Plastic Material News

Ensinger Chooses Victrex® T-Series™ Polymer for Compression Vanes in Pneumatic Tools

West Conshohocken, PA, USA - May 29, 2009 - When a major pneumatic tool manufacturer in Brazil wanted to develop a new line of high rotation tools, it turned to Ensinger, a global supplier of semi-finished products, finished parts and precision profiles, for help in manufacturing the compression vanes.  Requirements included resistance to flexural loads, and high wear and temperature resistance in dry-running operations.  Ensinger chose VICTREX® T-Series™ polymer for the vanes, which not only delivered enhanced mechanical and tribological properties, but helped the manufacturer satisfy environmental requirements.

The vanes are responsible for air compression in the tools and play a vital role in the system, keeping the rotor spinning and transmitting torque to the drive shaft. According to Ricardo Ehlke, Victrex South America Market Development Manager, “The primary reason leading Ensinger to choose the VICTREX T-Series polymer was its successful performance in the high PV condition generated at 18,000 rpm.  The polymer also offers the necessary chemical resistance if air lines become contaminated with oils, grease, and water particles. VICTREX T-Series polymer is a blend of VICTREX PEEK polymer and Celazole* polybenzimidazole (PBI) and is specially designed to perform in the most demanding applications requiring high thermal strength and wear resistance.”

The high rotation tools were developed in response to an industry need for higher productivity rates in manufacturing and maintenance operations. “In a search to find a solution that would increase the efficiency of its product range, the manufacturer decided that high rotation rotors were the answer,” said David Cislaghi, Product Development Manager of Ensinger Brasil. “To meet environmental requirements, they needed to eliminate any kind of lubricant inside the compression chamber.  This was the deciding factor in specifying VICTREX T-Series polymer as it eliminated the problem of emissions residue during the exhaust phase. The result is a healthier shop floor environment with lower rates of contaminated particles.”

The compression vanes were previously manufactured with a cotton-phenolic based thermoset, which is not recyclable. “Switching to VICTREX T-Series polymer offered advantages both from an environmental and processing point of view, due to its high purity and recyclable possibility,” said Cislaghi. “From a production point of view, using VICTREX T-Series polymer to injection mold the vanes is a much shorter process.  There is no secondary operation required to reach the tight tolerances. When the thermoset material was used, production required two different steps; first, a plate was produced, and second, the vane was machined out of the plate to the part print dimension. The result was low productivity and higher processing costs.”

As soon as the first vane profile was approved for the new product line, Ensinger worked with the tool manufacturer on ways to extend the concept and polymer to different vanes, standardizing profiles in order to cover their entire product range. The high rotation tools, including polishing machines, drillers, grinders and screwdrivers, are used in a wide range of industries and applications including engine production lines, aircraft fuselages, and general assembly operations in home appliances and electronic components. 

For more information, please call (800) VICTREX or visit the Victrex website at www.victrex.com.

Sustainable Packaging Expanding to Multiple Market Segments

DuPont Recognizes Breakthrough Achievements in its 21st Packaging Awards

Wilmington, Del., May 28, 2009 - A diverse group of businesses in multiple market segments are turning to sustainable packaging solutions to improve the environmental profile of their product offerings, according to DuPont as the company today announced the winners of the 21st DuPont Awards for Packaging Innovation at the industry’s first online interactive exchange on sustainable packaging.  Winners include well-known brands such as Estee Lauder, Procter & Gamble, Unilever and Conagra for food, pharmaceutical, personal care and other packaging segments.  For more information on the winners and their sustainable packaging innovations click here.

“Sustainable packaging is a growing and important focus area for DuPont and demand continues to grow across multiple sectors despite the economy,” said William F. Weber, vice president and general manager -- DuPont Packaging & Industrial Polymers.  “At DuPont, we work with consumer goods companies to minimize packaging content and improve environmental performance, as well as to be more cost effective.  This year’s award submissions also demonstrated a focus on source reduction, which provides the double benefit of an improved product environmental profile and cost reduction.”   

