Processing Guide for DaniMer 26806 Extrusion Coating Resin

Start with a clean machine. We recommend utilizing DynaPurge F (Shuman Plastics: 716-685-2121) www.DynaPurge.com to thoroughly clean residual polyolefins prior to use of DaniMer 26806. Use polystyrene or low temperature melt polyethylene as a purge before and after processing. It is very important to purge the extruder and die thoroughly after processing so that thermal decomposition of the resin does not occur and lead to difficulty in preparing the extruder for subsequent work.

Processing Temperature Profile with an LDPE Screw

Feed Throat Ambient Front Zone 450-480 F 232-249 C Middle Zone 430-460 F 221-238 C End Zone 410-430 F 210-221 C

Adapters and Pipes 380-410 F 193-210 C Die 400-420 F 204-216 C Backpressure: Moderate ( 800 – 1,300 psi )

DaniMer 26806 resin has a fairly wide processing range; every extruder may run somewhat differently. The most critical aspect of temperature when processing 26806 resin is to keep the melt temperature between 440F (227C) and 480F (249C) degrees. We recommend starting with temperatures at the lower end of the recommended range with gradual increases in temperature, as needed, to enhance flow and adhesion until optimal process characteristics are achieved.

Best adhesion results are achieved with flame and counter surface corona discharge treatment of the substrate surface. Reduce the air gap between the die and the paper surface (3”-5”: 70-130cm) if possible. The melt curtain should contact the paper first, about half way up the feed roll. The chill roll above 75F (24C) and the nip roll should be run with higher pressure to imbed the melt onto substrate.

DaniMer 26806 resin must be dry in order to be successfully processed. The material is shipped dry and sealed in a foil liner, but can absorb moisture if left open to the atmosphere. If resin has moisture content above 400 ppm then drying must be accomplished using desiccated air (- 40F dewpoint) with air temperature below 130 oF. Small samples can be dried in a vacuum oven.

Decomposition of DaniMer 26806 begins when the material is exposed to temperatures over 460F (238C) for a period of time. Although in some cases, higher temperatures are used to help with processing, but the material must be kept moving through the extruder and die at a high rate as to limit exposure of the resin to the higher temperatures. If the material begins to turn a caramel color, or produce holes in the melt curtain, then the higher heat is beginning to cause decomposition.

Page Two DaniMer 26806 Processing Guide

Important processing parameters are:  Resin moisture content below 400 ppm  Processing Temperature Profile  Resin Melt Temperature between 450- 470F (230-243C)  Die Gap 0.0025-0.0030”  Chill Roll Temperature at least 75F (24C)  Distance From Die Lip to Sheet Surface minimized  Position of Melt Curtain should enable contact of sheet before contact with nip/chill roll  Flame treatment of sheet surface  Nip Roll Pressure

Processing Temperature Profile & Resin Melt Temperature - run cool enough in the barrell to keep melt temperature below 470F (243C). A reverse temperature profile works better with a high compression screw to keep frictional and sheer heat down. Resin will begin to thermally degrade when exposed to temperature above 460F (238C) for long time periods. Since resin is not exposed to these temperatures for very long when running at production rates, thermal degredation should not be a problem. Resin should be hot enough to “smoke” a little, but watch for signs of thermal degradation i.e. instability in melt curtain, loss of melt strength, discolored resin etc.

Die Gap – should be set not less than 25 thousandths of an inch; preferably not more than 35 thousandths of an inch.

Chill Roll Temperature – to help adhesion, it is better to run the chill roll at higher temperatures 75-90F (24-33C). Go as high as possible but obviously short of the point where the resin sticks to the chill roll.

Distance From Die Lip to Sheet Surface – The air gap distance should be as small as possible to reduce amount of cooling in resin after it exits the die, and compensate for greater neck-in of PLA-based resin. Closer is better provided that flow of melt curtain is uniform across the die.

Position of Melt Curtain relative to Chill Roll and Sheet Surface – Melt curtain should be positioned so that the melted polymer contacts the paper sheet before making contact with the nip roll to ensure good adhesion.

Nip Roll Pressure – this should be somewhat higher than with polyethylene so that the polymer curtain is pressed onto the sheet fairly aggressively.

For technical questions or other information regarding DaniMer 26806 please contact:

John Moore 770-205-9542 Office 404-455-0679 Mobile