technology of pvc compounding and its applications (hand book)

TECHNOLOGY OF PVC COMPOUNDING AND ITS APPLICATIONS

PVC RESINS MANUFACTURING & PROPERTIES

• Introduction
• Manufacture of PVCSuspension Polymerization Process
• Clean Reactor TechnologyLarge Reactor Technology
• VCM Containment
• Mass Polymerization Process
• Emulsion Polymerization Process
• PVC Mass Polymerization
• Comparative of PVC Produced using Different Processes
• Copolymers, Chemical Modification & Blends/Alloys of PVC
• Introduction
• Reactivity Rations for VCM Copolymerizations
• PVC Copolymers
• Vinyl Acetate Copolymers
• Recipe for VCM-VAC Copolymerization
• Effect of VAC on Properties of PVC Copolymer
• Copolymers with Olefins
• Effect of Ethylene or Propylene on PVC properties
• Copolymer with Vinyldene Chloride
• Copolymers with Acrylates
• Chemically Modified PVC
• Introduction
• Syndiotactic PVC
• Effect of PVC Polymerization Temperature on Crystallinity
• Chlorinated PVC
• Comparative  Properties of PVC & CPVC
• PVC Grafts
• Acrylic Graft
• Properties of PVC Grafts
• EVA grafted PVC
• Cross linked PVC
• Monomer for X-PVC Preparation
• PVC Blends & Alloys
• PVC/NBR Blend
• Properties of PVC/NBR Blends
• Powered NBR
• PVC/NBR
• Dynamically Vulcanized  PVC/NBR
• Comparative Properties of PVC/NBR Blends and Thermoplastic Rubbers
• Typical Properties of Elvaloy Resins
• Comparative Properties of PVC/EVA Blends
• PVC/ABS Alloy
• Dynamic Thermal Stability of PVC/ABS Alloys
• Comparative Properties of PVC Alloys
• PVC/Acrylic & Miscellaneous Alloys
• Properties of PVC/Acrylic Alloys
• Properties of PVC/Gadds Alloys
• Heat Deflection under Load for PVC Alloy
• Effect of processing Temp. on Rheological properties of PVC/Gadds Alloy
• Effect of PVC:Gadds Composition on Torque 

PROCESSING OF PVC

• PVC Resins
• Molecular Weight
• Injection Moulding
• Extrusion
• Additives for Improving Processing
• Heat Stabilizers
• Processing Aids
• Lubricants
• Impact Modifiers
• Compounding
• Low Shear Horizontal Mixers (Ribbon Blenders)
• Higher Shear Vertical Nonfluxing Mixers
• Dry Blend Properties
• Low Shear and High Shear Mixing in Horizontal, Jacketed Cylindrical Blenders
• Hot Melt Compounding
• Two Stage (Farrel) Continous High Intensity Fluxing Mixers
• Compounding Lines-Batch Type
• Suggested K-Value of PVC Resins
• Influence of Formulations on processing behavious
• The Polymer
• Relation of Polymer K-Values with Threshold Temperature
• Lubricants
• Heat Stabilizers
• Processing Aids
• Impact Modifiers
• Plasticized PVC
• Extrusion
• PVC Compounds-Some Routes and Processing
• Calendering
• Injection Moulding
• Unplasticized PVC
• Typical Formulation of Rigid and Flexible  PVC Films and Functions of various components there-in
• General Types of Industrial PVC Compounding Operations
• Equipments for Compounding of PVC
• Calendar Products and their Products
• Processing of Rigid PVC
• Injection Moulding -Rigid PVC
• Injection Blow Moulding (IBM)
• A Typical Injection Moulding Screw Design for Rigid PVC Material
• Three Station Horizontal Indexing Injection Blow Process
• Biaxial Orientation
• Conclusions
• Typical High-Flow PVC Formulation
• Blow Moulded Bottles and Containers
• Reheat Stretch Blow
• PET Vis-A-Vis PVC Stretched Bottles
• PVC Heat Shrinkable Bands
• Blow Moulding of PVC Bottles
• Injection Blow Moulding
• Orientation
• Cushioned Vinyl Flooring
• Wide Choice of Different Substrates
• Streen Coating System
• Way ahead in Flexibility
• Versatility in Coating
• One Pass Production
• Unique Process Improvements
• Principle of Operation
• Embossing problems a thing of the past
• Double sided Coating of Openweave Fabrics
• Single screen coating process
• Screen to screen coating process
• Principle of application
• Recycling
• Description of the Process
• Compounding Internal Mixers
• Internal Mixers
• Schematic View of Compounding Operations
• Unit Operations to Produce Glass Filled Polymers
• Post Compounding Operations
• Schematic of Banbury Mixer
• Schematic of a Grnulator
• Schematic of a strand pelletizer

ADDITIVES FOR PVC

• Introduction
• Plasticizers
• Plasticizer usage for PVC Compound
• Typical Properties of Plasticizer
• Physical Properties of Phthalate Plasticizers
• Physical Properties of less common Phthalates
• Properties of Specially Plasticizers
• Physical Properties of Miscellaneous Plasticizers
• Plasticizer Efficiency and Properties of Flexible PVC
• Plasticizer Efficiency
• Dry Blending Time for Plasticizers
• Effect of Plasticizers on Plastisol Gelation Temperature
• Effect of Structure of Plasticizer on PVC Properties
• Properties of Flexible PVC compounds at 50 PHR Phthalate Plasticizer Level
• Physical Properties of Flexible PVC using specially plasticizers
• Requirements for PVC Plasticizers
• General Relationships between the structure of Plasticizers and their behaviour in PVC
• Characteristics of the Major Types of Plasticizer
• Polymeric Modifiers for PVC
• Modifiers for Flow Improvement
• Flow Promoter for PVC
• Haake Rheogram for Rigid PVC Pipe Compound
• Standard PVC Pipe Compound 2 PHR Modifier
• Effect of Level of Flow Promoters on UPVC Rheological Properties
• Effect of Low Molecular Weight Polymers
• Typical Properties of Flow Promoters
• Modifiers for Impact Enhancement
• Mechanism of Impact Resistance
• Effect of Modifier Quantity
• Effect of EVA
• Effect of Processing Time on Impact Strength
• Systems with Honeycomb Network
• Effect of Processing Conditions
• Effect of Processing Conditions of UPVC
• Effect of MBS/Acrylic Quantity on UPVC Impact Strength
• Effect of Composition on Impact Resistance
• Effect of Temperature of UPVC
• Impact
• Applications for Impact Modifiers
• Heat Stabilizers for PVC
• HCI Absorption
• Elimination of Labile chlorine
• Prevention of Autoxidation
• Addition to polyene secuence
• Carbenium ion elimination
• Lead Stabilizers
• Structure of Lead Stabilizers
• Tin Based Stabilizers
• Structure of Tin stabilizers
• Barium Cadmium Stabilizers
• Stabilization by Barium and Cadmium Stabilizers
• Calcium-Zinc Stabilizers
• Non Metallic Stabilizers
• Epoxy Based Stabilizers
• Effect of Epoxy and Phosphite on PVC Static Thermal Stability
• Organic Phosphites
• Polyhydric Alcohols
• Antioxidants
• Light Stabilizers
• Lubricants
• Appearance and Melting Point of Lubricants
• Calcium Carbonate
• Physical Properties of CaCO3 Fillers
• Clay & Talc
• Silicas & Glass Fibres
• Properties of Glass Fibre Reinforced PVC
• Flame Retardant Agents
• LOI for Various Plastics
• Chlorinated Flame Retardants
• Brominated Compounds Metal Oxides
• Chemicals and Additives-A Review of Future Outlook
• Colourants
• Blowing Agents
• Heat Stabilizers
• Plasticizers
• UV Stabilizers
• Antimicrobials
• Flame Retardants
• Phosphate Ester Flame
• Retardants/Plasticizers for Polyvinyl Chloride (PVC)
• Effect of Various Flame Retardants in Plasticized
• Polyvinyl Chloride
• Plasticized PVC with High Oxygen Index Use of Brominated Phosphate
• Typical High emperature Wire Cable Polyvinyl Chloride Flame Retardant

COMPOUNDING

• Introduction
• Mixing Theory
• Limitations of Mixing Theory
• Mixing Evaluation
• Fillers
• Common Fillers and their uses
• Plasticizers
• Colorants
• Heat Stabilisers
• Antioxidants
• Ultraviolet Light Absorbers
• Antistatic Agents
• Flame Retardants
• Blowing Agents
• Lubricants
• Methods of Compounding
• Intensive Dry Mixers
• Internal Intensive Batch Mixers
• Continous Mixer
• Two Roll Mills and Pelletisers
• Underwater Pelletiser
• Single Screw Extruders
• Compounder Extruder
• Twin Screw Extruder
• Compounding Lines

COMPOUNDING OF PVC

• Selection & Characterization of PVC
• Major Types of PVC Resins
• Processing & Applications of PVC
• PVC Resins Properties
• Relation of PVC K-Value, Viscosity & Mole Wt.
• Effect of Polymerization Temp on % Crystallinity
• Syndiotactic Structure
• PVC Morphology and PVC Characteristics
• Effect of PVC Morphology on Extruder Output
• Rheological Properties of PVC Dry Blends
• Effect of PVC Resin Bulk Density on Rheological Properties
• Effect on Processing RPM on Rheological Properties
• Effect of Processing Temp. on Rheological Properties
• Effect of Bulk Density on DOP Absorption
• Introduction
• Elements of Compounding
• Methods of Compounding
• Intensive Dry Mixers
• Internal Intensive Batch Mixers
• Contionuous Mixer
• Two Roll Mills
• Single Screw Extruders
• Compounder Extruder
• Twin Screw Extruder
• What are some of them ?
• Custom Compounding for Special Properties
• General Guidelines for PVC Formulations for Common Product
• Formulating Rigid PVC Compounds
• PVC Pipe Formulations
• PVC Conduit Pipe Formulations
• Window Profile Formulations
• Interior PVC Profile Formulations
• PVC Siding Formulations
• Cellular PVC Profile Formulations
• Extruded PVC Sheet and Film (Single -Screw)
• Calendered PVC Sheet and Film Formulations-Second Alternative
• PVC Injection Moulded Pipe Fitting Formulations
• High Flow PVC Injection Moulding Formulations
• Extrusion Blow Moulding Rigid PVC Containers
• Crystal Clear Food Contact Bottles
• Clear Bottles good on taint and odour
• Blow Moulded Bottle Formulations
• Blow Moulded PVC Bottle Formulations
• CA-ZN Formulation (Mineral Water)
• CA-ZN Epoxy Recipe for 1 Litre Bottle
• PVC Bottle for Shampoo
• Shoe Soles
• Tests for Compound
• Floor Coverings/Wall Coverings
• Typical Light Stable Formulation
• Carbon Black Properties
• Comparison -Titanium Dioxide and Zinc Oxide
• Portable Water Pipe (Extruded from Dry Blend)
• General Purpose Vinyl Film by Calendering
• Sheeting for Outdoor Upholstry

COMPOUNDING OF PVC PASTES

• Plastisols
• Compounding Ingredients of Plastisols
• PVC Polymers
• Plasticisers
• Stabilisers
• Fillers
• Colourants
• Thickeners
• Other Additives
• Organosols
• Compounding Ingredients
• Preparation of Pastes
• Gelation
• Applications of PVC Pastes
• Rotational Casting Formulation for Dolls and Play Balls
• Compounding of PVC Latices
• Latex Property Modifiers
• Latex Stabilisers
• Surface active agent
• Defoaming Agents
• Thickeners
• pH Modifiers and Buffers
• Polymer End Properties Modifiers
• Heat Stabilisers
• Plasticisers
• Fillers
• Pigments
• Antiblocking Agents
• Coalescing Aids (Volatiles)
• Handling and Processing
• Mixing
• Dipping
• Coating
• Spraying
• Compounding of PVC Solution & Adhesives
• Plasticizers
• Stabilisers
• Fillers
• Pigments
• Lubricants
• Methods of Application of Solutions
• Applications of Solutions Adhesives

TESTING OF RESINS AND COMPOUNDS

• Testing of PVC Resin
• K-Value
• Bulk Density
• Plasticizer Absorption
• Particle Size Distribution
• Electrical Conductivity of Water Extract
• Powder Flow
• Sulfated Ash Content
• Fish Eye Count
• Testing of PVC Compounds
• Bulk Density
• Shore Hardness
• Tensile Strength/Elongation
• Static heat Stability
• Dynamic Heat Stability
• Brabender/Haake Gelation & Degradation Time
• Electrical Volume Resistivity
• Volatile Loss
• Ageing Test
• Cold Bend Temp. Test
• Testing of PVC End Products
• Films/Sheets/Profiles
• Tensile Stress at Yield
• Test for Dimentional Change at 120o C
• Rigid PVC Pipes for Potable Water Supplies
• Dimensions of Pipes
• Visual Appearance
• Opacity
• Short Term Hydraulic Test
• Long Term Hydraulic Test
• Reversion Test
• Impact Strength at oC
• Methylene Dichloride Test
• Flexural Strength
• Wires and Cables
• Thermal Stability Test
• Determination of PVC Cable insulation Degradation
• Comparison of Techniques to Assess FVC Degradation
• Problem Solving in PVC Compounding and Processing
• Resin
• Lubricants
• The Role of Lubricant
• In PVC Compounding
• Stabilizers
• Additives
• Material Characteristics and its effect of processing resins
• Development of an Optimum Formulation
• New Do's and Don'ts
• Plasticizer Migration
• High Purity Non-Stain Plasticizers for Floor and wall Coverings
• Testing
• Sample Preparation
• Cure
• Stain Specimen Conditioning
• Stain
• TGATensile Properties
• Hardness
• Results
• Chemical Resistance
• Rigid
• Chemical Resistance of Vinyl Compounds: Percent Change in Weight 

SPECIALITY PLASTIC COMPOUNDS & MASTERBATCHES

• Introduction
• Product
• Coloured Masterbatches
• Additive Masterbatch/Speciality Compounds
• Market
• Suggested Capacity
• Land & Building
• Raw Materials
• Utilities
• Manufacturing Process
• Plant & Machinery
• Personnels
• Estimated Cost of the Project
• Suggested Means of Financing 

PVC COMPOUNDS

• Introduction
• Product
• Market
• Suggest Capacity
• Land & Building
• Raw Materials
• Utilities
• Manufacturing Process
• For Rigid Pipes
• For Bottle Blowing
• For Blown Film
• For Flexible Hose Pipes
• For Mineral Water Bottle
• Plant & Machinery
• Personnels
• Estimated Cost of the Project
• Suggested Means of Financing

XLPE CABLE COMPOUND, JELLY FILLED TELECOMMUNICATION CABLE COMPOUND & SHEATING COMPOUND

• Introduction
• Product
• XLPE Compound
• MDPE Compound
• FRLS Compounds
• Land & Building
• Raw Materials
• Utilities
• Manufacturing Process
• XLPE Compound
• MDPE Compound FRLS & Low Halogen
• Compounds
• Plant & Machinery
• Personnels
• Estimated cost of Project
• Suggested Means of Financing

PLASTIC GRANULES FROM FRESH RESIN

• Manufacturing process of LDPE Granules from LDPE Resin
• Plastic Filler Granules (PP)
• PVC Granules
• Process of Manufacture
• Plant Economics
• Fixed Capital
• Raw Materials
• Total Working Capital
• Total Capital Investment
• Turn Over/Annum

PLASTIC GRANULES

• Process of Manufacture
• Concentration of Blending
• Removal of Colour to obtain Transparent Granules by Activated Carbon Treatment
• Filteration
• Distillation
• Cooling and Dehumidifying
• Granulation
• Weighing, Filling and Packing
• Plant Economics
• Fixed Capital
• Raw Materials
• Total Working Capital
• Total Capital Investment
• Turn Over/Annum

APPLICATIONS OF PVC

• Review of Major Applications
• Rigid PVC Pipes
• Advantages of Rigid PVC Pipes
• Graphical Sketch of a Twin Screw Extruder
• Applications
• Chemical Resistance
• Resistance of PVC Pipes to Common Chemicals under use Conditions
• Composition Energy Saving of PVC Pipes
• Weathering
• Summary of the Testing Results
• Flow through Rigid PVC Pipes
• Flow or Friction Losses
• Surge and Water Hammer
• Economics of Rigid PVC Pipes
• Water Flow Velocity
• Start up
• Schematic of a large tube die
• some Common Problems and Solutions of Pipe Extrusion
• Industrial Profiles
• Various Forms
• Major Applications
• Cellular PVC Profiles, Boards and Pipes
• Introduction
• Technology of Structural Foam extrusion
• Foaming
• Foaming Processors
• Free Foaming Process
• Inward Foaming Process
• Machine and Die Technology
• Extruders
• Dies
• Chemical Blowing agents
• Processing aids
• PVC grades
• Properties of Cellular UPVC Pipes
• Physical Properties of Cellular UPVC Pipe
• Physical Properties of Cellular UPVC Board and Profile
• Manufacturing of PVC Sheets
• Calendering
• Extrusion of PVC Sheets
• Extrusion Blowing of PVC Sheets
• Calandrette Process
• Further Processing of Sheets by Forming
• Requirements of PVC Sheets
• Roller Film Calender
• Calenders
• Blister Packaging
• Vacuum Formed Products
• Skin Packaging
• Problems and Suggested Remedies in Sheet Extrusion
• Calendered Film-Typical Problems
• Thickness Variation
• Film Curling or Side Bending
• Flatness Defects
• Blister Packaging
• Calendering of Rigid PVC Compounds
• Advantages of Calendering Process
• Blister Packaging Components
• Heat Seal Coatings
• Selection of Paperboard
• Blister Packing Vs Skin Packaging
• Blister Packaging Machinery
• Advantages of Blister Packs
• Blister Packaging Constraints
• Blister Packaging in Pharmaceutical Industry
• some Typical Applications of PVC Sheets
• Typical Blister Packaging Applications
• End Use Applications Chart
• Non Packaging Applications
• Tropicalised Blister Pack-ANew Concept
• Rigid PVC Free Foam Boards
• Areas of Application Overseas
• Advertising
• Building Sector
• Electrical Industry
• Miscellaneous
• Typical Values of PVC
• Integral Foam Sheets
• PVC Integral Foam Sheets Applications
• Characteristics
• Advantages
• Fabrication
• Major Applications
• Expanded PVC for Replacement of Wood
• Free Foaming
• Surface Treatment
• Fabrication of PVC Sheets
• Matchining
• Rigid
• Flexible
• Cutting
• Rigid
• Flexible
• Drilling
• Punching and Blanking
• Planning
• Routing and Milling
• Screwing and Tapping
• Grinding and Sanding
• Engraving
• Adhesive Bonding
• PVC to Other Materials
• PVC to itself
• Printing and Metallising
• Laminating and Plastification of Printed Master
• Welding
• Ultrasonic Welding
• High Frequency and Radio Frequency Welding
• Shaping of PVC
• Cold
• Hot
• Three Dimensional Shaping
• Simple Forming
• Injection Moulding-Rigid PVC
• Injection Blow Moulding (IBM)
• Biaxial Orientation
• High Flow Injection Moulding Applications
• Conclusions
• Typical High Flow PVC Formulation
• Blow Moulded Bottles and Containers
• Reheat Stretch Blow
• Pet vis-a-vis PVC Stretched Bottles
• PVC Heat Shrinkable Bands
• Blow Moulding of PVC Bottles
• Injection Blow Moulding
• Orientation
• Cushioned Vinyl Flooring
• Wide Choice of Different Substrates
• Prodution of Cushio Vinyl Flooring Using glass fibre
• Production using asbestos mat
• Rotary screen printing system for cushion vinyl flooring
• Screen Coating System
• Way ahead in FlexibilityVersatility in coating
• The screen coating system: Advantages
• One Pass Production
• Unique Process Improvements
• Principle of Operation
• Embossing problems a thing of the past
• Double sided Coating of Open weave Fabrics
• Single Screen Coating process
• Screen to screen coating process
• Principle of application
• PVC in Medical Applications
• Typical Medical Grade PVC Compound for Extrusion
• Moulding of PVC Footwear
• Compounding
• Moulding
• Machines
• Moulds
• PVC Uppers
• Processing
• Coatings
• Sectional View of a coating Machine
• Various types of spreader
• Rotational casting and slush moulding
• Dipping
• Injection Moulding
• Extrusion
• Graphical Sketch of a twin screw extruder
• Screw Temperature Control
• Application Principle
• Friction free Applications
• Clear, simple operation
• Two sided coating of openweaving fabrics
• Tarpaulin Coating Line
• PVC Coated Tarpaulines
• Properties of Vinylidene Chloride Copolymer Films
• Properties of VDC copolymer Films made
• From Aqueous Latices and from Solutions
• Lamination Methods
• Direct lamination in cleander of two PVC Sheets
• Lamination in calender of several sheets
• Independent Lamination and Embossing
• Laminating and Embssing Plant
• Lamination and embossing of three PVC or PVC/ABS sheets
• Embossing of wall paper coated with vinyl film
• Roller Melt Process
• Description of the Process
• Application Carrier Materials
• The Roller Melt Process is suitable for Recycling
• Processable Raw Materials
• Advantages of the Process
• Process of Plasticised PVC
• Processing of PVC Pastes
• Dipping Process
• Slush or Rotational Moulding
• Blown Films
• Moulding of PVC Footwear
• Moulding
• Flexible (Soft Plasticized) PVC Film

RECYCLING OF PVC

• Plastics Waste Management Hierarchy
• Coding as an aid to separation
• Recycling of Short Life PVC Products
• Bottles
• Separation by Hydrocyclones
• New Products from Recycled PVC Bottles
• Prospects for Chemical Recycling of PVC
• Tecoplast Bottle Plant
• Service Life of PVC Products
• Recyclable Vinyl
• PVC Bottles, Jars and Containers
• Design Considerations
• Physical Properties
• Marketing Consideration
• Safe and Recycleable
• Lower Mold Costs

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