product specifications. SPE Thermoforming Quarterly 21 Lead Technical Article

The rubber plateau width versus molecular weight cannot References be measured for these olefin polymers as the Tm is 1. James L. Throne, Thermoforming, Ed. Hanser Publishers, significantly higher than Tg. We cannot know how the New York (1987). relationship of plateau width to entanglement density of polyolefins compares to that of polystyrene. However, 2. L.E. Nielsen, Polymer Rheology, Marcel Dekker, INC., we can compare PP to the ultra-high MW HDPE grades New York (1977). that form well. Table 5 summarizes the relative thermal 3. Souheng Wu, “Control of Intrinsic Brittleness and transitions and the entanglement density across the Toughness of Polymers and Blends by Chemical Structure: polymer families. The entanglement molecular weight of A Review,” Polymer International, Vol 29, p. 229, 1992. PPmeans is 5x ofthat acquiring of PE. PP structure would have are anrequired Mw of 940,000such as g/mollight tocrosslinking be able to or match long thechain entanglement branching. density of HDPE. 4. Souheng Wu, “Secondary Relaxation, Brittle-Ductile The PP would no longer be easily extruded. Other means Transition Temperature, and Chain Structure,“ Journal of Table 1. Understanding Thermoformability as it of acquiring structure are required such as light crosslinking Applied Polymer Science, Vol. 46, p. 619, 1992. orRelates long chain to Thermal branching. Transitions and Entanglement Density 5. http://polymerdatabase.com/polymers/polyethyleneter ephthalate.html

6. http://faculty.uscupstate.edu/llever/Polymer%20Reso urces/FactorsTg.htm#stiffness

This presentation is provided in good faith for informational purposes only. Dow assumes no obligation or Table 1. Understanding Thermoformability as it Relates to liability. Thermal Transitions and EntanglementConclusions Density * The values presented in the table and charts represent Conclusions A rheological technique, using dynamic mechanical typical properties, but should not be construed as product Atesting rheological has been technique, developed using and validateddynamic mechanicalwhich permits the specifications. testingdetailed has analysis been ofdeveloped the rubber and plateau validated of amorphous which permits resins theand detailed the melting analysis region of the ofrubber semi-crystalline plateau of amorphous resins to determine suitability for use in deep draw thermoforming. resins and the melting region of semi-crystalline resins to This technique defines the temperature range in which the determineelastic and suitabilityviscous components for use in deep are at draw the rightthermoforming. balance to Thisprevent technique excessive defines sagging the in temperature the heating rangeprocess in yetwhich form the elasticevenly and around viscous the componentspart without areexcessive at the rightbuilt balancein stress. toAnalysis prevent of excessive entanglement sagging density in the canheating assist process in defining yet formcases evenly where around crosslinking the part or without long excessivechain branching built in are stress.required Analysis to generate of entanglement structure above density and beyond can assist the ineffects definingof molecular cases weight/entanglement where crosslinking density.or long chain branching are required to generate structure above and beyond the effects of molecular weight/entanglementReferences density.

1. James L. Throne, Thermoforming, Ed. Hanser Publishers, New York (1987). 2. L.E. Nielsen, Polymer Rheology, Marcel Dekker, INC., New York (1977). 3. Souheng Wu, “Control of Intrinsic Brittleness and Toughness of Polymers and Blends by Chemical Structure: A Review,” Polymer International, Vol 29, p. 229, 1992. 4. Souheng Wu, “Secondary Relaxation, Brittle-Ductile Transition Temperature, and Chain Structure,“ FollowJournal of Applied the SPE Polymer Thermoforming Science, Vol. 46, p. 619, Division1992. on Twitter @SPEThermo 5. http://polymerdatabase.com/polymers/polyethyleneter ephthalate.html 226. http://faculty.uscupstate.edu/llever/Polymer%20ResoSPE Thermoforming Quarterly urces/FactorsTg.htm#stiffness

This presentation is provided in good faith for informational purposes only. Dow assumes no obligation or liability.

* The values presented in the table and charts represent typical properties, but should not be construed as product specifications. ® tslusa.biz davis-standard.com

SPE Thermoforming Quarterly 23 Lead Technical Article

Barrier Packaging Materials & Processes By Jimmy A. Shah, Senior R&D Engineer at ICPG and Impact Plastics, Hamlet, NC

The use of plastics packaging across a wide range of necessary to support brand the differentiation that is industry segments is increasing due to plastics’ ability to essential to continued industry growth and food safety keep products safe and retain their quality until final use by Materials Used in Barrier Packaging the end-consumer. The outlook for the global packaging industry forecasts steady growth, with several projections Barrier properties to consider include moisture vapor anticipating the industry will near the trillion-dollar mark permeation, oxygen permeation, material organoleptic by 2022. Assessing the value proposition among material properties, UV protection, light permeability, aroma options available today must transcend the absolute preservation, and the permeability of other gases such as package cost because of the value today’s consumers put carbon dioxide and nitrogen. Understanding a product’s on factors such as sustainability, temperature flexibility, packaging needs is essential to protect the food product traceability, product safety/counterfeit protection, shelf- from the various environmental elements that typically life, and convenience. As markets mature and become cause food to spoil. Some of the most widely used more reliant on ecommerce and online shopping, the materials found in barrier packaging are metal, paper global packaging industry must adapt by focusing on and paperboard, glass and plastics. The benefits offered these needs. Creative adaptation of the work being done by plastic packaging include competitive cost, functional in material science is essential to finding the perfect efficiency as a result of physical properties, design flexibility balance between environmental responsibility and and innovation. These elements coupled with readily package functionality. This is especially true in our area of available supply and ease of use for both the consumer focus, rigid packaging, where the combination of material and converter, often make plastic barrier packages the science and modern multi-layer extrusion technology has product of choice when all of the design variables being pushed the boundaries of barrier packaging to extend considered. both product quality and shelf-life. These enhancements The most common plastics barrier packaging materials will ensure every market segment, e.g., food, medical, used in the industry include: cosmetics or automotive will benefit along with our environment. Polyvinyl dichloride (PVdC) is a clear and flexible thermoplastic polymer made through the polymerization Market Segments of Barrier Packaging of vinylidene chloride. It offers excellent optical properties The global market for plastics packaging can be as well as oxygen and moisture barrier properties. PVdC segmented based on the end-use application, with can serve as a barrier and a sealant. It is primarily used some larger segments defined as healthcare packaging, in hot-fill and “retort” processes even though it has consumer goods packaging, and food packaging. The very narrow extrusion process window. The material global market is further categorized based on type of can also turn yellow overt ime. Acceptance of PVdC packaging such as blister pack base webs, forming webs, has declined recently due to the presence of chlorine stand-up pouches, bags and pouches, wrapping film, and content and restrictions with recycling (mechanical and tray lidding film. chemical recycling systems). PVdC has been used as a barrier for fresh meat packaging for decades but without A large portion of the food packaging market segment a solid recycling plan, CPG’s have begun to turn away is dedicated to single-serve and portable light-weight from PVdC with 62% of brands, retailers and packaging packaging that fits into busy consumer lifestyles. One of producers committing to eliminating or phasing out the the main causes of food spoilage, and in turn food waste, material by 2025 according to the Ellen MacArthur Global is the growth of microbes such as bacteria, yeast and Commitment initiative. As a result, post-industrial scrap mold that feed and grow on the packaged food product. and post-consumer waste either ends up in landfills or is Extending product shelf life through a combination of incinerated. Incineration of this material carries its own packaging material, sterilization systems and customized concerns as it leads to the release of toxic chemicals such barrier specifications is critical to maintaining the integrity as dioxins, a well-known potent human carcinogen. of the food product, while providing the unique packaging

24 SPE Thermoforming Quarterly SPE Thermoforming Quarterly 25 Lead Technical Article

Ethylene Vinyl alcohol (EVOH) is a clear, non-chlorine typically is produced by adding around 5-10% rubber or based, flexible and a high gloss thermoplastic semi- butadiene copolymer. This increases the toughness and crystalline random copolymer made through the impact strength of the polymer and results in a very stiff copolymerization of ethylene and vinyl alcohol to offer product ideal for packaging applications. Use of HIPS is excellent oxygen barrier properties and resistance to oils, prevalent in food and medical thermoforming and FFS organic solvents and hydrocarbons. Because EVOH is semi- due to its low cost and easy processability. However, with crystalline, as the ethylene mol% increases, oxygen barrier the implementation of Proposition 65, use of HIPS in food properties reduce. EVOH is hydroscopic in nature, and if packaging applications is declining. exposed to moisture, will lose its gas barrier properties. Polypropylene (PP) is a semi-crystalline polymer that is As a result, this material is generally coextruded and/or hazy in its natural state, but can be made available as an laminated as a barrier layer sandwiched with PE, PP, PS exceptionally clear and high-gloss material through the or PET to protect the material from moisture and offer use of specialty additives and processes. This material is additional mechanical properties. This material is also very generally characterized as having a higher stiffness at a expensive, so use of this material in a coextruded structure lower density, resistance to higher temperatures, and an helps to control overall cost while also providing necessary excellent strength to weight ratio. There are three main barrier properties. grades (homopolymer, random copolymer and impact Polyamide (PA)- PA (also known as nylon) is a clear copolymer) of PP resin which allow for improvement of thermoplastic polymer with exceptional mechanical specific properties as determined by the composition of properties (impact strength, toughness, low elongation, the polymer chain. high tensile) and good oxygen barrier properties. Apart Polyethylene (PE) is a low cost, translucent thermoplastic from oxygen barrier, nylon also provides excellent barrier polyolefin material that offers great versatility that spans to chemicals, especially flavors and aroma. Nylon also food, medical, cosmetics, automotive and construction exhibits good resistance to high heat, allowing for use applications for its high impact strength and puncture in retort packaging applications even for products that resistance at temperatures as low as -40C. There are three contain fats and oils. Compared to other barrier materials different grades of PE: high density polyethylene (HDPE), (films in particular), nylon offers easy processing and has an low density polyethylene (LDPE) and linear low density operating temperature range that allows for compatibility polyethylene (LLDPE). The various grades of polyethylene in both freezer and microwavable applications. can be strategically included in package designs in both Barrier Packaging Substrates: the substrate and sealing elements. HDPE is easy to process as a substrate and provides excellent moisture and When developing the overall rollstock structure for chemical resistance, while LDPE and LLDPE can be used barrier packaging applications, factors including food in a multi-layer coextruded structure as a tie/sealing or product, part design, processing conditions, distribution bonding layer. environment and retail conditions must all be considered as each variable ultimately affects shelf-life performance. Enhanced Barrier PP and PE materials: Once these variables have been defined, further details Polyolefins are one of the most widely used resins in such as barrier specifications, shelf-life expectations, packaging applications (rigid and flexible) for their low part geometry, material attributes and part handling cost, excellent moisture barrier, ease of processing, and must all be considered to refine the design of the recyclability. As the global demand for packaging solutions thermoformed part and develop a rollstock structure with improved sustainability and recyclability continues that will deliver optimal barrier performance. Depending to take precedence, mono-material packaging structures on the end-use application and barrier requirements, have emerged as a solution made possible through major extruders can formulate customized coextruded barrier advancements in material science. Polyethylene and rollstock structures using substrates such as polystyrene, polypropylene are the most versatile materials used in the polypropylene, and polyethylene to meet the application plastics industry today, and plans for additional production requirements. capacity in the US alone will add nearly 4bn lbs by 2022. High Impact Polystyrene (HIPS) is a form of polystyrene Both PE and PP have excellent moisture barrier properties (PS) that carries a higher impact strength. Homopolymer but exhibit poor barrier properties to oxygen and many PS can often be brittle, and can be made more impact organic solvents. As a result, currently both PE and PP resistant if combined with other materials. This form of PS are widely used either in a coextruded structure or as a

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SPE Thermoforming Quarterly 27 Lead Technical Article substrate to an oxygen barrier laminated material or film Processing of Barrier Packaging Materials such as EVOH for applications that require a high oxygen Incorporation of barrier materials into extruded rollstock barrier. structures can be achieved through two methods: ICPG’s enhanced barrier technology can now offer a new Coextrusion is the process in which two or more plastic mono-material solution for barrier polypropylene structures materials (with similar or dissimilar characteristics and (both homopolymer and copolymer) with oxygen and behavior) are extruded as one. In a standard monolayer moisture barrier enhancement up to 60%, as well as added sheet extrusion process, one material is fed and extruded clarity and low haze compared to traditional polypropylene through a die. The coextrusion process involves multiple materials. This material also offers enhanced stiffness to extruders and multiple materials (depending on the meet or exceed polystyrene standards for snapability, structure), and the molten material is channeled through allowing for replacement of PS in form-fill-seal applications the melt pipes to create a laminar flow for the coextrusion as well as potential downgauging opportunities for existing feed block and die technology to weld the extrudates structures. ICPG’s enhanced barrier HDPE offers oxygen into a one-piece structure. When multiple material layers and moisture barrier enhancements up to 40% compared are combined, the end result yields a multi-layer structure to traditional polyethylene grades. Generally, multilayer deriving distinct properties from each material used in structures are made using a complex and expensive the structure. During extrusion of these materials, the technology and the final product is not recyclable due to required cooling is achieved by feeding the material the use of multiple materials (application-dependent). With through cooling rolls, also known as stack rolls or chill rolls. a mono-material structure, however, packaging solutions These rolls deliver the required cooling. They also help are 100% recyclable and can be integrated back in the to determine the sheet thickness and the surface texture structures to create a closed loop system. using specialty surface finish rolls like matte, sand matte, Considerations for Sealability - when to use a weld seal hair cell, and more. (lock tight) vs peel-able seal (easy peel)? Although new and advanced compounded materials are Regardless of the material or method used to produce the enhancing the properties of traditional plastic materials, package, distribution of the final product may require the coextrusion continues to expand material capabilities package to be sealed with a lidding film. It is important for food packaging applications, offering added benefits to choose the right lidding film, considering sealing through the combination of materials in terms of extended integrity and barrier characteristics necessary to protect shelf-life, cost control, and increased structural properties. the product’s quality for the targeted shelf-life. Barrier Extrusion Lamination lamination is the process of properties of a lidding film must be matched to the barrier applying a multilayer coextruded lamination film to demands of the overall package. a desired substrate such as paper, plastics, ceramic, Some options include easy-peel and weld-seal (or metal, etc. via heat, pressure or a combination of both. lock-tight) peeling characteristics. When the product is Laminates are very thin extruded film structures that are designed to be consumed within a short period of time produced using multiple layers of materials to achieve or a ready-to-use concept that requires quick and easy improved strength, stability, appearance and other access, the outer material is generally formulated such that enhanced properties. Use of laminates can be used to the lidding film creates an easy peel upon sealing. Weld- improve mechanical, barrier or chemical properties, or to seal, in comparison, is a permanent seal that acts similarly enhance the appearance of a substrate. Depending on the to tamper evident packaging where it can only be opened required property enhancement, a lamination method is once and cannot be re-sealed. There are a broad range selected to weld the lamination structure and the substrate of physical characteristics designed into lidding films, together such as dry lamination, wet lamination, thermal including various barrier properties, clarity, thickness, color, lamination, etc. Regardless of the lamination method used, composition, food compatibility, heat resistance, chemical in all cases the webs are combined at a lamination nip, resistance, and sustainability. Properties such as dwell i.e., typically two rolls pressed against each other under time, temperature, and pressure play an important role in a controlled temperature, pressure, and gap. Since the the seal integrity of a package. The substrate material and web is combined using just the heat and pressure from lidding material combined with above processing variables the stack/chill roll, it is important that the lamination web plays the most vital role in a package’s seal effectiveness. has low thermal properties (low melting point) so that the preheating caused from the stack roll and pressure will

28 SPE Thermoforming Quarterly Lead Technical Article

thermally laminate and create a strong bond soon after it natural gas, our crackers’ ability to crack both heavy and exits the stack roll and pull roll system. . light feedstocks combined with the addition of on-purpose lamination, etc. Regardless of the lamination method used, in all cases the webs are combined at a polymer-grade propylene projects in development, ICPG offers extrusionlamination thermal nip , laminatedi.e., typically materials two rolls using pressed against each other under a controlled temperature, designing for the future using polyolefins is the most PE, PP, PS, the basepressure substrate, and gap. and Since desired the web lamination is combined using just the heat and pressure from the stack/chill roll, it environmentally and cost-effective course of action. film web for enhancedis important properties that the such lamination as oxygen web barrier, has low thermal properties (low melting point) so that the preheating caused from the stack roll and pressure will thermally laminate and create a strong bond soon UV barrier, and decorative films. Depending the end-use Author & Company Notes application eitherafter of theit exits process the stack can roll be and used pull to roll create system. an Jimmy Shah began his career with Impact Plastics as effective barrier packagingICPG offers materialextrusion withthermal enhanced laminated barrier materials using PE, PP, PS, the base substrate and desired Extrusion Process Engineer and today is an integral part and other desiredlamination properties. film web for enhanced properties such as oxygen barrier, UV barrier, and decorative films. Depending the end-use application either of the processof thecan teambe used at ICPG.to create He anis aneffective active barriermember for Society Benefits of Coextrusionpackaging material vs. Extrusion with enhanced Lamination barrier and other desiredof Plastics properties. Engineering (SPE) and also serves as a Co-Chair Some of the benefits of coextrusion vs. lamination in for Next Generation Advisory Board (NGAB) that helps Benefits of Coextrusion vs. Extrusion Lamination barrier packaging applications include high productivity, connect young professionals to industry veterans. Jimmy consistent quality,Some cost of savings, the benefits and sustainability. of coextrusion The vs. lamination inhas barrier a Master’s packaging of Science applications in Plastics include Engineering high from the table below summarizesproductivity, the consistentbenefits quality,and considerations cost savings, and of sustainability University. The tableof Massachusetts below summarizes Lowell. the benefits each method: and considerations of each method: Coextrusion Lamination

High output rate with exceptional bond and Moderate output rate for effective bond strength. material properties.

Complex equipment requiring continued Less equipment to maintain if added on line as maintenance. extrusion thermal lamination process.

Longer setup time. Setup time is short and easy.

High capital investment for equipment, materials Lower capital investment and more diverse range and storage. of lamination equipment and film options.

Shorter lead time as material is readily available in Longer lead time as lamination films is custom and stock. outsourced.

Ideal process for cost effective products as Less energy consumption compared to multiple reprocessed/recycled material can be easily extrusion system with coextrusion process, but integrated back in the system. materials cannot be re-integrated into structure

Rollstock specifications limited to equipment Lamination film can be outsourced in varying capabilities for gauge, width, and materials. gauge, width and materials based on application.

Theoretically, the coextrusion process is the more cost A division of Impact Plastics, ICPG produces custom- effective and idealTheoretically, method to the process coextrusion and processproduce is the more cost effectiveextruded and rollstockideal method products to process designed and produce for rigid a barrier packaginga barrier material. packaging But material.it is important But it is toimportant to understandthermoformed the end-use application,food packaging processing applications. method For more understand the end-use(thermoforming, application, lamination, processing in mold method labelling), volume, informationetc., to justify on the our cost, products quality and and output services rate visit www.icpg.co. for coextrusion vs. lamination. (thermoforming, lamination, in mold labelling), volume, References etc., to justify the cost, quality and output rate for coextrusion vs. lamination. 1. Future of Packaging, https://www.smitherspira.com/ industry-market-reports/packaging/the-future-of-global- Designing for the Future  ICPG, 2019 5 Highland Drive, Putnam CT | 860.963.1976packaging-to-2022 | www.icpg.co The environmental and aesthetic demands of today’s 2. Plastics coextrusion, https://www.thomasnet.com/ consumers related to package functionality as well as the sales growth of a product is well suited to the academic 3. Polymer Properties Database, http://polymerdatabase. and industry work being done to enhance the physical com/polymer%20classes/Intro.html properties of both polypropylene and polyethylene. In 4. Lamination system application and design considerations: addition, when you consider the US abundance of low-cost http://www.aimcal.org/uploads/4/6/6/9/46695933/_____ pasquale_abstract.pdf |

SPE Thermoforming Quarterly 29 Engaging with plastics industry professionals around the world to find solutions to your technical questions.

thechain.4spe.org

30 SPE Thermoforming Quarterly SPE Thermoforming Quarterly 31 Innovation Brief Innovation Brief Customer-Specific Plugs with Excellent Sheet Release Customer-Specific Plugs with Excellent Sheet Release

With theWith material the material series series “FORM “FORM”,”, K Kieferiefer WerkzeugbauWerkzeugbau GmbH GmbH of Schwaigern,of Schwaigern, Germany, Germany, is offering is offering 4 new plug assist material4 news with plug excellent assist materials material with excellentpropertie materials. properties.

With theThe material new suiteseries of“FORM”, mater ialsKiefer can Werkzeugbau be machined to customerKiefer is- constantlyspecific requirements. striving for new developmentsThanks to high and GmbH materialof Schwaigern, toughness Germany, and is offeringlong durability, 4 new plug machine downtimessolutions to arethe discretereduced. needs and requirements of assist materials with excellent material properties. thermoformers. |

The new suite• ofFORM materials X: pcanrocessin be machinedg difficulties to customer- that occur with conventional syntactic foams are a thing of For more information: specific requirements.the past Thanks with toForm high Xmaterial. The combination toughness of high thermal stability and low thermal and long durability,conductivity machine downtimes provides areoptimal reduced. properties forKIEFER today's Werkzeugbau advanced GmbH thermoforming products. www.kiefer-mold.de ______Recommended for PP and PET film applications. [email protected] • FORM• FORMX: processing LX: formulated difficulties thatas a occurcombination with of engineered thermoplastics and syntactic foam. conventionalEspecially syntactic rele foamsvant arefor acrystal thing of-clear PP and PET films with very good polishability. the• past FORM with Form 2X: X.formulated The combination for service of high up to 180 °C, with minimal loss in mechanical properties. thermalUsed stability with and almost low thermal all types conductivity of plastic sheet, especially PP. provides• FORM optimal T2X properties: formulated for today’s with advanced PTFE to reduce coefficient of friction between plug and sheet. thermoforming products. Recommended for PP

and PET film applications. Kiefer, with its state-of-the-art machining centers coupledCraftsmen with a large Dedicated inventory, canto Detailedoffer just-in- • timeFORM prod LX:uction. formulated The as company a combination’s development of department and the implementation works with engineered thermoplastics and syntactic foam. customers to ensure the optimal development of upper plug geometry. Especially relevant for crystal-clear PP and PET SERVICES for films with very good polishability. Kiefer is constantly striving for new developments and solutions toMOLDERS the discrete • MOLDMAKERS needs and • requirementsFORM 2X: formulated of thermoformers. for service up to 180 °C, with minimal loss in mechanical properties. Used OUR WORK IS with almost all types of plastic sheet, especially ForP P. more information: AN ARTFORM KIEFER Werkzeugbau GmbH • www.kieferFORM T2X:- formulatedmold.de with PTFE to reduce coefficient of friction between plug and sheet. [email protected]

Kiefer, with its state-of-the-art machining centers coupled with a large inventory, can offer just-in-time production. The company’s development department and the implementation works with customers to ensure the 262-786-4521 | www.wi-engraving.com optimal development of upper plug geometry.

32 SPE Thermoforming Quarterly 12 th EUROPEAN THERMO- THERMOFORMING FORMING FOR A GREEN against the formed plastic sheet. CONFERENCE The labeled and trimmed parts are then moved with the web to the FUTURE downstream stacking station, where they are conveyed to a Kilde (Skive, Denmark) Flexpacker automation system and packed into2020 pre-erected cartons.

O

Figure 8: IML-T lids and labels from ILLIG

Thin Gage Thermoforming Configuration # 4

Match Metal Form & Trim in Place – the difference between the match metal and the steel-rule knife trim configuration shown above is that a matchingSwitzerland punch and die is used within the form tooling to 18–20 MARCHtrim 2020 the parts. An | integral GENEVA coining feature is |usually included in this configuration as the coiner device helps to flatten out the flange of the parts while acting like a sheet clamp. The coiner can be temperature controlled and the coining pressure can be adjusted to allow for thicker or thinner flanges. MARK YOUR CALENDARS AND

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invites you to the n Workshops

12th European Thermoforming n Exhibition

Conference to be held in n Networking Events Figure 9: Shows the components of a typical match metal trim-in-place tool with integral coining device. The call out bubbles Geneva from 18th to 20showth the March position of the 2020. punch and die during the forming ofn the Parts part and thenExhibition the trim action soon after. There are many ways in which the formed and trimmed parts can be ejected from the mold cavities, but the most popular is to move the lower tooling half down and away from sheet line with parts still in the Who should attend? Thermoformers,mold cavities) OEM’s, and then Machinery tilt the entire &lower Tooling tooling Producers, to a part retrieval Film and and stac Sheetking device. Suppliers, It is the chosen Resin Producers, Recyclers …method Venue: to manufactureStarling Hotel cups inand Geneva tubs and welcomesother similar you.part geometries, but not suited for large trays such as salad bowls.

Further information about this event may be obtained from Yetty Pauwels at Society of Plastics Engineers, Thermoforming Europe Division Tel. +32 3 541 77 55, [email protected] www.e-t-d.org SPE Thermoforming Quarterly 33 Thermoforming & Sustainability Triumvirate Recycling Project Proves Worthy

Triumvirateby Rob Coker, EuropeanRecycling Plastic Product Project Manufacturer Proves magazine Worthy by Rob Coker,(Editor’s European note: this Plastic article Product first appearedManufacturer in EPPM magazine magazine in November 2019) (Editor’s note: this article first appeared in EPPM magazine in November 2019)

