STRETCHONOMICS : How to improve stretch hood process economics

3,317 views

Published on

Description of some important aspects of stretch hood performance, highlighting some findings about stretching behavior which may help understanding market requirements and trends.

Published in: Technology

STRETCHONOMICS : How to improve stretch hood process economics

  1. 1. How to improve stretch hood process economics Dr. Nicolas Kokel LyondellBasell Industries AMI Stretch & Shrink Film 2008 Marriott Marquis Hotel - Atlanta, USA STRETCHONOMICS
  2. 2. LyondellBasell Industries
  3. 3. LyondellBasell Industries Capabilities Global Assets & Supply Chain Global Technology & Development Global Market Reach Regional Focus Supplier of Innovative Resins Used in Stretch Hoods
  4. 4. Present for You in Atlanta <ul><li>Ken Adams </li></ul><ul><li>Iggy Triassi </li></ul><ul><li>Dennis Hudson </li></ul><ul><li>Chris Shelley </li></ul><ul><li>Stephen Imfeld </li></ul>
  5. 5. “ Stretchonomics”
  6. 6. How to Improve Stretch Hood Process Economics? <ul><li>Optimized Film Extrusion </li></ul><ul><ul><li>Enhanced film quality (low gels, orientation, melt fracture…) </li></ul></ul><ul><ul><li>High throughput conditions </li></ul></ul><ul><ul><li>Good gauge profile </li></ul></ul><ul><li>Optimized Packaging Capabilities </li></ul><ul><ul><li>Enhanced, robust & reliable packaging technology </li></ul></ul><ul><ul><li>Lowest possible clearance </li></ul></ul><ul><li>Minimized Film Costs </li></ul><ul><ul><li>Lower thickness </li></ul></ul><ul><ul><li>Smaller tube + higher stretching ratio => Enhanced & Versatile Film Performance </li></ul></ul>Stretchonomics
  7. 7. Stretching Performance Test Method Time (sec) Stress (MPa)
  8. 8. Stretching Process Simulation <ul><li>Blown film sample cut in cross direction </li></ul><ul><li>Ring-closed with a piece of adhesive tape </li></ul><ul><li>Two fingers of device inserted into the film ring </li></ul><ul><li>Stretching cycle according to real conditions </li></ul>Stretching in blown film cross direction Elastic Recovery Measurement Device
  9. 9. