Additives Miracle Workers for The Plastics Industry ! Dr. Y.B. Vasudeo Sr. Vice President Product Application & Research Centre Reliance Industries Limited Jayvee Organics Endowment Lecture 26 th September 2003 Mumbai
Opening Remarks ! • “Additives are rapidly becoming the miracle workers for the plastics industry, whether they are traditional favourites like plasticizers, impact modifiers and antioxidants or new technologies such as nanocomposites and antimicrobials; their importance is increasing all the time”
Additives – A Curtain Raiser ! “Innovation is the ticket for suppliers who seek to stay competitive in a tough global market From improved versions of workhorse grades to better service strategies and formulations, designed for new emerging polymers and interpolymer competition, will be the rule of the additives business”
Scope Of The Endowment Lecture • Global scenario and market trends • From additives to product innovation • Additive-driven plastics business avenues for the Indian entrepreneur
Additives - An Introduction • Additive – “A chemical added in minor amounts to a host plastic to improve the overall performance of the system” – Additives are categorized by the functions that they perform rather than their chemistry • Additive functions – Modifiers – Property extenders – Processing aids
Additive Classes • Modifiers – Plasticizers – Chemical blowing agents – Coupling agents – Impact modifiers – Organic peroxides – Nucleating agents
Additive Classes • Property Extenders – Flame retardants – Heat stabilizers – Antioxidants – Light stabilizers – Antistatic agents • Processing aids – Lubricants – Mould release agents – Antiblock / slip agents
Additives : Global Business Snapshots • Additives : Growing sector of the speciality chemicals industry – Industry overview – Technical trends – Commercial trends
Industry Overview
Industry Overview
Industry Overview
Performance Additives • Coming to the true ‘performance’ additives, flame retardants are largest, estimated at about 850,000 tonnes worldwide, with a value of some $2 billion. Heat and UV stabilizers are about 300,000 tonnes, but one estimate puts them as high as 462,000 tonnes. • Latest power bill and attention drawn to theft and percentage revenue loss, counter by SEBs to install meters and likely revenue generation. Effect on flame retardant additive business.
FRPP Compounds : First Success ! Flame Retardant Repol PP for Battery Box Applications
Technical Trends Consumption of plastics additives in Polyolefins Source : TownsendTarnell
Technical Trends % Sales in PVC (By Volume) Consumption of plastics additives in PVC Source : TownsendTarnell
Additives : Business Perspectives Worldwide Suppliers • 350 companies of additive suppliers worldwide • 100 companies have annual sales over $100,000 Additives business has a high proportion of very small suppliers of speciality products
Additives : Business Perspectives Worldwide suppliers of chemical additives by class Involved in two 350 classes companies Worldwide suppliers 13% Involved in all of additives by three classes 4% Involved in one class class 83% Involved in one class Involved in all three classes Involved in two classes Worldwide suppliers of 250 chemical additives by No. of companies 200 class 150 100 50 0 Modifiers Property extenders Processing aids
Additives : Business Growth Processing aids Property 2001 extenders 1996 Modifiers 0 1 2 3 4 5 6 7 8
Commercial Trends In Additive Suppliers Business • Globalization – Following key end user sectors (auto, medical, electronics, packaging) – Set up manufacturing worldwide – Deliver same formulation everywhere • Redefinition of core business and identification of key sector – For new technology – For new product development – Examples : » Great Lakes : Flame retardants » Elf Atochem : Peroxides » Crompton : OBS additives
Commercial Trends In Additive Suppliers Business Cost of new product development driven by • Competition • Patent expiration • Environmental regulations • Interpolymer competition • Smart and intelligent packaging systems
Additive Supplier’s Strategies • Approach I – Concentrate on specific industries, meeting specific regulatory requirements • Approach II – Concentrate on specific materials and chemistries • Additive business in recent years has emerged as a major global segment of “value-added” speciality chemistry
Additives : Ingredients For Growth Of Plastics • Food Packaging – Role of Additives • Additives • Antioxidants • Pigments • Processing aids • Lubricants • Clarifiers • Issues • Organoleptic properties • Migration
A Quick Guide To Food Contact Additives Additives Class Comments Stabilizers o Generally regarded as most effective • Phosphites / o Highest performance at lowest dosage phosphonites o Contribute to colour and transparency retention when required o Improvement of organoleptic properties, a continuing aim
A Quick Guide To Food Contact Additives Additives Class Comments Plasticizers • Polymeric o Usually polyesters – based on adipic acid – extend life of PVC end products; retard migration, extraction and volatility • Epoxidized o Widespread food contact approval soyabean oil • Citric acid esters o For direct food and medical applications Processing aids • Fluoropolymers o Suitable for PE & PP (indirect food contact) o Most clarifiers approved for food contact • Nucleating agents applications in RCP
Contribution Of Additives To Success Of Polymers In Packaging • PPAs and lubricants eliminate melt fracture in PE blown film, cast film and thin-walled extrusion • PPAs are now targetted for increased output rates and increasing filler and additive dispersion
Contribution Of Additives To Success Of Polymers In Packaging • The success of flexible packaging is attributed to “PPAs” • The success of rigid packaging in clear applications is attributed to “Clarifiers”
Additives Drive Automotive Plastics In New Directions : Growth Drivers • Increased demands on polymer performance • Plastics with increased thermal stability • Plastics with longer weatherability • Pressure to reduce costs of of plastic parts • Ability to lower moulding cycle times • Beneficiaries : – Antioxidants – Light and heat modifiers – Viscosity modifiers – Impact modifiers – Glass beads – Nanofillers
Additives Facilitate Growth Of Wood Plastic Composites • New stabilizer package • New coupling agents • New antimicrobials Wood / PP Door Trims Wood / PVC Profiles
Growth Areas For Additives For Plastics In Auto Applications • Light stabilizers for TPOs and PVC (6.5% pa) • Coupling agents for glass filled formulations (6% pa) • Nucleating agents – Speed crystallisation – Shorten moulding cycle and productivity • Flame retardants for PP and PVC • Additives for long glass fibre reinforced thermoplastics (30% pa) & masterbatches for LFTs (80% filled) • Additives for nanocomposites based on PE & PP • Additives for TPV masterbatches for replacement of thermoset rubber
Additives for Interpolymer Material Competition Styrenics Vs Filled Polypropylene Compounds • Attribute for ABS replacement – Additives for imparting high gloss to PP compounds – Additives for improving scratch resistance of PP Thermoformed Door Liner From Blend of Repol C015EG & Repol H020EG With Modifiers
Additives for Interpolymer Material Competition Styrenics Vs Filled Polyproyplene Compounds • Low cost additive formulations of PP will win the game over styrenics
Niche Products With Help From Additives Additives for tribological polymers used in bearing applications • Friction – complex phenomenon • Neat polymers cannot satisfy demands • Tribological additives contribute to the best balance of – Co-efficient of friction – Wear – Cost – Performance • Examples – MoS 2 – Graphite – PTFE – Silicones
Tribological Effects In PP • Effect of silicone masterbatch content on the co-efficient of friction of PP Silicone Content Decrease in COF % % 0 0 1 10 5 20 10 35
PVC Plasticizer Adds Value To Waterbeds • Waterbeds : means for combating sleep and back problems • Waterbeds : cure for allergies • Waterbeds : hygenic alternative to foam mattresses • The high level of acceptance of waterbeds even among conservative customers is attributed to improved properties of PVC film, the crucial component of a waterbed mattress
PVC Plasticizer Adds Value To Waterbeds
Attributes Of PVC Membrane For Waterbeds • Soft • Seams must be weldable to avoid leaks • High tear strength • High elongation properties • Role of Additives - Selection of plasticizer – key to PVC performance - Phenol alkyl sulphonate – new emerging additive • Advantages - Greater saponification resistance compared to phthalates - Reduced tendency to migration
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