Cups andCups trays andmanufactured trays manufactured from recycled fromplastic recycled is plasticto individual is precisely articles what in several Battenfeld sorting-c Ccascades,ncinnati thus, precisely Illigwhat Maschinenbau Battenfeld-cCncinnati,, and Der Illig Grüne Maschinenbau, Punkt (The Greenproducing Dot) are a highquality producing fraction in a joint of PET project. trays. This fraction, and Der Grüne Punkt (The Green Dot) are producing in a ground into flakes and sorted again, has served as a raw joint project. material. The aim was to close the reusable material cycle for disposable packaging made of PP and PET. The aim was to close the reusable material cycle for The sheet used as the initial product for making PP cups disposableAt packagingtheir K made2019 ofbooths, PP and PET.the Atthree their Kcompanies orprovided PET trays wasinformation produced onabout the ultra-modern their latest three-layer 2019 booths, the three companies provided information sheet line in the technical lab of Battenfeld-Cincinnati. about theircontribution latest contributionss to sustainability to sustainability and and the the conservation This lineof resources, is equipped showingwith a 75 T6.1a viable high-speed way toextruder, conservationreach of highresources,er recycling showing rates. a viable way to reach which is suited for PP processing, as well as a 120-40 Star higher recycling rates. extruder for PET.

Battenfeld-Cincinnati extruders; Battenfeld-Cincinnati, Bad Oeynhausen, Germany) (Image: Battenfeld-Cincinnati extruders; Battenfeld-Cincinnati, Bad Oeynhausen, Germany) The materials used to produce the sheet were supplied ‘Perfect Plasticising’ by Der Grüne Punkt and Germany’s dual system The compact PP extruder offers low energy consumption waste collections.The materials To recover used the to material, produce the the plastic sheet were supplied by Der Grüne Punkt and Germany’s and high output rates, whilst the PET extruder has a special packaging waste first passed through several steps of dual system waste collections. To recover the material,process technology the plastic combination packaging of awaste single screwfirst with a an elaborate sorting process (NIR, swim-sink and hydro central planetary roller section where the melt is subjected cyclone separation). The PET proportion was cleaned passed through several steps of an elaborate sortingto a high process level of degassing(NIR, swim and-sink decontamination. and hydro by conventional washing, while the PP was prepared by Both extruders are designed for perfect plasticising and additionalcyclone optimised separation). sorting and The washing PET processes,proportion as was cleaned by conventional washing, while the PP homogenisation of the plastic melt even when 100 per cent well as regranulation as Systalen PRIMUS PP. was prepared by additional optimised sorting and regrindwashing is used.processes, as well as regranulation Der Grüne Punkt has now embarked on a new course as Systalen PRIMUS PP. The ideal thermoforming sheet is then produced by the by separating the various packaging products according Multi-Touch roll stack, which is also part of the equipment.

34 SPE Thermoforming Quarterly With its large number of roll gaps in the recalibration Dr Markus Helftewes, CEO of Der Grüne Punkt, said: section, it produces tension-free sheet with a high degree “The co-operation with BattenfeldCincinnati and Illig is a of flatness and a transparency which depends on that pioneering effort in several respects. This project points of the raw material. A two-roll stack takes care of pre- to a first-class recovery option for PET trays, a fraction calibration. In this case, it is arranged in a 45° position to for which no practical recycling possibility has previously suit both PP and PET sheet. existed. We are now able to demonstrate how plastic Finally, ILLIG produced cups and trays from the waste from the Yellow Bag can be transformed again into extruded sheet in various test runs at its technical lab. food-grade plastic packaging. This is groundbreaking, and All manufactured end products have proved equal with I am very glad that we, together with our partners, are once comparable packaging solutions from virgin material more able to set benchmarks.” | in their profile of attributes. While the monolayer sheet made of PP regrind was processed on an RDM-73K thermoforming line with a cup mold, an RD-74d with a tray Have an idea for an article? • Article length: 1,000 - 2,000 words. mould was used to process the sheet made of PET regrind. Look to past articles for guidance In this case, Illig tested three monolayer sheets and a • Format: .doc or .docx composite sheet with outer layers made of PET regrind in • Artwork: hi-res images are encouraged (300 dpi foodgrade quality with ‘excellent results’ in each. with appropriate credits. • Send all submissions to:Conor Carlin, Editor ‘Groundbreaking’ [email protected] The partners have thereby proved the basic feasibility ALL FINAL COPY FOR EDITORIAL APPROVAL of re-processing 100 per cent recycling material from FEB 15 Spring MAY 15 Summer domestic waste collection systems into packaging JULY 31 Fall NOVEMBER 13 Winter products with the necessary profile of attributes. The next phase will be to test the renewed food grade quality of the All artwork to be sent in .eps or .jpg format packaging, and to optimise the process. with minimum 300dpi resolution.

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SPE Thermoforming Quarterly 37 Thermoforming & Sustainability THE ANNUAL TECHNICAL CONFERENCE FOR PLASTICS PROFESSIONALS Arrows vs. Triangles: Good Intentions Gone Awry ANTEC® 2020 is the largest, most respected and well-known By Conor Carlin, SPE Vice President, Marketing & Communications technical conference in the plastics industry. It’s where classroom theory connects with real world solutions.

Increased public awareness of plastics and the environment acknowledges prior regulation, it makes clear that “… Why should you attend? has led to a search for more information about how best existing statutes or regulation will take precedence…” ANTEC® 2020 represents the ideas, research and trends shaping to manage these materials at the end of their useful over the new one. In addition, the new regulation only our plastics industry. A new program format will be introduced this year-including 4 keynotes each day and 300+ concurrent sessions. lives. Plastics, polymers, and chemistry are complex, with applies to new molds or tooling, though no enforcement REGISTER Post and pre-conference workshops will also be offered! many branches of knowledge spreading out in different mechanism is evident in the text, and modification to older directions. Most people who are not scientists tend to items is not required. This explains why we still see chasing Your registration fee includes lunch on Monday and Tuesday, interact with plastics in a utilitarian way – the materials are arrow symbols today, despite the authors’ attempts to 7 coffee breaks and 3 receptions—giving you the additional ubiquitous and useful. In our consumption-driven world, decouple the RIC system from recycling messages. networking opportunities you asked for! however, plastics can pose problems when they are no NOW! longer useful to us. This post is not meant to address Plastic material derived from non-fossil resources such as Early Registration Who Should Attend? polylactide (or PLA, which was not fully commercialized Ends February 17! waste management, sustainable materials management, SPE is comprised of 22,500+ members, all from diverse backgrounds or plastics recycling. The goal is to highlight a single, small in 1998) is still classified as 7 which means it gets lumped and careers—ANTEC® is no different. Managers, engineers, R&D in with such diverse materials as acrylonitrile-butadiene- scientists, technicians, sales & marketing associates, executives, element to address a larger point: the confusion created by academics and students are all invited to enhance their career in the numbers found on most plastic packaging. styrene (or ABS, used for Lego bricks) and polycarbonate plastics through this networking and knowledge sharing event. (or PC, used in many optical applications), and multilayer Contrary to popular (though perhaps waning) belief, materials. Paradoxically, the increase in lightweight, these numbers are not recycling codes. They are resin multilayer, flexible packaging reduces overall carbon identification codes. They do not imply recyclability, accounting, but poses new and thorny issues for end-of- though many people assume that they do, causing a chain life management. Some industry participants point out reaction of problems. In 1988, the plastics industry trade that today’s materials are not compatible with recycling association (then known as SPI, or Society of the Plastics and waste management infrastructure that was mostly Industry), introduced resin identification codes (RIC) to developed in the 1990s. Declining municipal budgets and help materials recovery facilities (MRFs) and recycling a relative dearth of private investment in the sector have facilities sort different types of plastic resin. The “chasing stalled greater technological innovation and improvement. arrows” logo was created with numbers to identify these In short, consumption habits – and associated waste resins. Prior to 1988, plastic items were not marked or streams are – changing faster than infrastructure systems’ stamped with any identification. In response to rising ability to manage that waste. Can we ask if the RIC is costs associated with tipping fees at landfills, the plastics still relevant? What would a new system look like? Is industry attempted to create a system that would allow one even required given advances in high-speed, near- waste management groups to segregate potentially useful, infrared sorting technologies (link from 1993!!) and digital valuable materials. In the US, 39 states adopted the SPI RIC watermark systems? system in some form and created legislation mandating the use of the codes, though slight differences existed We don’t all get updates from ASTM in our email inboxes, among states, e.g. some mandated that all items over 16 so it requires some effort to stay current with a topic that ounces required coding, while others started coding at 8 overlaps industry, technology, and politics (you can find ounce items. a good summary here). Yet we must acknowledge that convenience can lead to thoughtlessness, and bureaucratic In 2008, the American Society for Testing and Materials approaches to fast-moving societal issues are sub-optimal. (ASTM) took over management of the RIC system. This Much changes with time; we are required to adapt to new group issued new guidelines in 2010, including changing rules, regulations, and realities. Little signs on the bottom the logo from chasing arrows to a solid triangle. The of empty bottles might not seem worthy of our attention, numbers did not change. Because the new standard but sometimes a small change can make a big difference. | www.4spe.org/antec

38 SPE Thermoforming Quarterly THE ANNUAL TECHNICAL CONFERENCE FOR PLASTICS PROFESSIONALS

ANTEC® 2020 is the largest, most respected and well-known technical conference in the plastics industry. It’s where classroom theory connects with real world solutions.

Why should you attend? ANTEC® 2020 represents the ideas, research and trends shaping our plastics industry. A new program format will be introduced this year-including 4 keynotes each day and 300+ concurrent sessions. REGISTER Post and pre-conference workshops will also be offered!

Your registration fee includes lunch on Monday and Tuesday, 7 coffee breaks and 3 receptions—giving you the additional NOW! networking opportunities you asked for! Early Registration Who Should Attend? Ends February 17! SPE is comprised of 22,500+ members, all from diverse backgrounds and careers—ANTEC® is no different. Managers, engineers, R&D scientists, technicians, sales & marketing associates, executives, academics and students are all invited to enhance their career in plastics through this networking and knowledge sharing event.

www.4spe.org/antec

SPE Thermoforming Quarterly 39 Board of Directors

MACHINERY COMMITTEE Ian Munnoch PROCESSING COMMITTEE DIRECTORS EMERITI James Alongi MSA Components, Inc. Jim Arnet (Chair) Lola Carere MAAC Machinery 6556 County Road KP Hagans Plastics Co. 302 Sable Trace Ct. 590 Tower Blvd. Mazomanie, WI 53560 121 W. Rock Island Road Acworth, GA 30102-7617 Carol Stream, IL 60188 T: 812.322.5080 Grand Prairie, TX 75050 T: 770.883.7055 T: 630.665.1700 [email protected] T: 972.974.3516 [email protected] [email protected] [email protected] Matt O’Hagan Richard Freeman Steven Clark (Chair) LyondellBasell Robert Browning Freetech Plastics Inc. Monark Equipment 7674 Park Meadow Lane McConnell Company 2211 Warm Springs Court PO Box 335 West Bloomfield, MI 48324 P.O. Box 450633 Fremont, CA 94539 4533 S. Garfield Road T: 248.760.8590 Atlanta, GA 31145 T: 510.651.9996 Auburn, MI 48611 [email protected] T: 770.939.4497 [email protected] T: 989.662.7250 [email protected] [email protected] Laura Pichon Steve Hasselbach Ex-Tech Plastics Bret Joslyn CMI Plastics Brian Golden PO Box 576 Joslyn Manufacturing 222 Pepsi Way SencorpWhite 11413 Burlington Road 9400 Valley View Road Ayden, NC 28513 400 Kidd’s Hill Road Richmond, IL 60071 Macedonia, OH 44056 T: 252.746.2171 Hyannis, MA 02601 T: 847.829.8124 T: 330.467.8111 [email protected] T: 508.771.9400 [email protected] [email protected] [email protected] Donald Hylton Ed Probst Stephen Murrill McConnell Company Travis Kieffer Probst Plastics Consulting Profile Plastics 646 Holyfield Highway Plastics Unlimited, Inc. P.O. Box 26365 65 S. Waukegan Fairburn, GA 30213 303 1st St. N.W. Wauwatosa, WI 53226 Lake Bluff, IL 60044 T: 678.772.5008 Preston, IA 52069 T: 414.476.3096 T: 847.604.5100 x29 [email protected] T: 563.589.4752 [email protected] [email protected] [email protected] Roger Kipp Jay Waddell Eric Short Roger C. Kipp Consulting Plastics Concepts & Innovations Brian Winton SIMONA PMC 3C Owens Landing Court 1127 Queensborough Road PTi 2040 Industrial Drive Perryville, MD 21903 Suite 102 2655 White Oak Circle Findlay, OH 45840 T: 717.521.9254 Mt. Pleasant, SC 29464 Aurora, IL 60502 T: 567-525-4924 [email protected] T: 843.971.7833 P: 630-585-5800 [email protected] [email protected] E: bwinton@ptiextruders com Gwen Mathis Dan Sproles 6 S. Second Street SE Steve Zamprelli Sproles Business Consulting Lindale, GA 30147 MATERIALS COMMITTEE Formed Plastics, Inc. 5210 Canton Street T: 706.346.2786 Juliet Goff 297 Stonehinge Lane South Bend, IN 60071 [email protected] Kal Plastics Carle Place, NY 11514 2050 East 48th Street T: 574-747-7997 [email protected] T: 516.334.2300 Vernon, CA 90058-2022 [email protected] T: 323.581.6194 [email protected] Paul Uphaus Primex Plastics Roger P. Jean (Chair) 4164 Lake Oconee Drive Simona PMC Buford, GA 30519 PO Box 1605 T: 1.800.935.9272 2040 Industrial Drive [email protected] Findlay, OH 45840 T: 567.208.9758 [email protected] Why Join? It has never been more important to be a member of your professional Phillip Karig society than now, in the current climate of change and global growth in the plastics Mathelin Bay Associates LLC 11939 Manchester Road #148 industry. Now, more than ever, the information you access and the personal networks you Saint Louis, MO 63131 create can and will directly impact your future and your career. Active membership in SPE – T: 314.630.8384 [email protected] keeps you current, keeps you informed, and keeps you connected. Visit www.4spe.org for details. The question really isn’t “why join?” but …Why Not?

40 SPE Thermoforming Quarterly 2020 THERMOFORMING DIVISION ORGANIZATIONAL CHART

Chair Eric Short

Chair Elect Secretary Treasurer Councilor Prior Chair Communications Steve Zamprelli Paul Uphaus Ed Probst Jay Waddell Bret Joslyn TBD

2021 Conference Recognition Finance OPCOM Assistant Treasurer Grand Rapids, MI Membership/Nominating Juliet Goff James Alongi Executive Committee James Alongi Brian Golden & Laura Pichon Mark Strachan

Conference Coordinator AARC Consultant Magazine Editor Technical Committees Jim Arnet Lesley Kyle Conor Carlin OpenMindWorks

Processing ANTEC Networking Jim Arnet Matt O’Hagan Jim Arnet

Materials Student Programs Website Roger Jean Matt O’Hagan Phil Karig

Students & Educational Machinery Facilities Steve Clark Upcoming SPE Thermoforming Matt O’Hagan Division Board Meeting Conference April 30 - May 2 Communication Estes Park, CO Lesley Kyle For more information, contact Lesley Kyle [email protected] or 914-671-9524. Publications Paul Uphaus

Thermoforming Division Membership Benefits

• Access to industry knowledge from one central location: • Discounts, discounts, discounts on books, seminars and www.thermoformingdivision.com. conferences. • Subscription to Thermoforming Quarterly, voted • For managers: workshops and presentations tailored “Publication of the Year” by SPE National. specifically to the needs of your operators. • Exposure to new ideas and trends from across the • For operators: workshops and presentations that globe. will send you home with new tools to improve your • New and innovative part design at the Parts performance, make your job easier and help the Competition. company’s bottom line. • Open dialogue with the entire industry at the annual conference. Join today!

SPE Thermoforming Quarterly 41 Sponsor Index

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