During the event, members of the program’s independent jury panel provided their perspectives on the achievements of 10 winners from a diverse cross-section of food, pharmaceutical, cosmetics and other packaging segments.  Julian Carroll, managing director of the European Organization for Packaging and the Environment (EUROPEN), led an interactive session on issues arising from lack of consensus on standards for reporting sustainability of packaging.  Ronald Cotterman, executive director of sustainability for Sealed Air Corporation, led a session on future post-use solutions for packaging after it has fulfilled its primary purpose of protecting food and other products.  The event has been archived and is available by registering at: this link.

“To reduce the event’s environmental footprint, DuPont is using web-based technology for the award ceremonies and related activities taking place at the DuPont Sustainable Packaging Exchange.  This enables the entire industry to learn from winners of this year’s DuPont Awards, which focuses on breakthroughs in sustainable packaging and to interact with industry experts.  This is aligned with DuPont’s commitment to help reduce the environmental footprint of the value chains where we participate,” added Weber.

The DuPont Awards for Packaging Innovation is the industry’s longest running, independently judged global awards program honoring packaging materials, technology and service innovations.  The program has a special emphasis on recognizing innovations that demonstrate sustainable packaging breakthroughs.  This year’s panel was facilitated by Anne Johnson, director of the Sustainable Packaging Coalition.  Over 120 entries were received from around the world.

DuPont – one of the first companies to publicly establish environmental goals 19 years ago – has broadened its sustainability commitments beyond internal footprint reduction to include market-driven targets for both revenue and research and development investment. The goals are tied directly to business growth, specifically to the development of safer and environmentally improved new products for key global markets.

DuPont is a science-based products and services company.  Founded in 1802, DuPont puts science to work by creating sustainable solutions essential to a better, safer, healthier life for people everywhere.  Operating in more than 70 countries, DuPont offers a wide range of innovative products and services for markets including agriculture and food; building and construction; communications; and transportation.

DSM Engineering Plastics Increases Akulon Prices

Evansville, Ind. - May 28, 2009 - As a result of recent escalation in the cost of key raw materials, DSM Engineering Plastics will increase prices in North America for Akulon® polyamide 6 resins (unfilled grades, both medium and high viscosity) by $0.10/lb.

This increase will take effect as of June 15, 2009. While DSM Engineering Plastics continues to pursue and implement cost savings initiatives targeted at absorbing the impact of the raw material escalation, this additional increase is necessary to ensure DSM Engineering Plastics’ sustainable long-term growth in North America.

RTP Company Flame Retardant Compound Selected for Mac3 Float Switch

Winona, MN, USA - May 27, 2009 - Italian manufacturer MAC3 Water Systems, a world leader in developing products for the flow control industry, has developed the Mac3 level regulator, or float switch, with the help of flame retardant materials from custom compounder RTP Company. The float switch allows level-controlling and monitoring equipment, such as pumps, valves, or alarms, to automatically start and stop when a specified fluid level has been reached.

"The Mac3 regulator features a waterproof float equipped with an inner micro-switch connected to the cable," explained Lorenzo Ronchi of MAC3 Systems. "The float's orientation depends on the liquid level and determines the attitude of the micro-switch, which controls the pump operation. The pump is automatically switched on and off, providing both overflow and dry running protection."

The regulator's design, which includes a protective double-walled waterproof chamber, ensures maximum reliability of the mechanism. Engineers designed the shape of the float switch to be completely smooth, making it virtually impossible for solids to collect on its surface and disrupt performance. Its rounded shape makes this device suitable for a variety of environments, particularly waste systems.

Due to its potentially destructive surroundings, the float's outer casing required a flame retardant compound with both high impact values and UL approval. MAC3 Systems selected an RTP 100 Series flame retardant polypropylene compound for the casing, which is UL94 recognized with elevated RTI ratings. This compound's excellent impact resistance, combined with resistance to common chemicals, protects the float switch from damage and ensures consistent functionality.

"The most significant benefit of the Mac3 regulator is its high reliability," said Ronchi. "This is due to the use of high quality materials, strict manufacturing procedures, and extensive testing. RTP Company also greatly contributed to the product's reliability by providing excellent service and material recommendation, ensuring the best possible results and making it easy for our engineers to develop a successful product."

For more information on RTP Company custom engineered thermoplastic compounds, call (800) 433-4787 or (507) 454-6900, or visit their website at www.rtpcompany.com.

About MAC3 Water Systems
MAC3 Water Systems, located in Firenze, Italy, is the world's leading manufacturer of float switches. For over 25 years, the company has been designing and manufacturing an extensive line of flow control devices. For more information, please visit www.mac3.it.

Borealis Lighting’s Innovative LED Technology Relies on Polycarbonate from Bayer MaterialScience

Another bright idea:

Pittsburgh, May 27, 2009 — Light emitting diode (LED) lighting is growing in popularity around the world, which is no surprise given the many benefits of LED technology, including a typical lifecycle of 50,000 hours, low maintenance and low energy consumption. Due to the energy savings it offers over traditional incandescent bulbs, LED technology is a more environmentally responsible way to light a space. The U.S. government has invested hundreds of millions of dollars funding programs from basic research to demonstration projects replacing traditional lighting sources with more efficient LED lighting. Furthermore, the Energy Independence and Security Act of 2007 mandated that energy efficiency standards of light bulbs increase by 30 percent, therefore effectively phasing out most common types of incandescent light bulbs as early as 2012 , making LEDs one of the preferred lighting options for the future.

Borealis Lighting, a division of PolyBrite International, is at the forefront of LED lighting technology, designing and manufacturing solid-state LED lighting systems and products. Borealis Lighting’s patented PolyBrite™ polymer and light transmitting technology is a unique polymer/LED combination that conducts, angles and radiates a light source through the polymer lens material illuminated by LEDs.

The lenses of several lamp products from Borealis lighting for indoor and outdoor illumination are molded from Bayer MaterialScience’s Makrolon® polycarbonate resin. Makrolon polycarbonate offers advanced benefits for this application. For example, it does not block as much light as other materials, and the higher light transmittance allows the PolyBrite technology to use fewer LEDs.

“I have always had success with Makrolon polycarbonate resin and I knew that we could count on the material to consistently meet our needs,” said Carl Scianna, president of PolyBrite International and inventor of PolyBrite technology. “Makrolon polycarbonate resin is a superior choice for this application because of its high impact strength and glass-like transparency, among the many other benefits it offers. Experts from Bayer MaterialScience worked with us from the start, providing support as we developed our innovative LED solutions.”

Borealis Lighting uses Makrolon 6557 polycarbonate in its R20, PAR30 and PAR38 lamps. The lamps are used in a variety of general lighting applications, including residential, commercial and retail areas.

Each lamp offers an eco-friendly, energy-saving alternative to incandescent or compact fluorescent light (CFL) bulbs. The Borealis R20 LED lamps are used for ambient illumination and down lighting of common areas and work spaces, while the PAR30 and PAR38 LED lamps are used for ambient illumination and down lighting of larger spaces.

The Borealis lamps that feature Makrolon polycarbonate resin all provide brightness that is comparable to incandescent lamps, but with reduced glare and improved shock and vibration resistance. The PolyBrite combination of polymer and LEDs can be either extruded into a variety of light-scattering shapes, or injection molded, depending on the particular application.

“We are always happy to be able to provide materials ideal for applications like the Borealis Lighting LED lamps – innovative products of the future,” said Gerald DiBattista, market segment leader, IT, Electrical/Electronics Polycarbonates, Bayer MaterialScience LLC. “LED lighting technology requires a material that can withstand the heat while remaining strong, and offers high light transmittance and flame resistance. Makrolon 6557 polycarbonate offers those characteristics with the reliability and reputation of Bayer MaterialScience behind it.”

“All customer feedback from these particular lamps has been positive,” said Scianna. “People like the aesthetic look, as well as the practical benefits of the lamps.”

PolyBrite International, Inc. headquartered in Naperville, Ill., serves its international and domestic customers by providing the highest quality, environmentally friendly “green” lighting products. PolyBrite manufactures Borealis lighting products for residential, commercial and retail lighting and has been recognized as a leader in the LED lighting industry. All Borealis LED lighting products are entirely under the control and management of PolyBrite to ensure the highest quality. More information on PolyBrite’s LED Lamps, Lighting Systems and products are available on the Internet at www.polybrite.com or www.borealislighting.com or by calling 1-800-320-3801.

Bayer MaterialScience LLC is one of the leading producers of polymers and high-performance plastics in North America and is part of the global Bayer MaterialScience business with nearly 15,100 employees at 30 sites around the world and 2008 sales of 9.7 billion euros. Business activities are focused on the manufacture of high-tech polymer materials and the development of innovative solutions for products used in many areas of daily life. The main segments served are the automotive, electrical and electronics, construction, medical, and sports and leisure industries.

Borealis Increases Polyethylene and Polypropylene Prices

Borealis, a leading provider of innovative, value creating plastics solutions, announces that it will increase all polyethylene and polypropylene prices by EUR 60/tonne as of June 1, 2009.

“This increase is necessary to preserve sustainable margins and to ensure our innovation programmes,” comments Lorenzo Delorenzi, Executive Vice President Polyolefins, Borealis.

A. Schulman Expands Sunprene® Elastomers Line for Industrial, Specialty Wire & Cable, and Heavy Truck Markets

Akron, Ohio – May 27, 2009 – A. Schulman, Inc. (Nasdaq-GS: SHLM) today announced the expansion of two series of Sunprene® Elastomers to serve the specific needs of the industrial, specialty wire and cable, and heavy truck markets.

Based on ultra-high molecular weight PVC, Sunprene Elastomers possess many rubber-like qualities, while offering thermoplastic processing, recyclability, and cost effectiveness compared with thermoset EPDM rubber and traditional thermoplastic elastomers. As a result, they provide exceptional tear and abrasion resistance, high flex fatigue, and excellent low temperature brittleness. The materials can be customized to meet a broad range of performance requirements.

The primary markets served are industrial hose and tubing, seals and gaskets, conveyor belts, specialty wire and cable, and heavy truck sealing applications.

“Sunprene Elastomers are a high-performance, economical alternative to thermoset EPDM rubber and traditional thermoplastic elastomers,” said Lee Pfaffle, Business Manager, Engineered Plastics North America of A. Schulman. “On cost, processing and performance, Sunprene Elastomers are an excellent solution for a variety of industrial, specialty wire and cable, and heavy truck applications.”

Sunprene Elastomers are available in two series. The first series is specifically formulated for extrusion applications and has hardness ranges from Shore 35A to 85A durometer, and a specific gravity range between 1.20 and 1.29. The other series, designed for both injection molding and extrusion applications, has hardness ranges from Shore 57A to 65A Durometer, and a specific gravity range between 1.22 and 1.27. This series provides the added benefit of "increased performance in compression set resistance.

“We’re very enthusiastic about the performance advantages that our Sunprene resins bring to the industrial, specialty wire and cable, and heavy truck markets,” said Paul Boulier, A. Schulman Inc.’s Chief Marketing Officer. “The expansion into these markets is evidence of our ability to identify new opportunities to leverage our Engineered Plastics technology for a variety of demanding, specialty applications.”

Eastman Chemical Company Announces Distributors of Eastman Tritan™ Copolyester

Four Distributors to Increase Accessibility to New-generation Copolyester

Kingsport, Tenn. — May 27, 2009 — Eastman Chemical Company announced today that it has chosen four companies — PolyOne Corporation, Ashland Distribution, Amco Plastic Materials Inc. and CCC Plastics — to distribute Eastman Tritan™ copolyester in the United States and Canada. Through the distributors, Tritan will be more easily accessible and offer new application opportunities for diverse customers in various industries.

Eastman Tritan™, a new-generation copolyester, delivers the advantages of traditional copolyesters, such as clarity and toughness, as well as offers high-heat and chemical resistance, improved design flexibility, and ease of processing. It is manufactured without bisphenol-A (BPA).

“Eastman Tritan™ copolyester has been successful in several markets, such as housewares and infant care, and we continue to look for new applications and opportunities,” said Ricky Owens, sales manager, distribution and inside sales, Eastman Chemical Company. “By working with these respected distributors, which are able to offer a wide array of products and services to a variety of customers, we hope that Tritan can help provide additional material solutions in new industries.”

Eastman Chemical Company began working with the distributors during the first quarter of 2009 to help make Eastman Tritan™ copolyester accessible to a more diverse customer base. Tritan has been launched in the reusable sports water bottle, infant care, small appliance, housewares, medical and sign markets. During the past year, national and international companies like Thermos, Nalgene, Evenflo and Vita-Mix have developed product applications with Tritan.

“While we are able to work with large, recognizable product manufacturers in their development of innovative products made with Eastman Tritan™ copolyester, there are many smaller customers that can benefit from the new-generation copolyester,” Owens said. “Our distributors can offer their customers valuable insight and access to diverse material options, including Tritan.”

For more information about Eastman Tritan™ copolyester, visit www.eastman.com/tritan.
For more information about PolyOne Corporation, visit www.polyone.com.
For more information about Ashland Distribution, visit www.ashland.com.
For more information about Amco Plastic Materials Inc., visit www.amco.ws.
For more information about CCC Plastics, visit www.cccplastics.com.

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LyondellBasell Launches New High-Performance Adflex Resin for Use in Blown Film

Rotterdam, Netherlands, May 26, 2009 - LyondellBasell has launched a new polypropylene resin based on its proprietary Catalloy technology to be used by customers in a wide range of blown film applications. The new grade, Adflex 7492 XCP, offers customers an outstanding combination of transparency and superior resistance to impact, puncture and tear propagation. With a film thickness of 30µm and 13 % haze value, the resin represents a new benchmark for highly-modified polypropylene grades.

Catalloy Process Resins

Produced using LyondellBasell’s proprietary Catalloy process, Adflex 7492 XCP exhibits an exceptional balance of softness, film clarity and good processing performance. Until now, several polypropylene products offered customers a wide range of characteristics for blown film applications. But when customers required transparency, no resin on the market could address this need.

“Thanks to the efforts of our researchers, we have now a competitive alternative on the market that delivers exceptional transparency, while maintaining  softness, mechanical properties, good bubble stability and throughput,” explained Caroline Cathelin, LyondellBasell’s Customer Project Manager for Europe, Africa, and Middle East. “After pilot plant development, and successful trials, it was clear that our experimental grade has set a new performance standard for polypropylene used in transparent film applications.”

According to Cathelin, the application potential is wide, ranging from consumer and industrial packaging to film used in agricultural and industrial environments. “With the successful development of Adflex 7492 XCP, we intend to develop new applications and opportunities in blown film applications, where PP grades previously have fallen short of customer expectations.”

Reducing raw material costs

Test results have demonstrated that the resin shows promise in co-extruded blown film applications, where the new Adflex grade was used in the core layer. The throughput that has been achieved is close to fractional MFR LDPE, and the finished product displayed excellent clarity when clarified PP skin layers were used. “If customers require superior mechanical properties of the final film, they may also consider the use of mLLDPE skin layers in combination with a core layer of Adflex 7492 XCP,” said Cathelin. With this perfect balance of stiffness, toughness and clarity, Adflex 7492 XCP also offers the potential to reduce raw materials costs. “The resin’s property profile will enable customers to down gauge film thickness while maintaining the rigidity of newly designed blends and coex film structures,” said Michael Möller, LyondellBasell’s Catalloy Process Resins Marketing Manager for Flexible Packaging. This performance combination enables possible cost reductions through reduced material consumption.”