3 - Coperion K-Tron

A Leap in Polyolefin Applications
with Advanced Calcium Carbonates
Gil Morieras
Director Marketing Asia Pacific
Group Marketing – Plastics
Oftringen, Switzerland
23 June, 2015
Content
Omya : A group at your service
Product portfolio
Advancements in :
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Thermoforming sheets
Blow Molding
Nonwoven
Raffia
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This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
Key Facts & Figures
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This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
Omya Asia Pacific Region
OMYA Asia Pacific in Brief
• Territory of 25 countries
• Regional Head Office in Kuala
OmyaJapan
Tokyo

Zezia
•
Changxing Omya

Ramadan City
Omya Chemical
Merchands,
Manila
•
•
•
•
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This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
Lumpur, Malaysia
28 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
10 joint ventures
1 distribution company in
Philippines
Indian Product Portfolio – Very Fine treated CaCO3
Omyacarb 1T - IP
• Thin Films
• Blow Molding
• High Speed Raffia
Omyacarb 1T - RC
• Thin Films
• PP None woven
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This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
Indian Product Portfolio – Fine treated CaCO3
Omyacarb 2T – IP / Omyacarb 2T - OJ
• Films
• Injection Molding
• Raffia
Omyafilm 723 - BI
• Films
• Thermoforming Sheets
• Raffia
Omyacarb 2 T - SM
• Films
• Raffia
Omyacarb 2 T - DS
• Raffia
• Thermoforming sheets
• Films, None Woven
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This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
Available from
July 2015
Indian Product Portfolio – Special Grades
Omyafilm 780 - LR
• Breathable films 20 microns
• Extrusion coating
Omyafilm 753 - CU
• Breathable Films < 18 microns
• Extrusion Coating
• <15 gsm PP None woven
Millicarb
• BOPP
• Pearlized Films
• Low density films
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This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
Thermoforming
Advantages of GCC in
Polypropylene thermoforming
Sheets
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This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
Why use CaCO3 for PP Sheet Extrusion?
- Improved thermal conductivity
- Faster melting in extruder
- More homogenous melt
- Faster sheet-cooling on calender rolls
 Faster Extrusion Line Speed
- Low coefficient of expansion
- Lower melt volume
- Lower friction to barrel surface
- Lower torque and die pressure
 Increased Extruder Output Rate (by volume)
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This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
CaCO3 in Thermoforming Sheets
Heat Transport
Thermal diffusivity in
mm²/sec
Productivity improvements
Thermoforming:
0.3
0.3
0.2
0.2
0.1
0.1
0.0
HIPS
Cycle Time Reduction
no sheet preheating
with sheet preheating
cycles per min
18 cavities yoghurt beakers
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12% & 35% more cycles
(with & w/o pre-heating)
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20
15
10
HIPS
PPH
30% CaCO3
This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
virgin PP
PP 30%
CaCO3
PP 60%
CaCO3
CaCO3 in Thermoforming Sheets
Performance improvements
Stiffness:
E-Modulus in N/mm²
CaCO3 Enhancing PPH Stiffness
2500
2000
1500
1000
500
E-Modulus
Increase in CD & MD
=> 15% & 30%
CD
0
0 % carbonate 30
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This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
MD
CaCO3 in Thermoforming Sheets
Performance improvements
Impact Resistance:
Dart Drop Impact Resistance Improvements
1200
Weight in g
1000
800
DDI Increase 250%
(at same weight or
at same gauge)
600
400
200
0
virgin PPH
30% CaCO3
same thickness
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This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
30% CaCO3
same weight
CaCO3 in Thermoforming Sheets
Post-Shrinkage / Orientation
30% CaCO3
Virgin PPH
Thermoformed yoghurt cups after 30 min at 140°C
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This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
CaCO3 in Thermoforming Sheets
Improved economics !!!
110.0
Cost Saving with CaCO3 in thermoformed PPH
overhead & labour
mould depreciation
machine production & depreciation
sheet cost
Cost in %
100.0
90.0
80.0
70.0
60.0
50.0
PPH
20%
CaCO3
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This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
30%
CaCO3
40%
CaCO3
HIPS
Application Examples
•
Disposable dishes and cups
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Food trays, pots and covers
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Plant pots and seeding trays
•
Profiled building products
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Household articles
•
Automotive interior trim items
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This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
Extrusion Thermoforming
Filling polypropylene with up to 60% calcium
carbonate is a proven solution for running
polypropylene on existing polystyrene
thermoforming machinery with comparable line
performance and end-product quality.
The main benefits of using Omya calcium
carbonate in polypropylene include:
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Higher extruder output and faster cooling on chill roll
Reduced cooling time in mold, faster cycles
Higher stiffness
Lower shrinkage
Processing on existing PS thermoforming machinery
More isotropic physical properties
Improved forming accuracy
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This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
Blow Molding
The higher thermal conductivity and lower specific heat of
calcium carbonate are key advantages in molding
applications.
Blow Molding
Calcium carbonate is used in blow molding applications to
produce bottles or containers by offering substantial
benefits such as:
 Increased flexural modulus
 Sustained top load and drop impact
 Improved ESCR (Environmental Stress Crack Resistance)
 Reduced cycle time
 Lower melt temperature
 Reduced titanium dioxide amount
 Improved printability
 Cycle time improvement
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23.06.2015
This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
GCC in blow molding – mechanical properties: top load
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23.06.2015
This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
GCC in blow molding – mechanical properties: Drop test
Minimum
Requirement
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23.06.2015
This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
GCC in blow molding – properties: ESCR
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23.06.2015
This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
Nonwoven
Omyacarb® in nonwoven
applications
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23.06.2015
This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
Omyafilm® in Non Woven Fabrics
Nonwoven fabrics are broadly defined as sheet or web structures bonded together
by entangling fiber or filaments mechanically, thermally or chemically
Meltblown nonwovens have extremely fine fiber diameters and produced using
spinneret at very high speed and high temperature.
Special Omyafilm® have been developed to be used in standard equipment
(Reicofill or other conventional manufacturing equipment)
Omyafilm® could be used in Non woven in Hygiene sectors and non woven bags
production, goal is to work at constant weight.
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23.06.2015
This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
Omyafilm in Nonwoven applications
Reduce Stickiness
Increase Softness and smoothness
Improved Dimensional Stability (Isotropic Shrinkage)
Similar Wind up speed
Slightly reduce tenacity
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23.06.2015
This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
Carbon Footprint
CaCO3 as a mean for high sustainability and Carbon footprint
improvement.
Our CaCO3 reduce dependency on petrochemical based products, for
natural ground calcium carbonate , the IMA carbon footprint figure is 75 kg
of CO2 emitted per ton of CaCO3 produced.
Our product is compatible with different solid waste treatment options.
Could be in a landfill
Can be incinerated in properly functioning incinerators
Can be composted
Can be processed using Mechanical Biological Treatment
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23.06.2015
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.
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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
• Advantages of using Omyacarb® 2T in PP woven
tapes :
• Achieve high filler loading in Masterbatches
• Optimized mineral dispersion ( Low FPV)
• Prevent using waxes and lubricants which reduces
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•
•
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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)
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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 : Higher requirements
• For high speed line or high demanding applications,
Omyacarb® 1 T is the optimum solution :
• Appropriate surface treatment to avoid Die build up
during processing
and dust accumulation
• Lower WCO : Speed could be increased
• Increased elongation @ break compare to coarser
grades. Improves post-weaving operation and
production efficiency.
• Improve knitting process less yarn breakage
• Increase tensile strength thus enabling higher filler
loading
• Higher tape surface smoothness
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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%)
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This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
Cost Savings
Omyacarb 1 T
Compounding Costs
Formulation
PE
Omyacarb 1T
Omyacarb 2T
Masterbatch @ 80% OM 2T
Masterbatch @ 78% OM 1T
Tapes
Tapes
Omyacarb 2 T
50
2000
USD + 30 / Ton
with 22 % Omyacarb 2T
with 25 % Omyacarb 1T
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This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.
562
623
28%
32%
1614
1559
Thank You
www.omya.com
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This document contains proprietary information which shall not be
used and disclosed without Omya explicit written authorization.