What is Specialty Compounding?
Within the plastics industry, compounding is the process of mixing and blending a base polymer with additives to manufacture a polymer blend that provides a specific set of properties. The compounding process is typically achieved via extrusion. The base polymer and the requisite additives are mixed and fed through an extruder. The screws of the extruder facilitate the melting and mixing of the polymer blend. The material, often now referred to as a compound or composite, exits the extruder via the die. The extrudate exits in long, individual strands that are often cooled using water baths or by spraying. After adequate cooling, these strands are cut into pellets and inspected as necessary for quality control. These pellets are then packaged and transported for further plastics processing such as injection molding.
Specialty compounding is a form of compounding that achieves a more customized and specific set of physical, thermal, electrical, and aesthetic characteristics in the final plastic product. While traditional compounding provides well-made products, manufacturers are turning to specialty compounding to ensure their products meet rigorous regulations and stand out from competitors. The possibilities are truly endless with specialty compounding!
It should be noted that specialty compounding is not a simple task and requires expertise as it demands precision as well as creativity. Amcor is a leader in specialty compounding solutions. Because we recognize that this process can be confusing, Amcor guides customers through each step of the specialty compounding process from product development through production including selection of the base resin, additives, fillers, and colorants to ensure the final product meets the customer’s unique and specific criteria.
Properties Enhanced by Specialty Compounding
The first step when creating a specialty compounded solution is identifying the best base resin for a given application. There are many base polymers to choose from and each provides its own set of pros and cons. At Amcor, there are a variety of base resins to select from including polypropylene, polyethylene, and polystyrene.
The next step is to determine which additives should be added to provide the requisite properties in the final plastic product. There are numerous properties that can be enhanced by specialty compounding and some of the most common are below.
- Color: does the final product need a specific or unique color in order to stand out? Colorants can be added to modify the color – and there are numerous colors to choose from to achieve the specific look you desire!
- Anti-static and conductivity: does the final product need to have anti-static properties? These additives are used to minimize the potential for static electricity build up on the surface of the plastic, and in some cases even prevent it entirely.
- Flame retardance: does the product need to prevent, delay, or slow down combustion? These additives are common in electrical products to avoid the ignition and burning of plastics.
- Anti-aging: nearly every plastic is prone to degradation when exposed to UV light, such as from sunlight, and oxygen including ozone. This degradation causes brittleness, discoloration, and loss of some physical properties. Additives, referred to as anti-oxidants, stabilizers, or anti-ozonants, are added to combat the deterioration of the plastic and to significantly extend the life span of the final product.
- Sterilization and anti-microbial: will the final product be used in the medical field, such as an implantable medical device? If so, there is a good chance it will require an additive to protect against deterioration of the plastic and reduce the potential for a microbiological attack.
- Odor: additive technologies have advanced significantly in recent years and manufacturers now have the option to alter the smell of the final plastic product! These additives modify the odor of the plastic to produce a more pleasing aroma.
- Other physical properties: there are literally hundreds of additives and each one modifies a specific property of the final polymer. Some physical properties that are often enhanced are impact resistance, stiffness, wear resistance, as well as resistance to heat, water, and chemicals.
Amcor: Your Specialty Compounding Partner
Our state-of-the-art compounding and blending processes ensure consistent master-batches and blended products each and every time. Our technical team takes a “hands-on” approach and is knowledgeable with resins, additives, manufacturing processes, and equipment. Whether you are foaming, molding, manufacturing film, extruding, or thermoforming, Amcor can be a valuable resource by your side.
Amcor is a manufacturer of polyethylene film and bags, as well as polyolefin compounds, additives, blends, and masterbatches. Amcor has grown from a single product line to hundreds of products and five product divisions. In addition to selling products, we also provide tech support, assistance with your equipment, and process recommendations. Amcor is also a full line distributor of various chemicals, resins, and gases for the plastic industry. With warehousing and distribution facilities across the United States, Mexico, Eastern Europe and China, we service companies of all sizes and locations across multiple industries.
Amcor realizes that quick turnaround, on time delivery, a quality product, and personal service are what it is all about. Contact us today to learn how we can assist with your next project!
Benefits of Polymer Processing Aids Amcor
Polymer Processing Aids (PPAs) are additives combined with the base polymer to improve the processability and processing characteristics of the material as well as improve the quality of the final product. More specifically, PPAs improve the melt processability and handling of the polymers and improve the appearance of the final product by removing flow marks and die lines.
Internal and external PPAs are very common additives and are often lubricants. Their primary objective is to reduce the friction between the melting, or molten, polymer and the metal production equipment –providing a smooth flow of material by improving flow characteristics such as viscosity. Internal processing aids improve the polymer flow properties by reducing friction within the polymer blend itself. External processing aids migrate to the surface of the polymer to reduce the friction between the plastic and the metal manufacturing equipment, allowing the melt to slip through the die or mold more easily without sticking. Internal and external PPAs can be utilized together to achieve the desired processing characteristics.
Polymer processing aids are used in many applications including blown and cast film processes, pipe and sheet extrusion, blow molding and compounding. Processing aids are very effective for use in the production of high viscosity, high molecular weight polymers such as LDPE, LLDPE, LDPE, HDPE, PP, PS, and others – and are found in a variety of products ranging from plastic bottles to construction pipe to films. PPAs offer significant benefits even at very low addition rates in the Parts Per Million (ppm) range. Additionally, processing aids are typically very stable and able to be used for high temperature operations.
Benefits of Polymer Processing Aids
As the name implies, polymer processing aids provide benefits during the processing of the polymer but they also provide benefits to the final product. In particular, PPAs improve the polymer flow characteristics to reduce the potential for processing issues such as melt fracture, die build up, or gel formation. Melt fracture is a common polymer flow issue caused by the high stress experienced at the die exit; melt fracture causes a roughening of the polymer surface, often referred to as “shark skin” and can also lead to distortion of the final product. Die build-up is the deposition of material when exiting the die, which requires more frequent production stoppages to clean the die and also lowers product quality. Die buildup gets worse with time and can require cleaning in a matter of hours in some cases instead of days or weeks! Gel formation is the result of undesirable linking of the polymer molecules; PPAs improve the polymer flow, reducing the residence time during production and, therefore, reducing the potential for gel formation.
Below is a summary of the benefits of polymer processing aids.
- Reduced melt fracture often referred to as “sharkskin”
- Reduced die lines and die build-up
- Reduced gel formation within the polymer
- Improved product appearance such as surface finish, transparency, gloss, and smoothness
- Higher productivity and lower operating costs due to lower cycle times and longer continuous production runs in between cleaning and maintenance.
- Energy savings due to lower friction between the equipment and the polymer that allows for lower operating pressure and motor torque within the extruder.
Selecting the right polymer processing aid for your application is crucial –especially since a small change in dosage on a ppm level can have a huge impact on your operations! It is not always easy to determine which processing aid is best since there are many options to choose from. This is why it is important to choose a partner like, Amcor, that will guide you through the selection process. Additionally, Amcor provides tech support, assistance with customer’s equipment, and process recommendations to ensure you are set up for success!
About Amcor
Amcor is a manufacturer of polyethylene film and bags, as well as polyolefin compounds, additives, blends, and masterbatches. Amcor has grown from a single product line to hundreds of products and five product divisions. In addition to selling products, we also provide tech support, assistance with your equipment, and process recommendations. Below are some highlights of Amcor’s polymer processing aids (The “Ampro” Product Line):
| · Flow Enhancers | · Surface Enhancers (warpage/roughness) | · Mold Release Agents |
| · Cooling/Cycle Time Reducers | · Purge – “Ampure” | · Web Break Reducer |
Amcor is also a full line distributor of various chemicals, resins, and gases for the plastic industry. With warehousing and distribution facilities across the United States, Mexico, Eastern Europe and China, we service companies of all sizes and locations across multiple industries.
Amcor realizes that quick turnaround, on time delivery, a quality product, and personal service are what it is all about. Contact us today to learn how we can assist with your next project!