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Page 1
Polyolefin Dispersion – A New Vistas for Flexible Packaging
Presented by:Ravi Rao, Dow Chemical International Pvt. Ltd.Technical Service and Development - Director
Co-authors:Prashant Mogre, Dow Chemical International Pvt. Ltd.Technical Service and Development LeaderAminur Rahaman, Dow Chemical International Pvt. Ltd.New Venture & Business Development R&D
TAPPI PLACE Conference 10 - 11, Nov 2009, Mumbai, INDIA13 - 14, Nov 2009 , New Delhi, INDIA
Page 2
Agenda• Polyolefin Dispersion (POD) Technology• Polyolefin Dispersion – Chemistry• POD –Applications and Performance• Conclusions
Page 3
What comes to mind when you think of polyolefins ?
Molded Articles & Containers
PlasticPellets
Films
What comes to mind when you think of polyolefins ?
Page 4
Waterborne Polyolefin Dispersions • 40-55 % Solids , < 500 cps Viscosity
Page 5
Aqueous Polyolefin Dispersion
Dow’s proprietary BLUEWAVE™ Technology enables » Dispersion of polymers which are not self-dispersing
• Ethylene /Propylene Copolymers• LDPE, HDPE
» Deliver high molecular weight polymers (>75,000 Mw)» Thermoplastic and elastomer formulations» Low viscosity – Typically less than 500 cps» High solids – up to 60%» Solvent free – No solvents added in process
™Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
Page 6
POD Technology• Continuous Mechanical Dispersion Process &
High Internal Phase Emulsion (HIPE)
Continuous High Shear Mixer
Optional Surfactant
Dilution Water
Initial Water
Liquid or Molten Polymers
HIPE SystemWater Continuous PhaseRhombohedral ParticlesHigh Viscosity90+% Solids
Conventional LatexSpherical ParticlesLess than 75% Solids
POD
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Polyolefin• Propylene copolymer• Ethylene copolymer
Stabilizing Agent• Polymeric • Surfactant
Aqueous Medium
Chemistry – Overview POD Structure
Page 8
Polyolefin Dispersions – Grades
-63122LowOlefin Block Copolymer
Dispersion EDPOD 9501
-3265LowPropylene Copolymer
Dispersion DDPOD 4503
-2685MediumPropylene Copolymer
Dispersion CDPOD 4501
-5363LowEthylene Copolymer
Dispersion BDPOD 8502
-5363MediumEthylene Copolymer
Dispersion ADPOD 8501
Polymer Tg (deg. C)
Polymer Melting Point
(deg. C)
Carboxyl Content
Polymer Composition
TAPPI CodeProduct Designation
Page 9
Converting Options for Polyolefin Dispersions
Printing/Coating Processes (Rotogravure)
Spray Application
Dipping
Frothed Foams
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Film Formation – Hot Stage Microscopy
PolyolefinParticles
HomogeneousFilm
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Mechanical Properties• Cast film 250 microns made from dispersion C and dried at different temperatures
0
1
2
3
4
5
6
7
0 100 200 300 400 500 600 700Strain %
Stre
ss M
Pa
60°C, 10 mil, 30 min, VAC
70°C,10 mil, 30 min, VAC
80°C,10 mil, 30 min, VAC
0
1
2
3
4
5
6
7
0 100 200 300 400 500 600 700Strain %
Stre
ss M
Pa
60°C, 10 mil, 30 min, VAC
70°C,10 mil, 30 min, VAC
80°C,10 mil, 30 min, VAC
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Applications - PODs in Flexible Packaging
Tie Layer / Laminating Adhesive• Alternative to extrusion lamination
» Adhesion to polyolefins» Adhesion to polar substrates (paper, glass, foil,
polar polymers)» Adhesion to PE based printing inks» Wet sandwitch lamination possible
Heat Sealable Layer» Apply at low temperatures and high
speeds» Low HSIT (<70°C)» Use existing printing equipment
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0
0.5
1
1.5
2
2.5
3
50 60 70 80 90 100 110 120 130 140 150Heat Seal Temperature (°C)
Hea
t Sea
l Str
engt
h (lb
)
POD, 3.1 g/m2
POD, 12.7 g/m2
POD, 17.8 g/m2
POD - Heat Seal Strength on BOPP film
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Hot Tack strength - POD coated Chromo Paper
0
1
2
3
4
5
6
7
Temperature
Force (N/25 mm)
force N/25 mm
force N/25 mm 1.13 1.21 1.69 5.98 3.25 2.66 1.27
80 90 100 110 120 130 140
Tack
•Substrate: 70 gsm Chromo Paper•Dispersion: Propylene Based Dispersion C•Add-on coating: 5 gsm
Page 15
Key Properties of PODs for Flexible Packaging
Water resistanceOil & grease resistance Heat sealability
Elasticity /flexibility
Adhesion to polyolefins
Adhesion to polar substrates
Crystalline structure
Tie Chains
Olefin backbone
Functional
groups
Page 16
Application- Paper Coatings
• Extruded polyolefins have been widely used to modify paper
• Limitations exist for extruded polyolefins» Thickness (> 10 microns)» Adhesion to paper
• Beneficial properties of PODs provided to paper and board
» Oil and grease barrier» Moisture resistance» COF modification» Adhesion promoter / tie layer» Heat sealability
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Applications and Properties
Unique Balance of Properties (not possible with conventional dispersions)
» Heat sealability» Moisture resistance/barrier» Soft touch» Elasticity» Adherence to polar and non-polar substrates» Low temperature flexibility» Chemical resistance» Potential for recyclability» Potential for hypoallergenic properties» Food contact compliance» Calibration of hardness and melting points» High filler loading» Toughness» Anti-slip» Embossable
Flex Pkg
Footwear
Frozen Food Pkg
Carpet
Foams
Page 18
Summary: Polyolefin Dispersions – Applied Innovation• In POD- polyolefin dispersions put high molecular weight polyolefin in water based
dispersion to enable customers to create differentiated products or structures, eliminate solvent related issues and/or lower system cost
Positive performance of the Polyolefin
• Heat Sealability• Low temperature flexibility
• Water & Chemical Resistance
+Application benefit of water borne
system• Adhesion to polar substrates
• Acceptance of inorganic fillers• Low Viscosity application
• Can be used as an additive in latexes
Polyolefin dispersions promote Differentiation and growth
Waterborne Application Vs Extrusion Coating
• Thinner Coating• Use existing waterborne application equipment• Higher Line speed• Penetrate porous/fibrous webs• Coat at low temperature• Coat complex geometry• Coat in Pattern
Thank you!
Ravi [email protected]
Contact CIG Europe+32 34 50 2240
www.dowpod.com
™Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow