Cost Reduction Opportunities with Superior CaCO3 - Final - K-Tron

“Cost Reduction Opportunities
with Superior Calcium Carbonate”
Andy Liew
Omya Asia Pacific
Table of Contents
- Introduction to Omya
- China Product Portfolio
- Advancements in :
Raffia
Shopping bag
Nonwowen
BOPP
Breathable Films
- Open discussion
2
This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
Key Facts & Figures
•
Corporate head office in Oftringen, Switzerland
•
•
8,000 employees
More than 150 plants in over 50 countries
•
Turnover of EUR 3.0 billion
•
Ownership of mineral deposits for the next 100
years of business
•
Most plants are ISO 9001 / ISO 14001 certified
•
Pioneer in ISO 14001 for quarries
•
•
3
This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
In business for over 125 years
Privately-owned Swiss based Corporation
Omya Asia Pacific Region
OMYA Asia Pacific in Brief
Territory of 25 countries
Regional Head Office in Kuala
Lumpur, Malaysia
29 plant locations
•13 slurry manufacturing lines
•20 dry powder manufacturing lines
•1 PCC plant for paper making
19 quarries locations
Exclusive technology and marketing
partner in Japan
11 joint ventures
2 distribution company in Philippines
& Indonesia
4
This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
OMYA CHINA
5
This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
China Product Portfolio
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This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
China Product Portfolio – Very Fine treated CaCO3
Omyacarb 1T - JI
• Thin Films
• Blow Molding
• High Speed Raffia
Omyacarb 1T - LK
• Thin Films
• PP None woven
• High Speed Raffia
7
This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
China Product Portfolio – Fine treated CaCO3
Omyacarb 2T – JI
• Films
• Injection Molding
• Raffia
Omyacarb 2T - LK
• Films
• Thermoforming Sheets
• Raffia
Eskal 15T – JI
• PVC Rigid
• Cost Efficiency
• Excellent dispersion
8
This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
China Product Portfolio – Special Grades
Hydrocarb 95T - KU
• Breathable films 20 microns
• Extrusion coating
Omyafilm 753 – CU
• Breathable Films < 18 microns
• Extrusion Coating
Millicarb
• BOPP
• Pearlized Films
• Low density films
9
This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
CaCO3-powder: most important properties
Ground CaCO3-Marble
Surface
treatment:
Color
Metal-free
Composition
Surface coverage
Surface tension
Insolubles
Particle Size Distribution
Wt-% finer than
Particle size:
Particle size distribution
Top cut
Median particle size
Particle size (µm)
10
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used and disclosed without Omya explicit written authorization.
Purity:
PP
Raffia
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This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
CaCO3 in PP Woven Tapes
Calcium carbonate is conventionally used in PE or PP
woven bags, weaving tapes or bands to offer antisplitting and anti-fibrillation effects.
Polyolefin masterbatches based on appropriate
calcium carbonate offer:
Reduced splitting propensity of oriented
polypropylene
Increased stiffness
Reduced amount of titanium dioxide
Reduced raw material consumption
Conventional calcium carbonate loadings are in a
range of 2% to 30% in final articles.
12
This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
CaCO3 in PP Woven tapes
• Advantages of using Omyacarb® in PP woven tapes :
• Achieve high filler loading in Masterbatches
• Optimized mineral dispersion ( Low FPV)
• Prevent using waxes and lubricants which reduces WCO and Die build
•
•
•
•
up
Low humidity level in masterbatches
Reduce WCO
Increase life time for knives and increased screen pack change over time
Reduces dust accumulation ( spinning and knitting)
For finer product like Omyacarb® 1T
• Increase tensile strength thus enabling higher filler loading
• Higher tape surface smoothness
• Suitable in high speed line ( > 450m/mins)
13
This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
Cost Savings
5.5
5.0
4.5
4.0
g/D
3.5
3.0
2.5
2.0
7% Dosage
15% Dosage
Omyacarb 1T
22% Dosage
Omyacarb 2T
30% Dosage
Coarse Competitive
Finer product could allow you to increase final
content for same properties (+3%)
14
This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
Cost Savings
Omyacarb 1 T
Compounding Costs
PE
Omyacarb 1T
Omyacarb 2T
Masterbatch @ 80% OM 2T
Masterbatch @ 78% OM 1T
Formulation
Tapes
Tapes
Omyacarb 2 T
50
2000
USD + 30 / Ton
with 22 % Omyacarb 2T
with 25 % Omyacarb 1T
15
This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
562
623
28%
32%
1614
1559
Shopping
Bag
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This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
Film weight vs. thickness when adding Omyafilm®
By adding Omyafilm® the density of the film increases, i.e. to keep a
1.16
50
1.12
48
1.08
46
1.04
44
1
42
0.96
40
0.92
0%
5%
10%
15%
Example:
100% PE
46g/m2 @ 50µm
(ρfilm: 0.92 kg/dm3)
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This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
20%
25%
Thickness of film (micron)
Density of film (kg/dm3)
constant film weight, the film gauge has to be reduced:
38
®
30% Omyafilm -content
+15% Omyafilm
46g/m2 @ 45µm
(ρfilm: 1.02 kg/dm3)
Description of the study
Production of 5 blown films with the “Dr. Collin Lab. Line”
• Reference:
33% LDPE + 67% C4-LLDPE
• 10% Omyafilm®: 30% LDPE + 55% C4-LLDPE + 15% MB
• 20% Omyafilm®: 27% LDPE + 45% C4&C6-LLDPE + 28% MB
• 25% Omyafilm®: 25% LDPE + 39% C6-LLDPE + 36% MB
• 30% Omyafilm®: 23% LDPE + 34% C6-LLDPE + 43% MB
Remarks
“Reference” is related to a typical carrier bag formulation
All films were produced at constant weight (43g/m2)
LDPE/LLDPE ratio was kept constant in all formulations
18
This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
Film performances
Elmendorf tear resistance (cN)
Elmendorf tear propagation resistance
ISO 6383
600
778
503
962
1165
500
419
400
MD
CD
300
200
156
151
Reference
10% OF
187
212
163
100
0
20% OF
25% OF
30% OF
MD: All formulations containing Omyafilm® are okay
CD: Dramatic increase for all formulations containing Omyafilm®
19
This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
Film performances
E-modulus, i.e. secant 0.02-2%
ISO 527-3
600
E-modulus (N/mm2)
550
498
449
500
450
350
300
430
405
369
400
243260
502
MD
CD
266276
250
200
150
100
Reference
10% OF
20% OF
25% OF
30% OF
Increase for all formulations containing Omyafilm®
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This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
Film performances
Dart drop impact resistance
ASTM D 1709 A
225
200
Falling dart (g)
200
176
182
192
10% OF
20% OF
189
175
150
125
100
Reference
25% OF
30% OF
Higher for all film formulations containing Omyafilm®
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This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
Variation of formulation cost (general)
The use of Omyafilm® reduces the raw material cost
1400
14%
1200
12%
1000
10%
800
600
400
4.9%
5.5%
6.1% 6.5%
8.7% 8.9% 9.1%
8.4%
7.8% 8.1%
7.0% 7.4%
8%
6%
4%
4.1%
200
2%
0
0%
Reduction of cost (%)
Raw material cost for bags
(Euro/MT)
(at constant film grammage):
Price of PE (US $/ton)
Reference
Film with 15% Omyafilm
Cost reduction (%)
With increasing polymer prices, the savings become more significant
22
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used and disclosed without Omya explicit written authorization.
PP Nonwoven
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This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
PP multifilament fibers containing CaCO3
2 % GCC masterbatch
10 % GCC masterbatch
Scanning electron micrographs (SEM)
Fiber surface (top) & fiber cross section (bottom)
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used and disclosed without Omya explicit written authorization.
40 % GCC masterbatch
Advantages of Omya mineral modifier addition
Performance
• Reduced stickiness
• Increased softness and smoothness
• Improved dimensional stability (isotropic shrinkage)
• Similar wind-up speed
• Slightly reduced tenacity
Processing economics
• Better heat transport when using GCC may allow an increased
line speed
• Reduced extrusion pressure
• Less polymer to melt reduced energy consumption
Raw material economics
• Save resin via mineral addition and thinner fibers
• Lower carbon footprint
25
This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
Which CaCO3 for BOPP
Pearlized films?
BOPP Film
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09.05.2014
This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
BOPP Film basic
During stretching the CaCO3 particles separates from the polymer
and creates cavity. We then obtain a lower film density and a higher
film opacity.
As Larger the Cavities:
• as lower the film density [g/cm3]
• as higher the film thickness [µm] for same cast film
• as lower the requested raw materials to achieve same film thickness
27
This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
BOPP Film with CaCO3
Common Dosage and Film Density
With 8-15% CaCO3 it is possible to reduce the film density from 0,91 to
0,5-0,7 kg/dm3.
Influence of Particle Size to Film Properties:
Higher D50
Lower Film Density
Lower D50
Higher Gloss
Objective
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To reach the low density and high gloss of the Exxon Mobil film, where
density opacity and gloss are based on the incompatibility of PP with
Polybutylene Terephthalate PBT
This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
BOPP Film with Omya CaCO3
Suitable and cost-efficient
Easy to process
Products globally accessible
Lower carbon footprint
Preferred Particle Sizes
2,7 – 3,0µm:
Milicarb-OG
Low Density
1,4 – 1,8µm:
Omyalite 90T
High Gloss
29
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used and disclosed without Omya explicit written authorization.
Breathable
Film
30
This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
Water Barrier Microporous Breathable Films
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used and disclosed without Omya explicit written authorization.
Microporous Breathable Films : Examples
x2500 magnification cross section
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used and disclosed without Omya explicit written authorization.
SEM of film surface
x2500 magnification
Microporous Breathable Films : Applications
• Hygiene
Infant diapers
Sanitary napkins & panty liners
Adult incontinence products
• Building
Under-tile roofing films
House wraps
Wall and floor covering
• Medical / Clothing
Operating garments
33
This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
Microporous Breathable Films : Manufacturing
Compounding
• To disperse uniformly 50-70 % of CaCO3 in a polyolefin matrix
• To produce a batch with a very low humidity content
• Not to damage the CaCO3 or polyolefin chains
Extrusion
• To produce a thin film by casting or blowing
Stretching
• MDO Stretching
• CD and MD Tendering unit
• Intermeshing or interdigitating Stretching
34
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used and disclosed without Omya explicit written authorization.
Breathable Films Requirements
• ASTM E 96
• Depends on
• CaCO3 content
• CaCO3 choice
• Stretching ratio
• Hydrostatic
Water Pressure
WVTR
Water
Pressure
Mechanical
Properties
UV
Resistance
• Tensile Strength
• Shrinkage
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used and disclosed without Omya explicit written authorization.
• Building Films
CaCO3 Requirements
Hydrophobicity
Thermal
Stability
Narrow
PSD
Whiteness
36
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used and disclosed without Omya explicit written authorization.
Omyafilm 753 offer
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used and disclosed without Omya explicit written authorization.
The Omyafilm® Range of Products
Raw Material Resources for more than 100 Years
A Solution for many plastic Manufacturers
38
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used and disclosed without Omya explicit written authorization.