SABIC Polyethylenes SABIC Polyethylenes BVBV

Stretching the LimitsStretching the Limits

Marcel van EnckevortMarcel van Enckevort

SABIC Polyethylenes BVSABIC Polyethylenes BV

““The effect of Extrusion and Casting process The effect of Extrusion and Casting process variables on Stretch Film Performance”variables on Stretch Film Performance”

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IntroductionIntroduction

Stretching the . . .Stretching the . . .

As a converter you can improve your economies of scale by stretching the output and speed to the limits of your cast stretch lines.

LimitsLimits— Equipment— Application— Resins

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Outline

Introduction

Experimental set-up— Approach — Results— Conclusions

Comparison— Approach — Results— Conclusions

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Cast Stretch Wrap Film segmentsCast Stretch Wrap Film segments

Manual Stretch

100 – 150%

40% Market share

Automatic Stretch

150 – 250%

48% Market share

Power Stretch

> 250%

12% Market share

Photos: ITW MIMA Stretch Packaging Systems

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Cast Stretch Wrap Film Cost StructureCast Stretch Wrap Film Cost Structure

Source: SMS Folientechnik GmbH

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Facts & FiguresFacts & Figures

Almost 90% of the stretch film demand is in hand wrap and machine wrap applications

Maximum pre-stretch level up to 250%

More than 80% of your film cost price is determined by the resins

End users are looking for the lowest price!

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Are you fulfilling your potential?Are you fulfilling your potential?

Are you using optimal outputs/speed?— Nowadays modern stretch film lines can run at higher

speeds (up to 600 m/min)— Older stretch film lines can potentially run faster than

being done today!

Note: speed also determines the end film properties

Did you optimise line settings to use the full potential of the resins?

Are you using fit for purpose resins?

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ApproachApproach

Butene-based SABIC® LLDPE 318B (2.8/918)

A state-of-art cast stretch film line

Real world conditions

3-layer film concept A/B/C with 15% VLDPE in cling layer and 25% trim recycle in the core

Experimental design

15 experiments in 2 days

Easy adjustable variables

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Cast2020: SettingsCast2020: Settings

Dimension Value

Output> 1000 kg/h

Winding speed 500 m/min

Die gap 0.6 mm

Film thickness 20 µm

Layer distribution 15/70/15 %

Recycle in core layer

25%

Photo: SMS Folientechnik GmbH

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Cast2020: Settings – Cont.Cast2020: Settings – Cont.

Variable Range

Melt Temp.250 – 290 °C

Chill roll Temp.

15 – 25 °C

Vacuum box2 – 4 cm H2O

Photo: SMS Folientechnik GmbH

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SABICSABIC®® C C44-LLDPE Film properties-LLDPE Film properties

Improved by changing settings: Tear resistance TD with 15% Puncture resistance with 60% Ultimate pre-stretch level with 37% (from 230 to 340%)

Not influenced by the settings: Optical properties (Gloss, Haze) Cling Elastic recovery (snap back) Stress retention (bundling force)

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Ultimate Pre-stretch level Ultimate Pre-stretch level (HighLight(HighLight)

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Real world testingReal world testing

ROBOPAC Rotoplat 705 PVS

Setting Maximum

Pre-stretch 400%

Turntable speed

15 rpm

Wrapping speed

60 m/min

Semi-automatic Stretch Wrapper

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Real world testing – Cont.Real world testing – Cont.

Looking for the limits we found

several holes and film ruptures!

we also found consistent pre-

stretch levels up to

400 %400 %

BUT(ENE)

BUT(ENE)

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ConclusionsConclusions

Apply optimal processing conditions to utilise the potential performance present in your C4-LLDPE based films

Take advantage of the cost price benefits from maximising the use of C4-LLDPE

Achieve pre-stretch levels up to Achieve pre-stretch levels up to 400%!!400%!!

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Outline

Introduction

Experimental set-up— Approach — Results— Conclusions

Comparison— Approach — Results— Conclusions

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What about the SABICWhat about the SABIC®® C C66-LLDPE?-LLDPE?

compared SABIC® C6-LLDPE (and C4-LLDPE) with metallocene based-C6-LLDPE and with C8-LLDPE

Cast2020 cast film line

3-layer film concept A/B/C concept with 15% VLLDPE in cling layer and 25% recycle in the core

Melt temperature, chill-roll and vacuum box on midpoint settings

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ResultsResults

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ConclusionsConclusions

Utilising C6-LLDPE can:

Improve relevant film properties (e.g. Tear Resistance, Puncture Resistance and cling)

$AV€ on the cost of VLDPE (up to 50%) , using C6-LLDPE in the cling layer!

Easily obtain pre-stretch levels of 250%

And there is still room for improvement!

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FinallyFinally

Explore the limits of processing traditional C4 and C6 based LLDPE resins on your extrusion lines

Apply fit for purpose resins in your film structures

Enjoy the use of SABIC® LLDPE…..

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AcknowledgementAcknowledgement

SMS Folientechnik GmbH, Vienna

Polychem Laboratory

HighLight Industries

De Witt ROBOPAC, The Netherlands