additives feature | Foaming agents
Soft play mats could present technical
challenges for AZO replace- ments, says Reedy’s
Schroeck
as PVC, PE and PS. Processed correctly, they can allow converters to achieve the same small, or smaller, closed cells but at lower temperatures with less machine energy. Some more specialized processes like plastisol closures and soft play mats will see technical challenges. Carbonate foams do not generally have the same rapid expansion as ADC,” says Schroeck. “We are in the early stages of a partnership to create the same type of expansion at the same temperatures to more closely replicate ADC. It’s important to note that these are not quite ‘drop-in’ replacements, but viable alternatives for ADC in food, medical, and toy markets.” Polyfil Additives Technology claims that its new,
PolyOne Colorant Chromatics has launched a new chemical foaming solution for fluoropolymer wire insulation
patented CFA chemistry called Ecocell can act as a direct replacement for AZO in many applications. These include the extrusion of thin sheet, films, and profiles, as well as injection moulding. Ecocell has one decompo- sition point at 200°C (393°F), which is the same as the decomposition temperature as AZO. Ecocell concentrate meets the FDA criteria for food contact, and typical loading levels are approximately 1-2%. It produces small cells, similar to microcellular processes, but has the advantage of being an additive rather than an equip- ment-based system, explains Russ Bradley, market development manager for foam at Polyfil. The additive can be used on existing equipment with-
out need for modification. It can also be used as a nucleator for physical foaming processes. Ecocell’s cell size is small enough to allow its use in thin films down to 1 mil (0.025 mm). “Addition rates vary based on product performance parameters, but usually weight reductions of 10% to 50% are possible in LDPE films,” reports Bradley.
Ecocell is also being used in automotive applications. “Its biggest advantage here is that it is immediately deployable on existing equipment without the need for capital investments to upgrade lines to process-based foaming. It is also a more flexible alternative because production can be moved from one line to another or even to another facility – process based systems are locked into the specific production lines.”
Masterbatch movements In September, PolyOne Colorant Chromatics launched a new chemical foaming solution for fluoropolymer wire insulation that can reduce part density while enhancing the stability and efficiency of the manufacturing process. “It’s difficult to minimise the trade-offs between thermal stability, foaming control and high processing temperatures when applying wire insula- tion,” explains Barto du Plessis, general manager, PolyOne Colorant Chromatics. “This new technology balances all three performance requirements and boosts productivity without the need for additional equipment investment.” The masterbatch offers high heat resistance (340 - 380°C), which allows it to mix well in high-performance polymers. This enhanced dispersion produces a consist- ent cell structure of 200 microns or less, which results in reduced insulation thickness and density without adversely effecting electrical, chemical or thermal properties. The solution eliminates premature foaming, which maximises gas generation and enables greater process control. Bergen International’s new US manufacturing facility, which opened in 2014, has doubled the company’s capacity to produce CFA masterbatches, and a new laboratory facility has increased its research and development capabilities. The company, which focuses exclusively on CFAs for
plastics, sees increased demand for its products and notes that the R&D facilities will give it greater ability to develop custom products and to tailor existing products to specific customer applications.
54 COMPOUNDING WORLD | January 2015
www.compoundingworld.com
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