Polyolefin Dispersion – a New Vistas for Flexible Packaging
Polyolefin Dispersion – A New Vistas for Flexible Packaging
Presented by: Ravi Rao, Dow Chemical International Pvt. Ltd. Technical Service and Development - Director
Co-authors: Prashant Mogre, Dow Chemical International Pvt. Ltd. Technical Service and Development Leader Aminur Rahaman, Dow Chemical International Pvt. Ltd. New Venture & Business Development R&D
TAPPI PLACE Conference 10 - 11, Nov 2009, Mumbai, INDIA 13 - 14, Nov 2009 , New Delhi, INDIA Page 1 Agenda • Polyolefin Dispersion (POD) Technology • Polyolefin Dispersion – Chemistry • POD –Applications and Performance • Conclusions
Page 2 WhatWhat comes comes to mind towhen mind you think when you think of polyolefinsof polyolefins? ?
Plastic Pellets
Films Molded Articles & Containers
Page 3 Waterborne Polyolefin Dispersions • 40-55 % Solids , < 500 cps Viscosity
Page 4 Aqueous Polyolefin Dispersion
Dow’s proprietary BLUEWAVE™ Technology enables » Dispersion of polymers which are not self-dispersing • Ethylene /Propylene Copolymers • LDPE, HDPE » Deliver high molecular weight polymers (>75,000 Mw) » Thermoplastic and elastomer formulations » Low viscosity – Typically less than 500 cps » High solids – up to 60% » Solvent free – No solvents added in process
™Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow Page 5 POD Technology • Continuous Mechanical Dispersion Process & High Internal Phase Emulsion (HIPE)
Dilution Water
Initial Water Optional Surfactant
POD
Continuous Liquid or Molten High Shear HIPE System Polymers Mixer Conventional Latex Water Continuous Phase Spherical Particles Rhombohedral Particles Less than 75% Solids High Viscosity 90+% Solids
Page 6 Chemistry – Overview POD Structure
Polyolefin • Propylene copolymer • Ethylene copolymer
Stabilizing Agent • Polymeric • Surfactant
Aqueous Medium
Page 7 Polyolefin Dispersions – Grades
Product TAPPI Code Polymer Carboxyl Polymer Polymer Tg Designation Composition Content Melting Point (deg. C) (deg. C)
DPOD 8501 Dispersion A Ethylene Medium 63 -53 Copolymer
DPOD 8502 Dispersion B Ethylene Low 63 -53 Copolymer
DPOD 4501 Dispersion C Propylene Medium 85 -26 Copolymer
DPOD 4503 Dispersion D Propylene Low 65 -32 Copolymer
DPOD 9501 Dispersion E Olefin Block Low 122 -63 Copolymer
Page 8 Converting Options for Polyolefin Dispersions
Printing/Coating Processes (Rotogravure)
Dipping
Frothed Foams
Spray Application
Page 9 Film Formation – Hot Stage Microscopy
Polyolefin Particles
Homogeneous Film
Page 10 Mechanical Properties • Cast film 250 microns made from dispersion C and dried at different temperatures
7 60°C, 10 mil, 30 min, VAC 6 70°C,10 mil, 30 min, VAC
80°C,10 mil, 30 min, VAC 5
4
StressStress MPa MPa 3
2
1
0 0 100 200 300 400 500 600 700 Strain % Page 11 Applications - PODs in Flexible Packaging
Tie Layer / Laminating Adhesive • Alternative to extrusion lamination » Adhesion to polyolefins » Adhesion to polar substrates (paper, glass, foil, polar polymers) » Adhesion to PE based printing inks » Wet sandwitch lamination possible
Heat Sealable Layer » Apply at low temperatures and high speeds » Low HSIT (<70°C) » Use existing printing equipment
Page 12 POD - Heat Seal Strength on BOPP film
3
2.5
2
1.5 POD, 3.1 g/m2 POD, 12.7 g/m2 POD, 17.8 g/m2 1 Heat Seal Strength (lb)
0.5
0 50 60 70 80 90 100 110 120 130 140 150 Heat Seal Temperature (°C)
Page 13 Hot Tack strength - POD coated Chromo Paper
7
6
5
4 For ce (N/25 m m ) 3 Tack 2
1
0 80 90 100 110 120 130 140
force N/25 mm 1.13 1.21 1.69 5.98 3.25 2.66 1.27 Temperature
force N/25 mm •Substrate: 70 gsm Chromo Paper •Dispersion: Propylene Based Dispersion C •Add-on coating: 5 gsm
Page 14 Key Properties of PODs for Flexible Packaging
re ctu tru e s llin sta Water resistance Cry Oil & grease resistance ins Heat sealability Tie Cha
Elasticity /flexibility
one Adhesion to polyolefins Olefin backb
Adhesion to polar substrates
Fu g nc ro tio up na s l
Page 15 Application- Paper Coatings
• Extruded polyolefins have been widely used to modify paper • Limitations exist for extruded polyolefins » Thickness (> 10 microns) » Adhesion to paper • Beneficial properties of PODs provided to paper and board » Oil and grease barrier » Moisture resistance » COF modification » Adhesion promoter / tie layer » Heat sealability
Page 16 Applications and Properties
Unique Balance of Properties (not possible with conventional dispersions)
» Heat sealability Flex Pkg » Moisture resistance/barrier » Soft touch » Elasticity Footwear » Adherence to polar and non-polar substrates » Low temperature flexibility » Chemical resistance Frozen Food Pkg » Potential for recyclability » Potential for hypoallergenic properties Carpet » Food contact compliance » Calibration of hardness and melting points » High filler loading Foams » Toughness » Anti-slip » Embossable
Page 17 Summary: Polyolefin Dispersions – Applied Innovation
• In POD- polyolefin dispersions put high molecular weight polyolefin in water based dispersion to enable customers to create differentiated products or structures, eliminate solvent related issues and/or lower system cost
Positive performance of the Polyolefin dispersions promote Polyolefin Differentiation and growth • Heat Sealability • Low temperature flexibility Waterborne Application Vs Extrusion Coating • Water & Chemical Resistance • Thinner Coating • Use existing waterborne application equipment + • Higher Line speed Application benefit of water borne • Penetrate porous/fibrous webs • Coat at low temperature system • Coat complex geometry • Adhesion to polar substrates • Coat in Pattern • Acceptance of inorganic fillers • Low Viscosity application • Can be used as an additive in latexes
Page 18 Thank you! www.dowpod.com
Ravi Rao [email protected]
Contact CIG Europe +32 34 50 2240
™Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow