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| Baerlocher | VCA 2018 | Dane Tallen15/3/181 |
VCA 2018
Dane Tallen
15th March 2018
Ca based solutions for injection moulding –
Can one size really fit all?
| Baerlocher | VCA 2018 | Dane Tallen15/3/182 |
Modern factories and all technologies to serve PVC convertors everywhere
15/3/18 Baerlocher | VCA 2018 | Dane Tallen3 |
UK
Ca basedTurkey
Ca based Pb
*Brazil / Peru / Argentina
Pb Ca based LMM
Italy
LMM Sn
Germany
Ca based
China
Ca based Pb
Malaysia
Ca based Pb
USA LMM
Ca based
India
Pb
Ca based
LMM
*Joint ventures in South America
Our PVC stabiliser footprint
| Baerlocher | VCA 2018 | Dane Tallen15/3/184 |
Global stabiliser consumption for pipes and fittings
99
% S
n1
% O
the
rs
84
% P
b5
% S
n1
1%
Ca
/Zn
0%
Pb 4
% S
n
96
% C
a B
as
ed
77
% P
b2
% S
n
21
% C
a/Z
n
77
% P
b2
% S
n
21
% C
a/Z
n
40
% P
b2
0%
Sn
40
% C
a/Z
n
94
% P
b
1%
Sn
5%
Ca
/Zn
| Baerlocher | VCA 2018 | Dane Tallen15/3/185 |
Trend towards lead free in EU
.0
20000.0
40000.0
60000.0
80000.0
100000.0
120000.0
140000.0
160000.0
2000 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016
Pb and COS from 2000 till 2016
ELSA EU 28 ECOSA EU 28Source ESPAELSA – European Lead Stabilisers Association ECOSA – European Calcium Organic Stabilisers Association
| Baerlocher | VCA 2018 | Dane Tallen15/3/186 |
Equipment variation
| Baerlocher | VCA 2018 | Dane Tallen15/3/187 |
Product variation - Size
| Baerlocher | VCA 2018 | Dane Tallen15/3/188 |
Product variation - Colour
| Baerlocher | VCA 2018 | Dane Tallen15/3/189 |
Product variation – Screw design
| Baerlocher | VCA 2018 | Dane Tallen15/3/1810 |
Product variation – Raw material form
▪ Pictures provided by MTI
11 |
Active Aspiration is recommended
| Baerlocher | Rollepaal Symposium / Dr. FokkenJan-18
1. Charging of raw materials
2. Filter cleaned by compressed air
3. Mixing up to 70°C / aspiration
closed
4. Suction started, fumes are
removed
12 |
Active Aspiration is recommended
| Baerlocher | Rollepaal Symposium / Dr. FokkenJan-18
▪ Venting
• A sufficient vacuum is required to draw off any moisture or volatiles
• Ensure that the material at this point is not a powder, as powder will block the vacuum system
▪ If powder, increase temperatures prior to the port or close shear gap
• Always ensure that the vacuum system is working correctly as this directly affects fittings
| Baerlocher | VCA 2018 | Dane Tallen15/3/1813 |
Compounding process
| Baerlocher | VCA 2018 | Dane Tallen15/3/1814 |
Traditional lab development - Rheology
| Baerlocher | VCA 2018 | Dane Tallen15/3/1815 |
Traditional lab development - Stability
▪ Vicat softening temperature (VST)
▪ Silver streaks
▪ Cold flow marks
▪ Mimic real processing conditions
▪ Development of dry blend and compound formulations
| Baerlocher | VCA 2018 | Dane Tallen15/3/1816 |
Hurdles to overcome
| Baerlocher | VCA 2018 | Dane Tallen15/3/1817 |
Fitting flaws
▪ OEM co-operation – Joint project with tool maker IFW
• Superb presses and tools
• Saves customer trial time
• Optimisation of product development
| Baerlocher | VCA 2018 | Dane Tallen15/3/1818 |
Non standard solutions were required
▪PhD sponsorship – Long term research project • many aspects of product performance during the moulding
process.
| Baerlocher | VCA 2018 | Dane Tallen15/3/1819 |
Non standard solutions were required
▪
Clamping force : 220ton
Screw diameter & length : Ø 60mm
Injection Volume : max. injection volume 791cm³
Injection Speed : 560cm³/sec
Sited at our fastest growing Ca based facility in China
| Baerlocher | VCA 2018 | Dane Tallen15/3/1820 |
Injection Molding Machine
ENGEL e-victory 1640/220
▪ Functionality : fully automatic
▪ Steel quality : high quality steel 1.2316 for cavity plates; other plates 1.2312 / 1.2085
▪ Core pulling : hydraulically
▪ Execution: : incl. 4 pcs. sprue-inserts and 2nd core for 2 different wall thicknesses
| Baerlocher | VCA 2018 | Dane Tallen15/3/1821 |
IFW Injection mould for PVC Socket Dn 100
▪ Mimic process conditions at converters
▪ Reproduceable specimens for Vicat Softening temperature testing
▪ Check for cold flow marks and silver streaks
▪ 2 sets of screws for compound and dry blend materials
| Baerlocher | VCA 2018 | Dane Tallen15/3/1822 |
What does it give us
| Baerlocher | VCA 2018 | Dane Tallen15/3/1823 |
Development is accelerated
| Baerlocher | VCA 2018 | Dane Tallen15/3/1824 |
So – Can one size really fit all?
Dry blend
Dark colours
Dry blend
Light colours
Compound
Dark colours
Compound
Light colours
BAERLOCHER (M) SDN BHD
Lot 635 & 660, Kawasan Perindustrian Tuanku Jaafar, Sungai Gadut,
71450 Seremban, Negeri Sembilan, Malaysia.
Phone : +60 (0) 6 678 0240
Fax : +60 (0) 6 678 0239
General Email : [email protected]
Website : www.baerlocher.com
| Baerlocher | VCA 2018 | Dane Tallen15/2/1825 |
THANK YOU