Eastman Provista™ copolymers
Extrusion of tubes and profiles
Contents
Eastman Provista™ copolymers—Extrusion of tubes and profiles 1
Applications 1
Description 1
Drying 1
Typeofdryer 2
Extruder 3
Figure1—Typicalextruder 3
Screwdesign 4
Extrudertemperatureprofile 4
Pipeandtubingdiedesign 5
Figure2—Typicaloffsetdie 5
Figure3—Typicalstraight-throughpipedie 5
Figure4—Diedesignforthin-walltubing 6
Drawdown 6
Vacuumsizing 7
Figure5—Tubingextrusionlineusingvacuumsizing 7
Sizingandquenching 7
Cutting 8
Figure6—Hot-airovenforimprovedcutting 8
Regrind 8
Purging 9
Regulatoryinformation 9
ApplicationsEastmanProvista™copolymerscombinesparkling
claritywithexcellenttoughnessandchemicalresistance,
makingthemappropriateforavarietyofapplications
ShapesandprofilesextrudedfromProvistacopolymers
exhibitexcellenttransparence,clarity,andphysical
propertiesappropriateforpricingchannels,signage,trim,
POPstructures,electronicpackaging,tubes,medical,and
variousotherapplications
TheprocessingcharacteristicsofEastmanProvista™
copolymersaresimilartothoseofmanyother
thermoplastics Inaddition,Provistacopolymersgive
highmeltstrength,thusenhancingtheirprocessibility
intheextrusionofprofiles
DescriptionEastmanProvista™copolymersareclear,amorphous
polymersthatareglycol-modifiedpoly(ethylene
terephthalate) Themodificationismadebyaddinga
secondglycol,cyclohexanedimethanol(CHDM),during
thepolymerizationstages Thesecondglycolisaddedin
theproperproportiontoproduceanamorphouspolymer
Additionalmodificationhasbeendonetoincreasethe
meltstrengthofthepolymer
EastmanProvista™copolymerswillnotcrystallizeand
thusofferwiderprocessinglatitudethanconventional
crystallizablepolyesters Plasticizersorstabilizersarenot
requiredinthispolymer
DryingForsuccessfulextrusionofEastmanProvista™copolymers,
drythepelletsbeforeprocessing Itissuggestedthatdryair
beusedtotransferpelletstoeliminateairleakagefromor
intotheclosedloopdryersystem
Asinthecaseofallthermoplasticpolyesters,Eastman
Provista™copolymersaresubjecttohydrolysiswhenthey
areinthemoltenstateduringprocessing Thishydrolysis
resultsinadecreaseinmolecularweightthatisreflected
byaloweringofphysicalproperties,especiallytoughness
Topreventhydrolysisduringtheextrusionprocess,Provista
copolymersmustbethoroughlydried Themoisturelevel
shouldbe0 04%orless
Dryingthematerialinadehumidifyingdryerata
temperatureof65°C(150°F)toreducethemoisture
contenttoalevel(0 04%maximum)thatwillprevent
significanthydrolysisinprocessingequipmentoperating
at195°–275°C(380°–525°F) Normally4hoursdrying
timeissufficient;however,extendeddryingtimesmaybe
requiredinhumidareasorwhenusingless-than-optimal
dryingequipment Dryertemperatureshouldnotexceed
65°C(150°F)topreventpelletsfromsofteningandsticking
togetherinthehopper
Eastman Provista™ copolymers Extrusion of tubes and profiles
1
Type of dryerThemostpracticalproductionsystemfordryingpellets
isahopperdryer Moderndryersuseamolecularsieve
desiccantmaterialinsmallbeadform Thedesiccantis
placedinthereturnair(orintake)streamofthedryerin
2ormorebedsorcanisters Onebedisonstreamremoving
moisturefromthereturnprocessairwhilethesecondbed
isbeingregenerated(dried)athightemperaturesby
secondaryheaters Severalcompaniessupplydryersto
theplasticsindustry
Itisimportantthatthedryerhavethecorrectdesign
requirementsfortheplasticmaterialbeingprocessed
EastmanProvista™copolymersshouldbedriedata
maximumtemperatureof65°C(150°F) Careshouldbe
takentoobtainadryerthatcanbeaccuratelycontrolled
todeliverairatthattemperatureassomedryerstendto
cycleuncontrollablyhotter Aninlettemperaturegauge
isausefuladditiontothedryinghopper
Dryairprovidessignificantlymoreefficientdryingthan
ambientair,particularlyduringhumidsummermonths
Consequently,adesiccant-typedryerisrequired Thistype
ofdryerprovidesdryingairwithadewpointof–40°C
(–40°F)orlower Dewpointisanabsolutemeasureofair
moistureandisindependentofairtemperature Dewpoint,
notrelativehumidity,shouldalwaysbespecifiedregarding
airdryness Itisworththesmalladditionalcostto
incorporateadewpointmonitor,whichisanoption
availableonmoderndryers
Thedryinghoppershouldbelargeenoughtoallow
adequatedryingtimeforthepellets Forexample,ifthe
typicalthroughputoftheextruderis45kg(100lb)per
hour,a278-kg(600-lb)capacityhopperisusedfora6-hour
dryingtime Agooddryinghopperhasascreenandcone
systeminthebottomtoassureuniformairflowthrough
thepelletbed Itisalsodesignedtoprovideanevenflow
ofpelletsfromtoptobottom(plugflow)aswellasan
air-lockloadingsystem Insulatedhoppersshouldbeused
tomaintainthepelletbedattheinletairtemperature
Vacuumloadersshouldbeusedtofeedtheregrindand
pelletsfromtheloader/blendertothedryinghopperand
thentotheextruderhopper Anotherapproachistousea
centraldryer/blendersystemtoserveseveralextruders
Thematerialfromacentralsystemcanbetransferred
automaticallytothehoppersofseveralmachinesorthe
driedmaterialmaybeloadedintocleandrumsandmoved
toindividualmachines
Dryersarespecifiedaccordingtotheirblowercapacityin
cubicmeters(m3)(cubicfeet[ft3])perminute(m3/min
[cfm])ofairdelivery Agooddryerdesigncriterionallows
0 062(m3/min)/kg/h(1 0cfmperlb/h)ofmaterialtobe
extruded Forexample,if45kg/h(100lb/h)ofmaterialis
tobeextruded,aminimumblowercapacityof2 8m3/min
(100cfm)isused Adryerwithablowercapacityof
2 8m3/min(100cfm)shouldbeconsideredthesmallest
sizeforanyuser Smallercapacitydryersshouldnotbe
usedbecausetheymaynotprovidesufficientairflowto
preventexcessiveheatlosses
Dryerrequirementscanbesummarizedas
•Typeofdryer:automatic,desiccant
•Airdryness:dewpointof–40°C(–40°F)orlower
•Airtemperature:maximum65°C(150°F)atthe
hopperinlet
•Circulation:0 062(m3/min)/kg/h(1 0cfmperlb/h)
ofplastictobedriedandnotlessthan2 8m3/min
(100ft3/min)perunit
•Monitors:(a)hopperinletthermometer,(b)dew
pointmonitor
•Hoppersize:6–10timesthehourlypoundagetobe
dried(Hold-upcapacitydependsonaverageincoming
pelletmoisturecontent )
•Hoppershape:forgoodairandpelletflow,atall,
slenderhoppershouldbeusedversusashort,large
diameterdesign
2
ExtruderEastmanProvista™copolymersrequirethesamefeeding,
melting,compression,andmeteringprocessesasthose
requiredbyotherthermoplastics Thescrewattheentry
point(Zone1)shouldbeheatedtoatleast165°C(329°F)
Caremustbetakentopreventoverheatinginthefeedzone
becauseprematuremeltingandscrew“roping”mayoccur
Feedthroatcoolingisrecommended,andoccasionally,
internalscrewcoolingofthefirst3or4flightsmaybe
necessary Asthepelletsareconveyeddowntheextruder
barrelbythescrew,additionalheatingandcompression
occurfollowedbyameteringzone Atypicalextruderis
showninFigure1
Itissuggestedthatanextruderbeselectedwithalength-
to-diameterratioofatleast24:1
Sincethediameteroftheextruderbarreldeterminesthe
availableheatingareaandmaterialoutputoftheextruder,
largemachinesupto6 35cm(2 5in )aretypicallyusedin
productionsituations
Anominalscreenpackisusedwhenextrudingshapesand
profilesfromEastmanProvista™copolymers;i e ,one
40-mesh,one60-mesh,andone80-meshscreen Theuse
ofafinermesh,denserscreenpackcanincreasethemelt
temperaturerangeabovethatsuggestedforthematerial
unlessanadditionalfilterareaisused
3
Temperature control panelfor extruder and die
Bimetallic steelcylinder (barrel)
Electrical outletsfor die heatersand accessories
Resistance heatersin aluminum housing(air cooling preferred)
Breakerplate andscreens
Insulatedhousing
Reductiongears
Screw cooling
Dry airinlet
Dry air
Dry air at 65ºC (150ºF)
Throat cooling
Feed screw
Drive motor
Airflow
Airflow control screen
Electrical air heaterHopper
Figure1—Typicalextruder
Screw designEastmanProvista™copolymerscanbesuccessfully
extrudedbyusingeitherasingle-stagesquarepitchor
barrierscrewdesign
Forexample,experimentalworkonprofileandtubing
extrusionsinEastman’slaboratoryhasbeendoneona
6 35-cm(2 5-in )extruderwitha24:1L/Dratiousing
thefollowingbarrierscrewdesign
•5feedflights12 2-mm(0 480-in )deep
•4transitionflights
•13 5meteringflights2 5-mm(0 098-in )deep
•Anoverallcompressionratioof2 5:1
Note:The term “overall compression ratio” only applies to
a barrier screw and is calculated using the metering and feed
zone flight depths. In reality, the true compression ratio is
unknown due to the variable degree of compression the melt
experiences throughout the barrier section.
Whiletheuseofanexistingscrewmaybepossible,
thedegreeofsuccessdependsontherequiredmelt
temperature,outputrate,andproductquality Surging,
poorhomogenization,excessiveloadonthedrivemotor,
andextrudatevoidsmaybecausedbyscrewswith
excessivelyhighcompressionratios,excessivelydeepfeed
zones,orpossiblytoomanytransitionflights Limited
evaluationsmayoftenbeconductedunderless-than-
optimumconditionsbyusinginternalscrewcooling,
reversetemperatureprofiles,orstarve–feeding
Extruder temperature profileMaintaining clarityThefollowingrelationshipsmustbeconsideredwhen
determininganoptimumtemperatureprofileforEastman
Provista™copolymers
•Increaseprocessingtemperaturesasthroughputis
increased
•Higherprocessingtemperaturesmaybenecessaryto
preventmeltfracture
•Thinnerpartwallthicknesseswillrequirehigher
processingtemperatures
Atypicaltemperatureprofileforthegivendiedimensions
andthroughputisprovidedasastartingpoint Adjustments
mightbenecessaryinspecificinstancestoconformtothe
precedingcriteria 1
Extruder:6 35cm(2 5in ),24:1L/D,3barrelzones,
1clamp,1diezone
Zone 1:205°C(400°F)
Zone 2:210°C(410°F)
Zone 3: 216°C(420°F)
Clamp:235°C(455°F)
Die:235°C(455°F)
Melt temperature (taken at the die): 230°C(445°F)
Die land length: 10mm(0 400in )
Die opening thickness: 2mm(0 080in )
Throughput:20kg/h(45lb/h)
1Temperatures shown in the example of a typical temperature profile may vary somewhat in other similar applications.
4
Pipe and tubing die designThediechannelsthemoltenmaterialintoatubular
profile Figure2showsatypicaloffsetdiedesign,and
Figure3showsastraightdiedesignforextrudingtubing
Theoutermostportionofthedieordiebodyholdsthe
dieringsinplace Theoutsidesurfaceofthetubingis
formedbytheinsidesurfaceoftheoutsidediering;
theinsidediering(sometimesreferredtoasthediepin)
shapestheinsidesurfaceofthetubing Dieringsurfaces
thatcontacttheplasticshouldbesmoothtoimpart
smoothsurfacestotheextrudedproduct
Arestrictionintheflowchannelisnecessarytomaintain
goodcontrolofmaterialflowthroughthedie The
restrictioninthe2diedesignsshowninFigures2and3
consistsofaraisedportionontheinsidedieringthat
reducestheflowchannelinthatareato0 40–0 75mm
(0 015–0 030in )forextrudingtubingwithwallthicknesses
of0 25–3 8mm(0 010–0 150in ) Forwallthicknesses
greaterthan3 8mm(0 150in ),therestrictedopeningis
usuallyaround1 5mm(0 060in )
5
Outside ringadjustment screws
Flow restriction
Die bodyBand heaterInside die pin
Outside die ring
Material entrance
Band heaters
Flow streamlining ring
Inside ring support
Hole for start-up orother applications
Figure2—Typicaloffsetdie
Die body
Air supplyfor start-up
Ring adjustment screws
Outside die ring
Inside die pin
Retainer ring
Flow restriction
Spider(materialdirection)
Figure3—Typicalstraight-throughpipedie
Thatportionofthedieflowchannelimmediately
followingtherestrictionisreferredtoastheland For
extrudingtubingfromEastmanProvista™copolymers,the
recommendedratiofordielandlengthtowallthickness
is10:1withadrawdownratioof1 5:1(somewhatlessis
acceptablefortubingbelow25mm[1in ]indiameter)
Intheextrusionofthin-walltubing,itmaybenecessary
tochangetheratiofordrawdownand/orlandlength-
to-wallthickness Theinsidedieringcanbeundercut,as
showninFigure4,toprovidechangestothelandlength
Theundercutareamakesavailablealargevolume,or
reservoir,ofmaterialandprovidesuniformflowofmaterial
tothedieexit
Wallthicknessuniformitycanbeachievedbymoving
theoutsidedieringwiththeadjustingscrewsshownin
Figure4ontheoutsideofthediebody
DrawdownDrawdownistheratioofthesizeoftheextrudateasit
leavesthedietothesizeofthefinishedproduct
Asmentionedbefore,thedrawdownallowanceusedinthe
extrusionoftubingfromEastmanProvista™copolymersis
about1 5:1,whichmeanstheoutsidediameterofthedie
orificeis1 5timesthediameterofthesizingplateentrance
Thethicknessdrawdown,however,hasbeenshownto
beapproximately½theoveralldrawdownratio Ifthis
turnsouttobelessthanneeded,openthewallthickness
asnecessary
Thedrawdownratioisnotaprecisefigure Reworking
thedieopeningisoftennecessarybeforeproductionquality
partscanbemadeconsistently Itisimportanttoremember
thattoomuchdrawdownshouldbeavoided,asitcancause
excessiveinternalstrainsinthefinishedproducts
ProfilesofEastmanProvista™copolymersotherthan
tubingalsorequiresimilardrawdown Whenextrudinga
nonsymmetricalshape,problemsmaybeencounteredin
producingthedesiredwidth-to-thicknessratiobecause
ofthedistortionencountered Simpleprofiles,suchas
T-edging,angle,orchannelsections,maybeproduced
withoutsignificantproblems However,heavysections
withrandomlyspacedprojectionsmaycausedifficulty
Therefore,itissuggestedthatprofilesbedesignedwith
uniformthicknesseswherepossible
6
Outside ring adjustment screws
Short land length
Outside die ringFlow restriction
Material entrance
Expander ring
Die body
Band heater
Inside die pin(undercut)
Figure4—Diedesignforthin-walltubing
Vacuum sizingProbablythemostcommonlyusedmethodofsizingplastic
tubingandpipeisvacuumsizing Invacuumsizing,the
extrudateiscooledinawaterbaththatisundervacuum
Thevacuumchamber,usuallycalledthevacuumbox,isa
longwaterbathwithanairtightlid Themoltenextrudate
formsthesealaroundthesizingplateorsleeveatthe
entrancetothevacuumbox,andarubbergasketthatfits
aroundthecooledpipeortubeformsthesealattheexit
Figure5showsatypicalextrusionlineutilizingthevacuum
boxmethodofsizing Thereareseveralsuppliersof
vacuum-sizingequipment
Sizing and quenchingWhenvacuumboxsizingisusedtoextrudetubingand
hollowprofilesfromEastmanProvista™copolymers,the
sizingdeviceshouldbefabricatedfromthin(1 0–1 3-mm
[0 04–0 05-in ]thick)brass,bronze,orstainlesssteelhaving
aninteriorfinishofabout25rms Thelengthofthesizing
sleeveshouldbeapproximately1to1 25timesthe
diameterofthedesiredfinishedprofile Aforward-spraying,
cooling-waterringshouldbelocatedaroundthesleeveand
shouldbecapableofimpingingwateratthejunctureofthe
sleeveandvacuumbox Someextrudatelubricationsuchas
adetergent/watermixtureishelpfulduringstart-upbutis
usuallynotrequiredoncetheprocessisfullyoperational
Chilledwater(5°–10°C[45°–50°F])willallowmore
efficientcoolingofthetubingorprofilewithlessagitation;
however,20°–25°C(65°–75°F)waterworkssatisfactorily
withaproperlylocatedsprayring
Thevacuuminthevacuumboxshouldbesufficientto
achieveproperdimensioningyetlowenoughtoprevent
dragandchattermarksfromformingontheextrudate
Atypicalvacuumlevelforsizing25-mm(1-in )diameter
tubingwitha0 38-mm(0 015-in )thickwallwouldbe
380–510mm(15–20in )ofwater(vacuum)
EastmanProvista™copolymersexhibitgoodmeltstrength,
whichallowsonetorunonanairtablesizingsystem
However,water-cooledsizingblocksand/orplateshave
beenusedsuccessfullywithmuchgreaterthroughput
TubingandprofilesofEastmanProvista™copolymersare
usuallycooledadequatelyforcutofforsawingwhen
exitingthevacuumboxorplate-sizingtank Ifthefinished
partshrinksordistortsasitleavesthecoolingtank,itwill
probablybenecessarytoinsertanextracoolingtankprior
topullout
From air dryer—dehumidified
Sizing plate or sleeveWater-cooling bath
Water spray rings
Vacuum gauge
Rubber gasket
Floor line
Recirculating water pump
Water reservoir
Extruder
Die
Hopper (pelletmaterial supply)
Vacuum-sizingchamber
Pulloutassembly
Reheatstation
Cuttingunit
Tohandling
operations
Water venturivacuum jet orvacuum pump
Rack and spurgear positioning
adjustment
Figure5—Tubingextrusionlineusingvacuumsizing
7
CuttingProfilesandtubingextrudedfromEastmanProvista™
copolymersusuallyrequireclosecontrolwithrespectto
cuttingandsawing Theratherrigid,unplasticizedmaterial
mayshowatendencytosplit,shatter,orpossiblyleave
chipsandfragmentsattachedtotheseverededge
Acombinationofpartreheatingandcutter-blade
lubricationcansignificantlyimprovethequalityofthe
cut Reheatingthepartmaybeaccomplishedwitheither
heatedwaterorair Waterheatingcanbeaccomplished
withimmersionheaters Temperaturesofapproximately
50°C(120°F)notonlyhelpprovideacleanercutbutcan
alsohelpreducestresses,whichcausebowingofthe
extrudedpart
Heatingwithhotairjustpriortocuttingcanbedone
simplybyahot-airovenorahot-airgunasshownin
Figure6 Moreelaborateoven-typesetupsmightinclude
ceramicorUVheatersinplaceofthechannelinFigure6
Amarkedimprovementinchipandfragmentelimination
hasbeenaccomplishedbyusingalubricatingdeviceinthe
cuttingmandrel Anatomizedwatergeneratorwasevaluated
inEastman’slaboratoryforsprayingalightatomizedmist
ofwater,waterplussilicone,andwaterplusliquiddetergent
intothecutter Wateralonewasfoundtobeaseffectiveas
theother2coolantsandlesstroublesometouse
Cuttingproblemsmayvaryamongdifferentsection
thicknesses,linespeeds,andprofiles However,itmaybe
safelyassumedthatEastmanProvista™copolymerwill
usuallyrequirespecialconsiderationswhencutting
RegrindTheexcellentthermalstabilityofEastmanProvista™
copolymerspermitsreuseofcleanregrind However,care
mustbetakentopreventcontaminationoftheregrindby
otherplasticsinthescrap-handlingequipment Otherwise,
clarityandtoughnessofextrudeditemscouldbereduced
Degradedpurgingcompoundsshouldbediscardedand
notreused
Cut partsCutter
Puller
Hot-air gunHeat-resistanttubing
Profile or tube
Channel iron
Figure6—Hot-airovenforimprovedcutting
8
PurgingPurgetheextruderwitheitherEastmanProvista™
copolymersorEastar™copolyester6763 Inmostcases,
theextrudercanbeshutdownwithProvistacopolymers
onthescrew Aninertgas,e g ,drynitrogengas,should
beappliedonthepellethopperandventareastohelp
preventoxidativedegradationofthemoltenpolymer
duringheat-upand/orcool-downperiods
Cellulosicmaterialscanbeusedtopurgetheextruder
priortoscrewremoval
Therewillbesituationswhereitisnecessarytogoto
greaterlengthstoensureacompletelycleanextrudate
Thesesituationsmightinclude
•TransitioningfromanotherplastictoEastmanProvista™
copolymers
•Occasionalblackflakesandspecsintheextrudate
causedbysittingidleforlongperiodsoftimeat
elevatedtemperatures
•Changingtoadiethatcontainscharand/oroldextrudate
fromapreviousrun
UndriedEastmanProvista™copolymersorothercopolyesters
shouldbeusedatabarrelanddietemperatureslightly
abovetheprocessingtemperatureofthematerialthatis
tobepurged Runthescrewcompletelyempty,theninput
additional“wet”polymer Runtheextruderatvariable
speedstohelpdislodgeforeignmaterials Repeatthisuntil
theextrudateisclearofanyresidualpolymer Themoisture
inthepelletswillprovidea“steam-cleaning”effect
Diesthathavenotbeenstreamlinedareverydifficult
topurgebecauseofthe“deadspots”commonlyfound
insuchdies Thesewillusuallyhavetoberemovedand
cleanedmanually
Itisnotrecommendedthatpurgingcompoundsofany
kindbeusedtocleananextruderthathasbeenrunning
EastmanProvista™copolymers
Regulatory informationUnderregulationsadministeredbytheU S FoodandDrug
Administration(FDA),EastmanProvista™copolymersmay
lawfullybeusedasarticlesorcomponentsofarticles
intendedforuseincontactwithfoodsubjecttoprovisions
of21CFR177 1315and21CFR174 Provistacopolymers,
assuppliedbyEastman,complywiththecompositionaland
inherentviscosityrequirementsofFDAregulationsat21
CFR177 1315(b)(1) Thespecificationsof21CFR
177 1315(b)(1)clearthefollowingconditionsofusefor
nonorientedcopolymers:hot-filltemperaturesnotto
exceed82 2°C(180°F)forcontactwithfoodsincluding
foodscontainingupto25%aqueousalcoholbyvolume,
excludingcarbonatedbeveragesandbeer;storage
temperaturesnottoexceed48 9°C(120°F);andnothermal
treatmentincontainer Compliancetestsperformedby
EastmanonnonorientedfilmmadebyEastmanfrom
polymersamplesrepresentativeofthisproductmetthe
requirementsof21CFR177 1315(b)(1)forfood,including
upto15%ethanolbyvolume Fromtheseresults,we
expectthatothernonorientedarticlesmadefromour
product,undergoodmanufacturingpracticesandaccording
toourrecommendations,willmeetthecompliance
requirementsoftheregulationincludingupto15%
ethanol Dependingonyourprocessesandproducts,itmay
bepossibleforyourproductstomeetthecompliance
requirementsforupto25%ethanol
EastmanProvista™copolymersmeetISO10993and/orUSP
ClassVIrequirements
EastmanProvista™copolymersarelawfulforuseinmeat
andpoultrypackagingoperationssolongasthesupplier
ofthepackagingproduct,suchasfilmorotherfinished
packagingmaterial,complieswithUSDAregulations
at9CFR317 24or381 144
UsersofEastmanProvista™copolymersmustmaketheir
owndeterminationthattheiruseofthematerialissafe,
lawful,andtechnicallysuitablefortheirintendedapplications
9
Conversions of metric/U.S. customary values may have
been rounded off and may not be exact conversions.
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www.eastman.com
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that should be observed when handling and storing Eastman
products are available online or by request. You should obtain
and review the available material safety information before
handling any of these products. If any materials mentioned
are not Eastman products, appropriate industrial hygiene and
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should be observed.
Neither Eastman Chemical Company nor its marketing affiliates
shall be responsible for the use of this information or of any
product, method, or apparatus mentioned, and you must make
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© Eastman Chemical Company, 2011.
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