Film Extrusion Manual Third Edition

544 Pages·2020·110.692 MB·English

by  James F. Macnamara Jr

Film Extrusion
Manual
Third Edition

Process, Materials, Properties

Global Editor:
James F. Macnamara Jr.
Copyright© 2020

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ISBN: 978-1-59510-299-7
TAPPI PRESS Item Number: 0101R360EL
Printed in the United States of America
Table of Contents
Preface xv
Chapter Editors and Author/Contributor Contact Information xvii
Chapter 1—Film Extrusion Introduction
Chapter Editor: BRUCE FOSTER, PolyKnows LLC
Section 1.1—Film Extrusion Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
BRUCE FOSTER, PolyKnows LLC
Introduction 3
History 3
Since 2005 3
The Future 3
References and Additional Resources 4
Chapter 2—PRIMARY EQUIPMENT
Chapter Editor: MARTINE MICHON, Atlantic Coated Papers Ltd.
Section 2.1—The Film Extruder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
DONN C . LOUNSBURY, D.C.L. Solutions, Inc. and BILL HELLMUTH, Battenfeld Gloucester Engineering
Introduction 7
The Extruder 7
The Barrel and Feed Section 7
Barrel Heating and Cooling Systems 7
Closed-Loop Liquid Cooling 9
Gearcase and Thrust Bearing Assembly 11
Screws 13
Extruder Drives 16
The DC Static Drive 16
AC Variable-Frequency Drive 17
Description 17
Heat Control Panels 18
Extruder Maintenance 18
Preventive Measures 20
Unusual Noise Indicators 20
iii
iv Table of Contents
Drive Motor Maintenance 21
Stocking Spares and Limiting Downtime 21
Screw Removal: Why, When, and How 22
The Grooved-Feed Extruder 23
History 23
Concept and Description 24
The Process 24
Screw Characteristics 25
References and Additional Resources 27
Section 2.2—Screw Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
ANDREW W . CHRISTIE, SAM North America, LLC
Introduction 29
Feedscrew Terminology 29
Extruder Functions and Plasticating Screw Design 30
Feeding/Solids Conveying 30
Grooved Feed-Throat Extruders 32
Plug Flow Compared to Melt Flow 33
Melting 33
Barrier Screw Designs 34
Energy Required for Extrusion 34
Melt Conveying 35
Mixing in an Extruder 35
Mixers 36
Plasticating Screw Design Summary 38
Materials of Construction 38
Extrusion Process Analysis and Operation 39
Objective (Online Measured) Variables 39
Subjective (Offline Measured) Variables 39
Polymer Variables 40
Operating the Extruder 40
Feed Zone 41
Screw Running Tips 42
Summary 42
References and Additional Resources 42
Section 2.3—Die Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
BILL BODE, Battenfeld Gloucester Engineering
Introduction and Function of Die 45
Single-Layer Spiral Mandrel Die Components 45
Spiral Mandrel and Body 45
Die Lip Sets 45
Die Gaps 48
Mechanical Considerations 48
Stiffness of Components/Assembly/Disassembly 48
Additional Considerations 48
Materials of Construction and Surface Coatings 49
Materials 49
Plating/Surface Coatings 49
Corrosion 49
Cleaning 49
Coextrusion Dies 50
Rheological (Flow) Considerations 50
Table of Contents v
Mechanical Considerations 52
Other Types of Film Dies 52
Spider Dies 52
Wraparound Coathanger Dies 52
Upper Die Geometry 53
Controls 53
Section 2.4—Stacked-Die Technology for Tubular Film Coextrusion . . . . . . . . . . . . . . . . . . . . . . . . . . 55
JOHN PERDIKOULIAS, Compuplast International Inc.
Introduction 55
Conventional Coextrusion Dies 55
Stacked Dies 57
References and Additional Resources 61
Section 2.5—Winding and Web Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
R . DUANE SMITH, Davis-Standard LLC
Introduction 63
Definition of a Quality Roll 63
How to Achieve Roll Hardness 65
Winder Components 70
The Spreading Operation 72
Winder Drives and Tension Control Systems 74
Proper Shaft Selection 76
Automatic Roll Changing Systems 77
Conclusions 78
References and Additional Resources 78
CHAPTER 3—ANCILLARY EQUIPMENT
Chapter Editor: RORY WOLF, ITW Pillar Technologies
Section 3.1- Gear Pumps, Filtration, Static Mixers—Function, Design, Parameters, Examples . . . . . . . . . . . 81
KEVIN TUTTLE, Nordson Polymer Processing Systems
Gear Pumps 81
Filtration 84
Static Mixers 92
Gear Pump Addendum 95
References and Additional Resources 95
Section 3.2—Feedblock Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
CHRISTINE RONAGHEN, Cloeren Incorporated
Introduction 97
Primary Functions 97
Coextrusion Behavior: A Brief Introduction to Viscosity 100
Beyond Conventional Coextrusion 102
Coextrusion Performance and Corrective Actions 102
