ADDITIVES | PROCESS AIDS
Process aids can help compounders improve productivity and quality while delivering processing gains for their customers. Chris Saunders explores developments
Improving the process
Main image: Process aids, such as these Montan waxes from Voelpker, can improve dispersion, lubrication, and compatibilisa- tion during processing of polymer compounds
With raw material availability tight and energy costs soaring, today’s business climate is challenging for compounders. These extra challenges come on top of the ongoing need to refine products to meet demanding requirement from customers in terms of performance and value. Carefully selected processing aids and lubricants can play some part in improving output and quality, both in the compounding plant and in customers’ production operations.
German masterbatch maker Grafe claims significant energy-saving potential in series production through the use of its processing aids, which are designed to influence flow behaviour of polymers to increase efficiency at lower cost. “Our processing aids for cycle-optimised injection can be used with the right masterbatch carrier for a wide variety of high-performance polymers and engineering plastics, including ABS, PA, PBT, PET, PPA, PSU, POM, PPE, PPS and PSU,” says Danny Ludwig, Grafe’s Head of Product Management Colour & Functional Masterbatches. “For parts of the powertrain or components under the bonnet made of PPA, we were able to reduce the cycle time by 26% with a 4% masterbatch dosage,” Ludwig explains. “The use of our additive
40 COMPOUNDING WORLD | April 2023
enables a more stable processing window of PPA, improves the melt flow, and generates easier mould filling in injection moulding applications. Lower friction forces have an effect, which means burns or damage to critical geometries can be avoided and more complex elements can be realised.” Lower processing temperatures can result in significant energy-saving potential. According to Grafe, one of its customers in the packaging industry successfully reduced the cylinder tempera- ture in all zones by 40°C, decreasing their process energy requirement by 30%. In addition, the company says optimised flow behaviour at the lower temperature resulted in a 12% faster cycle time as the parts cooled more quickly and evenly. Last year, Ineos Styrolution launched a portfolio
of new styrenic powder grade modifiers, which it says result from a programme of customer testing running over the past several years. Modifications range from enhanced stiffness to improved long- term performance with regard to heat exposure, colour fastness and retention, UV resistance, dimensional stability, and impact resistance. “Over the years, Ineos Styrolution has developed
an extensive know-how with modifiers,” says Dr Alexander Glück, Ineos Styrolution’s European
www.compoundingworld.com
IMAGE: VOELPKER
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