Advances in chemistry improve film recyclability, precision of automotive parts and even asphalt
By Geoff Giordano
From flexible and rigid packaging to mobility and roads, the boundaries of ethylene polymers are poised to expand and create more sustainable options for everyday uses, according to Dow research presented at ANTEC® 2021 on May 6.
Jian Wang, research scientist for packaging and specialty plastics, illustrated the competitive advantages of machine direction orientation (MDO) technology for PE films. The goal: replace non-recyclable films featuring many layers with simplified films tailored to circular economy goals while retaining package performance.
Tenter frame production systems and MDO blown, printed PE webs enable single-material packaging, Wang explained, with film being stretched four to five times original length. PE alone can be made to deliver performance—high gloss, clarity, stiffness and heat resistance with sufficient barrier protection—and recyclability.
Furthermore, “blocked” MDO films improve manufacturing ease, while “unblocked” MDO films emphasize end-use functionality, resulting in robust and recyclable standup pouches. Blocked films feature three layers, with HDPE in the outer layer, MDPE or HDPE in the core for stiffness, and a final layer of LDPE. Putting this film through the MDO loader results in a single layer of stretched film. Unblocked MDO films feature HDPE outer layers, two inner layers of MDPE or HDPE for stiffness and optical properties, and a core of LLDPE for toughness and clarity.
Recyclable standup pouches can be achieved with PE alone in tenter frame or blown film lines. The pouch at left is a laminate of tenter frame biaxially oriented PE and PE, with no shrinkage. The pouch on the right uses PE with MDO. Both pouches are fully recyclable. Courtesy of Dow
For rigid packaging, Wang noted that consumer expectations, including the rigors of e-commerce, have resulted in an innovative PE closure resin called Evercap that can replace PP and satisfy the desire for mono-material packaging. This Dow resin approaches the same shrinkage performance as PP. And, in a six-foot drop test at 40°F, a PE closure on a 34-ounce ketchup bottle dramatically outperformed a PP enclosure, which was devastated by the fall.
Fabricio Arteaga Larios, application development leader for packaging and specialty plastics, discussed non-packaging applications of ethylene polymers. In automotive, metal replacement with TPOs featuring unique molecular architecture pays off in many ways, from weight and battery size reductions to dent resistance and design freedom, as well as tooling cost reductions, need for fewer parts and smaller plant footprints. The result: models made in quantities of less than 100,000 become economically viable, and vehicles last longer.
At least one innovative polymer architecture, Infuse resin, “pushes the boundaries between melt temperature and glass transition temperature” in comparison with traditional polyolefin elastomers. A notable opportunity for such resins is the ability to maintain a proper gap between fender and door panels under various temperature conditions.
Lastly, recycled plastics can be locked into asphalt to prevent cracking and fatigue, again increasing performance, particularly in extreme climates, while achieving carbon neutrality goals. And, the use of reactive modifiers and post-consumer resins can reduce the thickness of asphalt roads, saving significant construction costs.
“This is a clear example where a plastics waste stream can bring value to a final application,” Arteaga concluded.
View on demand: Dow’s presentation “Expanding the Boundaries of Ethylene Polymers for More Sustainable Solutions,” will be available on demand to ANTEC® attendees and those who register for access after the conference.
Kim McLoughlin Senior Research Engineer, Global Materials Science Braskem
A Resin Supplier’s Perspective on Partnerships for the Circular Economy
About the Speaker
Kim drives technology programs at Braskem to develop advanced polyolefins with improved recyclability and sustainability. As Principal Investigator on a REMADE-funded collaboration, Kim leads a diverse industry-academic team that is developing a process to recycle elastomers as secondary feedstock. Kim has a PhD in Chemical Engineering from Cornell. She is an inventor on more than 25 patents and applications for novel polyolefin technologies. Kim is on the Board of Directors of SPE’s Thermoplastic Materials & Foams Division, where she has served as Education Chair and Councilor.
A Resin Supplier’s Perspective on Partnerships for the Circular Economy
About the Speaker
Gamini has a BS and PhD from Purdue University in Materials Engineering and Sustainability. He joined Penn State as a Post Doctorate Scholar in 2020 prior to his professorship appointment. He works closely with PA plastics manufacturers to implement sustainability programs in their plants.
A Resin Supplier’s Perspective on Partnerships for the Circular Economy
About the Speaker
Tom Giovannetti holds a Degree in Mechanical Engineering from The University of Tulsa and for the last 26 years has worked for Chevron Phillips Chemical Company. Tom started his plastics career by designing various injection molded products for the chemical industry including explosion proof plugs and receptacles, panel boards and detonation arrestors for 24 inch pipelines. Tom also holds a patent for design of a polyphenylene sulfide sleeve in a nylon coolant cross-over of an air intake manifold and is a Certified Plastic Technologist through the Society of Plastic Engineers. Tom serves on the Oklahoma Section Board as Councilor, is also the past president of the local Oklahoma SPE Section, and as well serves on the SPE Injection Molding Division board.
Joseph Lawrence, Ph.D. Senior Director and Research Professor University of Toledo
A Resin Supplier’s Perspective on Partnerships for the Circular Economy
About the Speaker
Dr. Joseph Lawrence is a Research Professor and Senior Director of the Polymer Institute and the Center for Materials and Sensor Characterization at the University of Toledo. He is a Chemical Engineer by training and after working in the process industry, he has been engaged in polymers and composites research for 18+ years. In the Polymer Institute he leads research on renewably sourced polymers, plastics recycling, and additive manufacturing. He is also the lead investigator of the Polyesters and Barrier Materials Research Consortium funded by industry. Dr. Lawrence has advised 20 graduate students, mentored 8 staff scientists and several undergraduate students. He is a peer reviewer in several journals, has authored 30+ peer-reviewed publications and serves on the board of the Injection Molding Division of SPE.
Matt Hammernik Northeast Account Manager Hasco America
A Resin Supplier’s Perspective on Partnerships for the Circular Economy
About the Speaker
Matt Hammernik serves as Hasco America’s Northeast Area Account Manager covering the states Michigan, Ohio, Indiana, and Kentucky. He started with Hasco America at the beginning of March 2022. Matt started in the Injection Mold Industry roughly 10 years ago as an estimator quoting injection mold base steel, components and machining. He advanced into outside sales and has been serving molders, mold builders and mold makers for about 7 years.
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