Specifying a Feedblock 104
References and Additional Resources 104
Section 3.3—Film Stabilization, Forming and Collapsing Systems . . . . . . . . . . . . . . . . . . . . . . . . . . 105
JAMES STOBIE and HARINDER TAMBER, Macro Engineering and Technology Inc.
Introduction 105
Film Tube Collapse 108
Bubble Collapsing Improvements 111
vi Table of Contents
Tube Containment in High Cooling Applications 113
Summary 113
References and Additional Resources 113
Section 3.4—Material Handling Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
CLIFFORD J . WEINPEL and WALTER FOLKL, Foremost Machine Builders
Introduction 115
Bulk Unloading and Storage 115
In-Plant Distribution Systems 119
Piping Systems 121
Controls 122
Gravimetric Metering and Blending 122
Accuracy and Resolution 131
Summary 132
Addendum A 132
Addendum B 133
Addendum C 134
Addendum D 137
Section 3.5—Instrumentation and Process Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
TED SCHNACKERTZ, NDC Technologies
Introduction 139
Process Controls 142
Summary 143
References and Additional Resources 143
Section 3.6—Blown-Film Cooling Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
HARINDER TAMBER, Macro Engineering and Technology Inc.
Introduction 145
Single-Orifice Air Rings 145
Dual-Orifice Air Rings 147
Modified Dual-Orifice Air Rings 148
Automatic Air Rings for Gauge Control 148
Internal Bubble Cooling (IBC) 149
Multiple Air Rings 151
High Cooling Rates 151
Cooling Rate Equations 152
Thermal Analysis of Blown Film Quenching 153
Thermal Load 153
Heat Removal 155
General Considerations for Blown-Film Systems 155
Summary 155
References and Additional Resources 155
Section 3.7—Surface Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
RORY WOLF, ITW Pillar Technologies
Introduction: The Need for Surface Treatment 157
Flame Treatment 157
Plasma Treatment 158
Atmospheric Plasma Treatment (APT) Process 159
ASTM Test Methods 161
Table of Contents vii
Cotton Swab Method 162
Drawdown Test Method 162
Warnings and Cautions 163
Corona Treating 163
Types of Corona—Treatment Systems 164
Bare-Roll System 165
Universal—Roll System 166
Power Supply for Corona Treating 166
Corona—Treating Applications 167
Sizing: Material/Process Parameters 168
Conclusions 170
References and Additional Resources 170
Section 3.8—Atmospheric-Pressure Plasmas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
RORY WOLF, ITW Pillar Technologies
Introduction 173
The Ionization Process 176
Surface Effects 176
Influence on Adhesion 178
Surface Modification by Cleaning and Etching 178
Surface Temperature Elevation 179
Surface Sputtering 179
Surface Etching 179
Surface Modification by Functionalization 182
Characterizations of Surface Modification Effects 183
CHAPTER 4—MATERIALS
Chapter Editors: KELLY FREY, Chevron Phillips Chemical Company
and DORENE SMITH, Westlake Chemical Corporation
Section 4.1—Low-Density Polyethylene . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
JOEL PERRITT, Westlake Chemical Corporation
Introduction 187
Reactor Technology 187
Polymer Characterization—Properties and Terminology 188
Molecular Weight Distribution 191
Common Polyethylene Additives 193
Film Properties of Polyethylenes 195
General Processing Guidelines for LPDE 196
General Uses of LDPE 197
Section 4.2—Linear Low-Density Polyethylene (LLDPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
NORMAN AUBEE, NOVA Chemicals
Introduction 199
Applications 199
Polymer Characterization 200
Super Hexene LLDPE 202
Typical Film Properties 203
General Processing Guidelines 204
Blends 204
viii Table of Contents
Section 4.3—Metallocene Polyethylene . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
NILESH SAVARGAONKAR, ExxonMobil Chemical Company
Introduction 207
Metallocene LLDPE 207
Introduction of Long-chain Branching (LCB) 208
Rheological Behavior and Processing of mLLDPE 208
Physical Properties of mLLDPE 209
Sealing Behavior of mVLDPE and Plastomers 210
Physical Properties of Blends of Plastomers 212
Applications for Metallocene LLDPE 212
Newer Products 212
Summary 212
References and Additional Resources 214
Section 4.4—Polyolefin Plastomers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
JACQUELYN DEGROOT and JEFFREY ARIONUS, The Dow Chemical Company
Introduction 215
Properties 215
Hot Seal and Hot Tack of Ethylene-Based Polymers 217
Propylene-Based Plastomers 218
