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CONTROLLING SHEAR TO PRODUCE BRILLIANT EFFECT PIGMENT
MASTERBATCHESADVANCED TECHNOLOGY FOR SUPERIOR EFFECT PIGMENTS WITH
MINIMUM DAMAGE
© Copyright 2015 - STEER Engineering Pvt. Ltd.
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UNSEEN IS UNSOLD.
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Gone are the days of just form and function. Consumers now
look for aesthetics as well as performance. And in todays
overcrowded market place the competition for attention is a
fierce one. How does a packaged product stand out in a shelf
when there are ten other brands offering the same set of
benefits? How does a cosmetics manufacturer get millennials
to
buy the product? How does an automobile salesman convince
his customer beyond the usual technical specifications? The
challenge of getting noticed is, perhaps, one of the most
critical
issues that keeps manufacturers awake in todays world.
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At STEER, we have the answer to make you sleep better. As a
leader in materials
transformation, we incorporate our in-depth knowledge of polymer
sciences,
advanced technology and technical expertise to deliver
innovative solutions that
help create the differentiation that brands and manufacturers
look for. Our advanced
technology for processing special effect and mica-based
pigments, helps
manufacturers create a new degree of visual engagement. Whether
it is adding
lustre, sheen, glitter and sparkle, creating depth and
luminescence or simply playing
with multicolour effects, our technology helps you process
mica-based pigments
without damage to the extremely sensitive platelets, ensuring
effective
colouration, brilliant appearance and the right visual impact
and differentiation that
products and brands need to get noticed.
SPARKLE. GLITTER. SHINE. ATTRACT. AND SIMPLY DAZZLE.
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Our technology for processing the extremely sensitive mica-
based special effect pigments, with minimum damage, has
helped us deliver outstanding results to leading
manufacturers and compounders of effect pigments.
TRUSTED BY SOME OF THE WORLD’S
LEADING EFFECT PIGMENT MAKERS
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Mineral Mica is a delicate, natural, inorganic pigment. Coated
mica crystalline
platelets, such as those used in effect pigments in
thermoplastics (ex: for pearlescent
appearance), are extremely sensitive. Any alteration or change
in size of the structure
will hinder effective coloration and alter the appearance of the
pigments and plastics.
The biggest cause of attrition to the structure is exposure to
shear during various
stages and unfortunately most of the technology available today
does not
account for some or all of the following;Ÿ Efficient mixingŸ
Control over shear and elimination of shear peaksŸ Efficient energy
transmissionŸ Stagnation and Degradation and the resulting char
formation
Moreover, selection of the right twin-screw extruder is also
critical. Key
requirements include;Ÿ A deeper extruder flight depthŸ The right
Screw to barrel clearance to prevent Leakage and subsequent damage
due to shearing.Ÿ The ability to work with low-bulk density
materials.
PROCESSING MICA-BASED EFFECT PIGMENTS:
UNDERSTANDING GAPS IN TODAY’S TECHNOLOGY
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PROVEN INNOVATION ADVANCED TECHNOLOGYMEETS IN-DEPTH KNOWLEDGE OF
POLYMER SCIENCES:MEETS
STEER’S TECHNOLOGY FOR PROCESSING EFFECT PIGMENTS WITH MINIMUM
DAMAGE
Effective processing on a twin-screw extruder requires the
precise implementation of different
steps involved Wetting, Dispersion and Task Specific mixing
(Distribution and Stabilisation). At
STEER, we have mastered the art of processing mica-based
pigments with minimum damage,
allowing us to protect product quality, while ensuring an
effective and economical product.
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#1EFFECTIVEWETTING:
#2EFFECTIVEDISPERSION:
#3EFFECTIVEDISTRIBUTION &STABILISATION:
#4DEEPER ROOTDEPTH
#5ADDRESSING‘LEAKAGE’
#6LOW BULKDENSITYMATERIALS
EFFICIENT MIXING WITH STEERS PATENTED FRACTIONAL-LOBE
ELEMENTSSTEERs patented Fractional-lobe mixing elements, address
the gaps in todays technology by allowing for mixing through
elongation and laminar means in a non-filled process section. This
allows for frequent splitting and recombination of the melt pool.
STEERs mixing elements have fully intermeshing and self-wiping
characteristics to help with effective wetting in the intermeshing
zone. Besides the shorter lead angles increase the frequency of
holding.
SOLVING THE ISSUE OF SHEAR PEAKS IN THE 65-YR OLD 2-LOBE
KNEADING BLOCKSSTEERs special mixing elements reduce/eliminate
shear peaks and still maintain a fully intermeshing and self-wiping
characteristic. This reduction/elimination of shear peaks (through
the use of multiple lobes) results in controlled energy input,
improving both efficiency and effectiveness. Moreover the element
geometries facilitate a controlled energy input depending on task
Simple shear for the reduction of cohesive aggregates and
agglomerates, planar shear for high energy dispersion, low energy
elongation.
PREVENTING STAGNATION AND DEGRADATION:STEERs distributive mixing
elements with fully intermeshing and self-wiping profile prevent
stagnation and degradation and the resultant char formation. They
facilitate distributive mixing characteristics while generating the
right pressure. Besides, they also provide the ability to
facilitate melt homogenisation prior to discharge from the extruder
improving strand stability or dimensional accuracy.
1.71 DO/DISTEERs OMEGA 1.71 DO/DI (the new standard in
compounding) or the deeper root depth, draws more of the resin into
the screw root and away from the shear forces that occur when the
melt contacts the barrel wall.
One of the biggest causes of damage to the pigment is shearing
that can occur when plastic containing the pigment, leaks back into
the trailing screw channel. This occurs when the screw-to-barrel or
screw-to-screw dimensions are large enough to allow leakage of the
polymer. With STEERs OMEGA 1.71 DO/DI co-rotating twin-screw
extruder the Barrel to Screw Gap and Screw to Screw Gap are
maintained at less than 0.25mm to have fully wiping effect rather
than shearing effect.
STEERs OMEGA 1.71 DO/DI co-rotating twin-screw extruder provides
manufacturers the ability to work with shear-sensitive and low-bulk
density materials, making it the ideal equipment of choice for
working with mica-based pigments. Moreover, the patented conveying
elements increase throughput by 5x while reducing the attrition
that can occur with standard conveying elements.
STEER’S PATENTED SPECIAL ELEMENTS ARE AVAILABLE ONLY WITH STEER
PLATFORMS
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FOR FURTHER INFORMATION ON THE TRIALS OR TO WORK WITH US WRITE
TO [email protected] OR VISIT STEERWORLD.COM
EQUIPMENT:Ÿ STEERs Do/Di=1.71 Technology platform
OMEGA 40H; L/D=44Ÿ Special Design Elements by STEERŸ
Loss-in-Weight FeedersŸ Strand pelletizer
MATERIALS:Ÿ 70% LLDPE, 30% PigmentsŸ Iridion 305 Solar GoldŸ
Iridion 305 WM10 (PEWax dispersion)Ÿ Iridion 305 Pearlets PO (70%
MB in PE)Ÿ Antioxidant, Additives.
PROCESSING:Ÿ Three Screw Designs; Standard Hi-Shear
& Optimized Special ElementsŸ Screw RPM fixed @ 600 for all
trialsŸ 170-230C
TESTING:Ÿ Microscopic Examination at MERCK as
per MERCK Standard Procedure
THE PROOF IS IN THE PIGMENTSTRIALS CONDUCTED AT STEER’S
APPLICATION DEVELOPMENT CENTER IN BENGALURU, INDIA
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FOR FURTHER INFORMATION ON THE TRIALS OR TO WORK WITH US WRITE
TO [email protected] OR VISIT STEERWORLD.COM
“STANDARD” HIGH SHEAR DESIGN
“OPTIMIZED” USING STEER SPECIAL ELEMENTS – SIDE FEED
Pigment Top Cut = 60microns, Top Cut in Compounded Masterbatch =
28microns
Pigment Top Cut = 60microns, Top Cut in Compounded Masterbatch =
60microns,
OVERSIZE PARTICLE DETECTED INDICATING LEAST PARTICLE DAMAGE
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ADVANCED TECHNOLOGY FOR PROCESSING MICA-BASED PIGMENTS WITH
MINIMUM DAMAGE
DEEPER ROOT DEPTH FOR REDUCED SHEAR FORCES | BARREL TO SCREW GAP
AND SCREW TO SCREWGAP’ < 0.25MM TO PREVENT LEAKAGE | ABILITY TO
PROCESS LOW-BULK DENSITY & SHEAR-SENSITIVE
MATERIALS | BETTER ENERGY DISSIPATION | HIGH VOLUME, HIGH
TORQUE
STEER’S OMEGA 1.71 DO/DI CO-ROTATING TWIN-SCREWEXTRUDER — THE
NEW STANDARD IN COMPOUNDING
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ADVANCED TECHNOLOGY FOR PROCESSING MICA-BASED PIGMENTS WITH
MINIMUM DAMAGE
EFFICIENT MIXING THROUGH LAMINAR / ELONGATION MEANS |
ELIMINATION OF SHEAR PEAKS WHILEMAINTAINING A FULLY INTERMESHING
AND SELF-WIPING CHARACTERISTIC | EFFECTIVE DISTRIBUTION
& STABILISATION WITHOUT STAGNATION OR DEGRADATION
STEER’S PATENTED SPECIAL ELEMENTS
RFV Elements
SFV Elements
FME Elements
DSE Elements
FKB Elements
OSE (wave) Elements
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5 10 GLOBAL OFFICES, SATELLITE OFFICESAPPLICATION DEVELOPMENT
CENTERS3
STATE-OF-THE-ART FOUNDRY FOR SPECIAL STEEL1COUNTRIES
SERVED39
EMPLOYEES500+ PATENTS 33
350000 ELEMENTS SOLD EXTRUDERS INSTALLED470
Satellite Office
Application Development Center
Global Office
Countries Served
Foundry
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STEER AMERICA
1525 Corporate Wood Parkway, Suite 500, Uniontown, Ohio 44685,
USA
Tel: +1-866-984-1800Fax: +1-330-563-4413E-mail:
[email protected]: www.steeramerica.com
STEER CHINA
603,Building No.12, 3599#, Qixin Road, Minhang District ,
Shanghai, China 201101
Tel: +86-021-34718598Fax: +86-021-34718598 ext. 806E-mail:
[email protected]: www.scg.steerworld.com
STEER EUROPE
Tel: +44 2032904949E-mail: [email protected]:
www.steerworld.com
STEER INDIA - Bangalore
#290, 4th Main, 4th Phase, Peenya Industrial Area, Bangalore 560
058, India
Tel: +91-80-23723309/10
+91-80-42723300Fax:+91-80-28391374E-mail: [email protected]:
www.steerworld.com
STEER JAPAN
Fukui Building 4F, P3-21-7 Higashiueno, Taito-Ku, Tokyo 110-0015
Japan
Tel: +81-3-6411-5770Fax: +81-3-3831-3230E-mail:
[email protected]: www.steerjapan.com
STEER INDIA - Mumbai
#317, Regus Business Centre, Level-3, Neo Vikram, New Link Road,
Andheri (W) Mumbai 400053. India
Tel: +91 22 61984900Toll Free: 1800 425 55111Fax: +91 22
61984950E-mail: [email protected]: www.steerworld.com
STEER is a creator of materials platform technology that
effectively transforms and functionalises materials in the fields
of plastics, pharmaceuticals, food & nutraceuticals,
biomaterials and biorefining. Founded in 1993 by Dr. Babu
Padmanabhan with a vision to steer a new world, STEER today has 5
global offices and 10 satellite offices, serving over 39 countries
and employs over 500 gifted engineers, scientists and technicians
across the globe. With 33 patents for breakthrough innovations,
STEER is committed to the design, creation and implementation of
advanced platform technologies, components, elements, peripherals
and applications that help our customers, and the world at large,
to move forward.
ABOUT US
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STEER A NEW WORLD.STEERWORLD.COM | [email protected]
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