Raw material for TQ Films

Satish V. Awate Product Application & Research Centre Reliance Industries Limited

IPI seminar

Aug 2002 rev 0.1

“ a better product

at affordable price ”

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Index

Overview on PP films in flexible packaging sector

TQPP film extrusion process

Repol H 100 EY for TQ film applications

New Repol grades for advance applications

Manufacturing process for Repol

Product Application & Research Centre

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Flexible Packaging Sector : Overview

44%

27%

17%

12%

LD/LLDPE PP HMHDPE PVC

Total Film Market (01-02) ~ 1MMT

PP films: 2nd largest share in flexible packaging

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Polypropylene film : overview

2%

20%

78%

TQPP CPP BOPP

...largest contribution from TQPP films

PP Film Market (01-02) ~ 270KT

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Growth of TQPP film sector

0

200

400

600

800

1000

1200

1400

1600

1996-97 1997-98 1998-99 1999-00 2000-01 2001-020

50

100

150

200

250

MachinesConsumption (KT)

...supply driven market

CARG ~ 17%

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Drivers for growth of TQPP films

...aesthetic appeal of PP the key driver for growth

Growing demand in flexible packaging

Excellent optical properties viz. clarity & gloss

Better mechanical properties viz. stiffness

Good barrier properties

Cost effective packaging solution

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Characteristics of Polypropylene

higher crystallinity

formation of spherulites, as the melt solidifies

slower crystallisation rates

possible to get smaller size spherulite, by quenching of the film

...need an extrusion process with an

effective cooling arrangement

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Tubular Quenched Polypropylene (TQPP) film extrusion process

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Advantages of TQPP process

low capital

lesser space requirement

lower operating cost

less demanding operating skills

ease in changing the width / thickness of film

tubular film is an added advantage in manufacturing

of pouches / bags

…most cost effective process in plastics

Polypropylene grade for TQ film

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Repol H 100 EY PP homopolymer, with slip and antiblocking agents MFI : 11.0 g/10min The grade is designed to provide: - Good processability - Good clarity and gloss - Good stiffness Typical applications : packaging of textiles / food / other commodities

…largest selling PP grade in India

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Properties of TQ films made from PPHP

narrow sealing window and low seal stregnth

low impact properties

lower tear resistance

higher stiffness

...yet to make a mark in more demanding applications

New grades for advance applications of TQ film

Random Ter-polymer T 080 EY

Repol H 100 EY (modified)

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Repol T 080 EY

New random terpolymer from RIL 8 MFI grade, with slip & antiblock Repol T080EY is designed to provide :

• Soft in feel • Lower sealing temperature • Good dart impact and tear strength

• Good processability • High melt strength • Good gloss and clarity

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Dart Impact Strength

1.2

4.63.5

0

0.5

1

1.5

2

2.5

3

3.5

4

4.5

5

Dart Impact Strength (gm/micron)

PPHP Ter-polymer LLDPE(1 MFI)

17

Tear strength

1.2 1.2

3.42.8

9.9

12.5

0

2

4

6

8

10

12

14

MD TD

PPHP Terpolymer LLDPE

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Sealing characteristics : Hot Tack Strength

120 @ 1400C

185 @ 1280C 160 @

1160C

0

50

100

150

200

HTS

PPHP Terpolymer LLDPE

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Sealing characteristics : Heat Seal Strength

1000 @ 1400C

1300 @ 1280C

1200 @ 1160C

0

200

400

600

800

1000

1200

1400

HSS

PPHP Terpolymer LLDPE

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Advantages of Repol T 080 EY

• Lower melting temperature, hence lower processing conditions

• Lower sealing temperatures

• Better sealing characteristics

• Better mechanical properties

..for more demanding applications

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Applications for Repol T 080 EY

liners

carry bags

lamination films

(see-through pouch)

packaging on form fill seal (FFS) machines

stationery items (photo albums / document holders)

… value added products

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Modified Repol H 100 EY

significant improvement in throughputs

20 kg/hr 150 kg/hr

over stretching leads to bubble breakage /punctures at higher shear rates,

extensional viscosity decreases melts becomes thinner (stress thinning of PP)

resin has to be designed for higher extensional viscosity

...tailor made for high output machines

Manufacturing process for REPOL

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Manufacturing process for REPOL

Unipol manufacturing process combines the fluidized bed reactor technology of Dow-UCC the Super High Activity Catalyst (SHAC) of Shell

No atactic removal and deashing steps due to the highly active and highly selective catalyst Ability to make following grades of PP:

Homopolymer (PPHP) Impact Copolymer (PPCP) Random Copolymer (RCP) Controlled Rheology (CR)

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Unipol process

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Resin Property Modification

Type of catalyst and plant process parameters used during polymerisation, decide the following resin parameter:

− Tacticity −Molecular weight −Molecular weight distribution

Resin parameters and additives incorporated are determined by the requirements

− processability − end properties of a product

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Product Application & Research Centre : A Vital link between Plant - Business - Processors

Marketing

Manufacturing Manufacturing

Processors Processors

PARC

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WE believe in building strategic relationships

Between business enterprises and their vendors Converting basic needs into commercially viable technology Helping produce useful products

Research Institutions

Polymer Processors

End Users Machinery Manufacturers

PARC

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PARC

End Product Evaluation

Interaction with professional bodies/Nodal Institutes

Research Institutes

Grade Benchmarking/ improvement

Developmental

Activities

Resin Evaluation

Product Designing

BIS / ISO Activities

Technological Evaluation

VALUE

ADDITION

Customer Service/Support

Resin Evaluation

Additive Optimization

Product Designing

Areas of activities

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Thank You !