Applications 218
Processing Polyolyfin Plastomers 218
Acknowledgements 220
References and Additional Resources 221
Section 4.5—High Molecular Weight—High Density Polyethylene . . . . . . . . . . . . . . . . . . . . . . . . . . 223
MARK CANRIGHT and AMY M . LAIRD, ExxonMobil Chemical Company
Introduction 223
Polymer Characterization 223
Typical Polymer Properties 225
Biaxial Orientation 225
General Processing Guidelines 226
Blown-Film Die 227
Film Cooling 227
Collapsing Parameters 227
Treating 227
Applications and End Uses 227
Summary 228
References and Additional Resources 228
Section 4.6—Polybutylene-1 for Peelable Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
STEFANO PASQUALI, LyondellBasell Industries
Introduction 229
Polybutene-1 Key Features 229
Easy-Peel Application 229
Hot to Design a Peelable Film 229
Advantages of Using PB-1 in Easy-Peel Applications 232
Application Examples 233
Quality Testing 234
Summary 234
References and Additional Resources 234
Table of Contents ix
Section 4.7—Polypropylene . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
THOMAS J . SCHWAB and MARIO PERRON, LyondellBasell Industries
Introduction 235
Types of Polypropylene (PP) 235
Polypropylene Film Manufacture 236
Additives 237
References and Additional Resources 237
Section 4.8—Nylons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
SERGI SALVÀ SÀEZ and JA’NAYSHA HAMILTON, UBE America Inc.
Introduction 239
Nomenclature 239
Nylon Synthesis and Chemistry 239
Nylon Extrusion 242
Processing Techniques Used for Nylon Resins 245
Nylon Film Properties 247
Applications 249
Summary 251
References and Additional Resources 252
Section 4.9—Ethylene Vinyl Alcohol Copolymers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
MARK PUCCI, Soarus, L.L.C.
Introduction 253
Synthesis of EVOH Copolymers 253
Oxygen Barrier Properties of EVOH 253
Other Properties of EVOH 254
Multilayer Structures with EVOH 255
Solvent Barrier Prperties of EVOH 256
Processing of EVOH 256
Summary 257
Section 4.10—Polyesters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
JOSE TORRADAS, SALTOR LLC
Introduction 259
History 259
Chemistry 259
Pet Versatility 260
Physical State 260
Rheology 261
Properties of Polyester 261
General Processing 263
Specific Film Processes 265
Secondary Operations 265
Applications 266
Summary 266
References and Additional Resources 266
Section 4.11—Tie Polymers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
BARRY A . MORRIS and I-HWA LEE, The Dow Chemical Company
Introduction 269
Tie-Resin Selection 269
Bonding During Coextrusion 270
Bonding in End Use 271
Processing Guidelines 271
x Table of Contents
Summary 272
References and Additional Resources 272
Section 4.12—Ethylene Vinyl Acetate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
MATTHEW SONNYCALB, LyondellBasell Industries
Introduction 273
Polymer Characterization 273
Applications 275
General Processing Recommendations 276
References and Additional Resources 276
Section 4.13—Acrylate Copolymers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
MICHAEL G . BAKER, Westlake Chemical Corporation
Introduction 277
Chemistry and Manufacturing 277
Property Review 277
Processing Guidelines 278
Applications 280
Handling and Safety 280
Regulatory 281
Section 4.14—Acid Copolymers and Ionomers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
BARRY A . MORRIS and SCOTT B . MARKS, The Dow Chemical Company
Introduction 283
Properties 283
Applications 287
General Processing Considerations 287
References and Additional Resources 288
Section 4.15—Polyvinylidene Chloride (PVDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
KUN SUP HYUN, Formerly of the Dow Chemical Company
Introduction 289
Characteristics 289
Processing 289
References and Additional Resources 290
Section 4.16—Polymer Processing Additives (PPA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
CLAUDE LAVALLÉE, 3M Company
Introduction 291
Interactions 299
Conclusions 301
References and Additional Resources 301
Section 4.17—Additives for Film Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
TAD FINNEGAN and R . E . KING, III, BASF Corporation
Introduction 303
Acid Scavengers 303
Adhesion Promoters 303
Antiblock Agents 304
Antifogging Agents 305
Anti-Gas Fading (For Color-Critical Applications) 305
Antioxidants (For Long-Term Stability) 306
Antistatic Agents 307
Biocides 308
Cling Agents 308
Colorants 308