Blow Moulding

Trends, Technology & Applications

Polypropylene & Polyethylene Polypropylene & Polyethylene

Dr U.K.SaroopReliance Industries Ltd

Parable of

Three Wise Men

Parable of Three Wise Men:The Green House Effect

other

8%

Residential

13%

Industry

18%

Transportation

20%

World energy-related CO2

emissions by sector 2004:

� The world has warmed by 0.74°C in the last century

� Will warm 0.2°C per decade

� Global temperature would increase by 3°C by the turn of this century

(Source: Financial Times / International Energy Agency )

Climate Change – sparking events, that haven't

happened in 650,000 years

18%

Power

Generation

41%

Total = 26.08 bln. mt

Parable of Three Wise Men:Zurich by Turn of the Century

Pressing the Panic Button –

Three Wise Men called for providing immediate solution

Parable of Three Wise Men:Wiseman 1: Theory of Carbon Sequestration

� Carbon Capture and Sequestration

– help ameliorate global warming

� By 2050, every year 5-10 billion

Tons of CO2 will be buried

� Saline Aquifiers – sandstone

formations evaluated for storage

High Cost and Space requirements may become limiting

factors !

� US$ 6 million project in 2004

� Compressing 3,000 tons of CO2 into a supercritical fluid

� Pumping it 1.6 km below surface into 2.3 mtr. thick sandstone layer

formations evaluated for storage

Parable of Three Wise Men:Wiseman 2: Theory of Hydrogen Fuel

• Transporting energy both in Electrical and

Chemical Form

• Two conduits - ~ 1 mtr. Dia.

• Electricity – through (red) resistance free

pipes made of super conducting materials

• Chilled Hydrogen as liquid (blue)

maintain temp. ~ absolute zero

• Simultaneously transmit

– 5 gigawatts of Electricity

– 10 gigawatts of Thermal Power

Technology development – a long way to go !!

Parable of Three Wise Men:Wiseman 3: Theory of Common Sense

….. Use

more & more more & more

Polyolefins

The question is …..

Parable of Three Wise Men:The question is ???

And the answer is ….. POLYOLEFINS

Parable of Three Wise Men: Polyolefins: Environmental Value Added (A Case)

• Avg. mid-sized car in US contains $2219 of

Chemistry (Including both Chemical Products & Processing)

• Total amount of Chemistry in Automobiles US$ 31.5 bln

• Chemical products make up ~ US$ 800 of the total value

of the car

• On an avg. contains 150 kg of Plastics (8% of total wt)• On an avg. contains 150 kg of Plastics (8% of total wt)

• Enhancing Efficiency (West Europe Case)

• Each 4.5 kg of plastics substituted improves fuel

efficiency by 0.11 to 0.14%

• Annual fuel savings of over 2.3m t – equivalent to 9.2 m t

CO2 emissions

Polyolefins – offering hygienic, environmentally safe

products

PolyolefinsPolyolefinsin Rigid Packaging

Rigid Plastic Packaging

Rigid Plastic Packaging

Injection Moulding ThermoformingBlow Molding

Pails, Closures, Boxes Bottles, Jars Disposable Cups, Glasses, Punnets

Blow MouldingBlow Moulding

Processing

Blow

Moulding

ExtrusionExtrusion

Blow Moulding – Diverse Process Technologies

Injection Stretch Injection–Stretch Blow Moulding

(EBM)

InjectionInjection

Blow Moulding

(IBM)

Injection–Stretch

Blow Moulding

(ISBM)

Commonly used Plastics are : PP, HDPE, PVC, PC, LDPE, LLDPE, EVA,

Polystyrene, HIPS, ABS, SAN, PVC & PET

P O L Y P R O P Y L E NE

Versatile Polymer : Designer’s

Choice

Global PP Demand

MMTMMTMMTMMT

5353535340404040

60606060

PP - CARG 5.4%

Source Source Source Source –––– CMAI 2006CMAI 2006CMAI 2006CMAI 2006

41414141 53535353

0000

20202020

2005200520052005 2010201020102010

PlantPlantPlantPlant LocationLocationLocationLocation TechnologyTechnologyTechnologyTechnology ProcessProcessProcessProcess CapacityCapacityCapacityCapacity

IPCLIPCLIPCLIPCL BarodaBarodaBarodaBaroda MONTEDITION, ItalyMONTEDITION, ItalyMONTEDITION, ItalyMONTEDITION, Italy Slurry Slurry Slurry Slurry –––– HYHA HYHA HYHA HYHA IPCLIPCLIPCLIPCL NagothaneNagothaneNagothaneNagothane HIMONT, ItalyHIMONT, ItalyHIMONT, ItalyHIMONT, Italy SpheripolSpheripolSpheripolSpheripol 70,00070,00070,00070,000IPCL IPCL IPCL IPCL BarodaBarodaBarodaBaroda MONTELL, ItalyMONTELL, ItalyMONTELL, ItalyMONTELL, Italy AdipolAdipolAdipolAdipol 1,00,0001,00,0001,00,0001,00,000RIL HaziraRIL HaziraRIL HaziraRIL Hazira UNIPOL, USAUNIPOL, USAUNIPOL, USAUNIPOL, USA Gas PhaseGas PhaseGas PhaseGas Phase 4,00,0004,00,0004,00,0004,00,000

PP Producers in IndiaPP Producers in IndiaPP Producers in IndiaPP Producers in India

RIL HaziraRIL HaziraRIL HaziraRIL Hazira UNIPOL, USAUNIPOL, USAUNIPOL, USAUNIPOL, USA Gas PhaseGas PhaseGas PhaseGas Phase 4,00,0004,00,0004,00,0004,00,000RILRILRILRIL JamnagarJamnagarJamnagarJamnagar UNIPOL, USAUNIPOL, USAUNIPOL, USAUNIPOL, USA Gas PhaseGas PhaseGas PhaseGas Phase 6,50,0006,50,0006,50,0006,50,000HPL HaldiaHPL HaldiaHPL HaldiaHPL Haldia MontellMontellMontellMontell SpheripolSpheripolSpheripolSpheripol 2,10,0002,10,0002,10,0002,10,000

Total 1.43 Million MTATotal 1.43 Million MTATotal 1.43 Million MTATotal 1.43 Million MTA

RIL + IPCL Contribute 85% of Total PP in India

Polypropylene …

� Lightest Commodity Plastics – Density of 0.90

� High strength : weight ratio

� Excellent moisture barrier

� Very High Filling & Service Temperature (98 deg C)

PP : Versatile Polymer……

� Very High Filling & Service Temperature (98 deg C)

� Excellent chemical , fungal resistance & ESCR

� Integral hinge property

� Autoclavable and can potentially be steam sterilized

� PP has excellent chemical resistance & ESCR Properties.

� Easily recyclable

PP - A Versatile Polymer

…With the widest Performance Envelope

Optimum impactOptimum impactOptimum impactOptimum impact----stiffness balancestiffness balancestiffness balancestiffness balance

400400400400

600600600600Izod impact at RT, J/m2Izod impact at RT, J/m2Izod impact at RT, J/m2Izod impact at RT, J/m2

Flexural modulus, MPaFlexural modulus, MPaFlexural modulus, MPaFlexural modulus, MPa0000 1000100010001000 2000200020002000

200

Polypropylene…

• Reliance Manufactures & Markets three main types of

Polypropylene under the Brand Name “REPOL”

� Homopolymers : Have high heat resistance and good rigidity,

making them suitable for a vast range of applications;

� Copolymers: which are made by incorporating different� Copolymers: which are made by incorporating different

monomers, are extremely resilient materials and have wide

uses in automotive and industrial applications.

� Random copolymers : which are made by introducing ethylene

links into the polymer chain, tend to have improved optical

properties, making them ideal for applications such as

packaging where transparency is required.

Polypropylene…..

PP – Material of Choice for Blow Moulding Apllications

� Very low density

� High stiffness

� High surface hardness

� Very good chemical resistance & ESCR� Very good chemical resistance & ESCR

� Very Good Contact clarity & gloss

� Very low water absorption & transmission

� Good resistance to high temperature

� Elastomer modified grades for low temperatures toughness

� Ideal for smaller containers

Guidelines for Processing PP : Blow Moulds

� Material of Construction :

�Mild Steel

�Aluminium

�Beryllium Copper

� Essential requirements on the mould :

� Adequate cooling, preferably along the contours of the cavity

� Cooling of thicker areas of the article like neck, top and � Cooling of thicker areas of the article like neck, top and

bottom pinch-offs

� Proper alignment of the two halves

� Typical Construction of a EBM Moulds

– Venting : air vents & sand blasted mould surface to be

provided on mould to allow air to escape

� Pinch Off Design

– Pinch off land of 1.2mm recommended for PP as compared to

2.4mm for PE.

• For blow moulding applications, PP with MFI between 1 to

3 dg/min. should be used.

• Screw with L/D>20 and compression ratio >2 should be used

• Melt temperature should be between 180 & 220°C

Guidelines for Processing PP : M/c Parameters

• Melt temperature should be between 180 & 220°C

• Adequate venting of mould is required for good container

surface finish

• Hot wire cutter should be used for parison transfer

• Adequate mould cooling for faster cycles and better clarity

� Processing Temperatures

� Feed Throat : 170 - 190°C

� Melt Temp. : 180 - 220°C

� Mould Temperatures

Guidelines for Processing PP : M/c Parameters

� Mould Temperatures

� Blow mould temps. : 20°C

� Adequate mould cooling for faster cycles and better clarity

Reliance PP Blow Moulding Grades :

Grade Type MFI

(dg/min) Special Characteristics

H020EG Homopolymer 2.0 Good rigidity and processability

R019MZ Random Copolymer 1.9 Low odour, contains clarifier1.9

SR20NSMedical Grade

Random Copolymer 1.9Suitable for I.V.Fluid

application

SR20NC Random Copolymer 1.9 Low odour, contains clarifier

SRM100NC Random Copolymer 10.0Suitable for Clarified PP_ISBM

application

C015EG /

MI 1530Impact Copolymer 1.5 High impact copolymer

Clarified Polypropylene (cPP)

Additivated Random Co-Polymer

Opportunity Knocking

India visIndia visIndia visIndia vis----àààà----vis Global Averagevis Global Averagevis Global Averagevis Global Average7.5 %7.5 %7.5 %7.5 %

cPP Consumption : as a Percentage of Total PPcPP Consumption : as a Percentage of Total PPcPP Consumption : as a Percentage of Total PPcPP Consumption : as a Percentage of Total PP

Strive to Meet Global AverageStrive to Meet Global AverageStrive to Meet Global AverageStrive to Meet Global Average3.1 %3.1 %3.1 %3.1 %

PP Random Copolymer

Incorporation of Ethylene in PP

• Chain regularity disturbed.

• Decrease in crystallinity and rate of crystallization.

• Restrict the size of crystalline aggregates.• Restrict the size of crystalline aggregates.

• Better clarity.

Use of Clarifier (Nucleation)

• Large number of crystallites having size less than wavelength of light.

• Effect : Better clarity and high stiffness.

Nucleated vs Clarified PP

Nucleators and clarifiers induce formation of smaller spherulites that scatter less light.

Inorganic Nucleators : Larger than the wavelength of light.

Sorbitol-based Clarifiers form a fibrous network within the resin that makes the

crystallites smaller than the wavelength of light.

(Source: Milliken Chemical)

Polypropylene MorphologyPolypropylene MorphologyPolypropylene MorphologyPolypropylene Morphology

Nucleated PPStandard PP

100 micronsPhotomicrographs - cross-polarized light

Characteristics of Clarified PP : Characteristics of Clarified PP : Characteristics of Clarified PP : Characteristics of Clarified PP : • Glass like transparency

• Excellent moisture barrier & Chemical resistance

• Higher continuous use ambient temperature

• Hot fill ( upto 98 Deg C), Retortable &

Microwaveable

• Excellent balance of stiffness , flexibility

• Live Hinge property

• Excellent ESCR property

• Cost effective

Clarified Polypropylene (cPP) ideally suited for Modern Life Style

Applications of cPP

• Cream

• Baby feeding bottle

Bottles and containers for :

• Mineral water

• Cough syrup

• Sterile fluid• Shampoo

• Face powder

• Tooth powder

• Ketchup

• Sterile fluid

• Syrup & Squash

• Mouthwash

• Lotion

Oral care products

Blow Moulded Applications of cPP

Food applicationsSkin care products

Oral care productsShampoo bottlesBaby Feeding Bottles

I.V.Fluid Bottles

HIGH DENSITY HIGH DENSITY

POLYETHYLENE

Polyethylenes : Characteristics

• Represents a family of resins prepared from the

polymerization of ethylene gas using a variety of

catalysts

• Density, melt index, crystallinity, degree of • Density, melt index, crystallinity, degree of

branching and cross-linking, molecular weight

and molecular weight distribution can be

regulated over wide ranges. Further modifications

are obtained by copolymerization, chlorination,

and compounding additives.

• Extrusion Temperatures :– Melt temperatures in the range of 175 - 205ºC are

recommended.

– Normally, temperatures of s190 - 205ºC will result in optimum ESCR properties.

– No premium in stress crack resistance can be expected

Processing Of HDPE

– No premium in stress crack resistance can be expected by increasing melt temperatures above 215ºC.

• Mould Temperatures :– Mould temperatures should be preferably 20ºC to

minimize cycle time. The cycle time also depends upon mould design and atmospheric conditions.

– Mould temperatures should not be too low as this would lead to mould sweating.

PE Application Portfolio

0 . 9 6 0

0 . 9 5 5

0 . 9 5 0C a p s

0 . 9 4 5

0 . 9 4 0

0 . 9 3 5

<-----------------D

en

sity

IM ( In d u s t r i a l &

H o u s e h o l d )H M F & H M B M

G P B M ( P e s t i c i d e ,

C o s m e t i c s , L u b e &

E d i b l e o i l

c o n t a i n e r )

R a ff i a &

M F

H M P i p e s

W & C

0 . 9 3 5

0 . 9 3 0

0 . 9 2 5

0 . 9 2 0

0 . 9 1 5

0 . 9 1 0

0 . 0 1 0 . 1 0 . 3 0 . 5 1 3 1 0 2 0 3 0 5 0

M e l t F l o w I n d e x - - - - - - - - >

I M & M B

B l o w n F i l m ( G P ,

M i l k & L a m i n a t i o n

) & D r i p l a t e r a l s

C a s t

F i lmE C

<-----------------D

en

sity

R M

Applications of HDPE

• Edible oil

• Chemicals

• Petro Products (Lube Oil)

• Pharmaceuticals

• Pesticides

• Cosmetics

• Toys

• Automotive Parts (Arm rest, windshield

washer bottle)

Applications Of Polyethylene

Milk BottlesEdible Oil Containers

Lube Oil Containers

Bottles

Pesticide Containers

HDPE Blow Moulding Grades

Grade MFI Density Special Characteristics Typical Applications

Indothene

54GB012

1.2

(I5)0.954

Bimodal MWD, Good flow

and ESCR.

Small vol. Containers and GP

containers preferably upto 5 L

Indothene

52GB010

1.0

(I5)0.950

Broad MWD, Very good

swell and impact

5-30L containers for lube oil,

edible oil, adhesives etc.

Relene

B560030.3 0.956

Good melt strength and

rigidity

General purpose containers,

jerry cans (Upto 15L)B560030.3 0.956

rigidity jerry cans (Upto 15L)

Relene

TB50004

0.45

(I5)

0.952Good melt strength,

Swell and ESCR

Medium volume containers,

liners, sheets, air ducts etc.

Indothene

52GB003

0.45

(I5)0.952

Good melt strength and

swell, impact - stiffness

balance

Medium volume containers,

liners, sheets, air ducts etc.

Indothene

52GB001

0.40

(I5)0.952

Broad MWD, good swell,

melt strength & Impact

strengh

Large containers, L-ring drums,

liners & barrels upto 240L

RIL PartnershipRIL Partnership

Role of Business Development Group

� Evolution of conceptEvolution of conceptEvolution of conceptEvolution of concept

� Explore / Identify new marketExplore / Identify new marketExplore / Identify new marketExplore / Identify new market

� Identify Modern technologyIdentify Modern technologyIdentify Modern technologyIdentify Modern technology

� Identify Entrepreneur / InvestorIdentify Entrepreneur / InvestorIdentify Entrepreneur / InvestorIdentify Entrepreneur / Investor

� Downstream developmentDownstream developmentDownstream developmentDownstream development

� Nurturing new application / Promotion / Market extensionNurturing new application / Promotion / Market extensionNurturing new application / Promotion / Market extensionNurturing new application / Promotion / Market extension

� Securing Approvals From Testing Agencies & EndSecuring Approvals From Testing Agencies & EndSecuring Approvals From Testing Agencies & EndSecuring Approvals From Testing Agencies & End----useruseruseruser

� Regulations / Mandation for driving GrowthRegulations / Mandation for driving GrowthRegulations / Mandation for driving GrowthRegulations / Mandation for driving Growth

• Bulk Packaging

• Rigid Packaging

• Flexible Packaging

• Automobiles

Sector Management

• Lifestyle & Appliances

• Textiles & Fibers

• Pipe & Profiles

• Downstream Development

Concept to Commercialisation

Machinery Manufacturers

Machinery Manufacturers

A Vital link amongstA Vital link amongstA Vital link amongstA Vital link amongstM/c Mfg. M/c Mfg. M/c Mfg. M/c Mfg. ---- Business Business Business Business ---- Converter Converter Converter Converter ---- End UserEnd UserEnd UserEnd User

Extensive support fromExtensive support fromExtensive support fromExtensive support from• PAT PAT PAT PAT –––– Technical SupportTechnical SupportTechnical SupportTechnical SupportExtensive support fromExtensive support fromExtensive support fromExtensive support from• PAT PAT PAT PAT –––– Technical SupportTechnical SupportTechnical SupportTechnical Support

End Users ProcessorsProcessors

BD• Nodal AgenciesNodal AgenciesNodal AgenciesNodal Agencies• Govt. Agencies Govt. Agencies Govt. Agencies Govt. Agencies –––– for Spec infor Spec infor Spec infor Spec in• Nodal AgenciesNodal AgenciesNodal AgenciesNodal Agencies• Govt. Agencies Govt. Agencies Govt. Agencies Govt. Agencies –––– for Spec infor Spec infor Spec infor Spec in

Concept to Commercialisation

• Between business enterprises and their vendors

• Converting basic needs into commercially viable technology

• Helping produce useful products

We believe in Building Strategic RelationshipsWe believe in Building Strategic RelationshipsWe believe in Building Strategic RelationshipsWe believe in Building Strategic Relationships

Research Research Research Research InstitutionsInstitutionsInstitutionsInstitutions

Polymer Polymer Polymer Polymer ProcessorsProcessorsProcessorsProcessors

End UsersEnd UsersEnd UsersEnd Users Machinery Machinery Machinery Machinery ManufacturersManufacturersManufacturersManufacturers

Business Business Business Business DevelopmentDevelopmentDevelopmentDevelopment

In short…...

RILRILRILRIL

Mould Maker & M/c MfrsMould Maker & M/c MfrsMould Maker & M/c MfrsMould Maker & M/c Mfrs

Existing Customers Existing Customers Existing Customers Existing Customers

New Entrepreneur New Entrepreneur New Entrepreneur New Entrepreneur

State Ind. Dev. Corp. State Ind. Dev. Corp. State Ind. Dev. Corp. State Ind. Dev. Corp.

• Concept MarketingConcept MarketingConcept MarketingConcept Marketing• Product IdentificationProduct IdentificationProduct IdentificationProduct Identification• Market SurveyMarket SurveyMarket SurveyMarket Survey• Feasibility StudiesFeasibility StudiesFeasibility StudiesFeasibility Studies• DevelopmentDevelopmentDevelopmentDevelopment• ImplementationImplementationImplementationImplementationState Ind. Dev. Corp. State Ind. Dev. Corp. State Ind. Dev. Corp. State Ind. Dev. Corp.

OEM / End Users OEM / End Users OEM / End Users OEM / End Users

Standard / Specs. Standard / Specs. Standard / Specs. Standard / Specs.

• ImplementationImplementationImplementationImplementation• Supply chainSupply chainSupply chainSupply chain• Nurturing new DevpNurturing new DevpNurturing new DevpNurturing new Devp

360°°°° Support - Complete package of Value Added Services

to Customers & Entrepreneurs