Raw material for TQ Films Satish V. Awate Product Application & - PowerPoint PPT Presentation

Raw material for TQ Films Satish V. Awate Product Application & Research Centre Reliance Industries Limited IPI seminar Aug 2002 rev 0.1

“ a better product at affordable price ”

Index � Overview on PP films in flexible packaging sector � TQPP film extrusion process � Repol H 100 EY for TQ film applications � New Repol grades for advance applications � Manufacturing process for Repol � Product Application & Research Centre 3

Flexible Packaging Sector : Overview Total Film Market (01-02) ~ 1MMT 12% 17% 44% 27% LD/LLDPE PP HMHDPE PVC PP films: 2nd largest share in flexible packaging 4

Polypropylene film : overview PP Film Market (01-02) ~ 270KT 78% 2% 20% TQPP CPP BOPP ...largest contribution from TQPP films 5

Growth of TQPP film sector 1600 250 CARG ~ 17% 1400 200 1200 1000 150 800 100 600 400 50 200 Machines Consumption (KT) 0 0 1996-97 1997-98 1998-99 1999-00 2000-01 2001-02 ...supply driven market 6

Drivers for growth of TQPP films � Growing demand in flexible packaging � Excellent optical properties viz. clarity & gloss � Better mechanical properties viz. stiffness � Good barrier properties � Cost effective packaging solution ...aesthetic appeal of PP the key driver for growth 7

Characteristics of Polypropylene � higher crystallinity formation of spherulites, as the melt solidifies � slower crystallisation rates possible to get smaller size spherulite, by quenching of the film ...need an extrusion process with an effective cooling arrangement 8

Tubular Quenched Polypropylene (TQPP) film extrusion process 9

Advantages of TQPP process � low capital � lesser space requirement � lower operating cost � less demanding operating skills � ease in changing the width / thickness of film � tubular film is an added advantage in manufacturing of pouches / bags …most cost effective process in plastics 10

Polypropylene grade for TQ film

Repol H 100 EY PP homopolymer, with slip and antiblocking agents MFI : 11.0 g/10min The grade is designed to provide: - Good processability - Good clarity and gloss - Good stiffness Typical applications : packaging of textiles / food / other commodities … largest selling PP grade in India 12

Properties of TQ films made from PPHP � narrow sealing window and low seal stregnth � low impact properties � lower tear resistance � higher stiffness ... yet to make a mark in more demanding applications 13

New grades for advance applications of TQ film Random Ter-polymer T 080 EY Repol H 100 EY (modified)

Repol T 080 EY New random terpolymer from RIL 8 MFI grade, with slip & antiblock Repol T080EY is designed to provide : • Soft in feel • Lower sealing temperature • Good dart impact and tear strength • Good processability • High melt strength • Good gloss and clarity 15

Dart Impact Strength PPHP Ter-polymer LLDPE(1 MFI) 5 4.5 4.6 4 3.5 3.5 3 2.5 2 1.2 1.5 1 0.5 0 Dart Impact Strength (gm/micron) 16

Tear strength PPHP Terpolymer LLDPE 14 12.5 12 9.9 10 8 6 3.4 4 2.8 2 1.2 1.2 0 MD TD 17

Sealing characteristics : Hot Tack Strength PPHP Terpolymer LLDPE 185 @ 128 0 C 200 160 @ 116 0 C 120 @ 150 140 0 C 100 50 0 18 HTS

Sealing characteristics : Heat Seal Strength PPHP Terpolymer LLDPE 1300 @ 1200 @ 128 0 C 116 0 C 1400 1000 @ 1200 140 0 C 1000 800 600 400 200 0 HSS 19

Advantages of Repol T 080 EY • Lower melting temperature, hence lower processing conditions • Lower sealing temperatures • Better sealing characteristics • Better mechanical properties ..for more demanding applications 20

Applications for Repol T 080 EY � liners � carry bags � lamination films (see-through pouch) � packaging on form fill seal (FFS) machines � stationery items (photo albums / document holders) … value added products 21

Modified Repol H 100 EY � significant improvement in throughputs 20 kg/hr 150 kg/hr � over stretching leads to bubble breakage /punctures � at higher shear rates, � extensional viscosity decreases � melts becomes thinner (stress thinning of PP) � resin has to be designed for higher extensional viscosity ...tailor made for high output machines 22

Manufacturing process for REPOL

Manufacturing process for REPOL � Unipol manufacturing process combines � the fluidized bed reactor technology of Dow-UCC � the Super High Activity Catalyst (SHAC) of Shell � No atactic removal and deashing steps due to the highly active and highly selective catalyst � Ability to make following grades of PP: � Homopolymer (PPHP) � Impact Copolymer (PPCP) � Random Copolymer (RCP) � Controlled Rheology (CR) 24

Unipol process 25

Resin Property Modification � Type of catalyst and plant process parameters used during polymerisation, decide the following resin parameter: − Tacticity − Molecular weight − Molecular weight distribution � Resin parameters and additives incorporated are determined by the requirements − processability − end properties of a product 26

Product Application & Research Centre : A Vital link between Plant - Business - Processors Manufacturing Manufacturing PARC Marketing Processors Processors 27

WE believe in building strategic relationships Between business enterprises and their vendors Converting basic needs into commercially viable technology Helping produce useful products Research Institutions Machinery PARC End Users Manufacturers Polymer Processors 28

Areas of activities Customer Service/Support VALUE End Product Technological ADDITION Evaluation Evaluation Developmental PARC Interaction with professional Activities bodies/Nodal Institutes Research Institutes BIS / ISO Activities Grade Resin Product Additive Resin Product Benchmarking/ Evaluation Designing Optimization Evaluation Designing improvement 29

Thank You ! 30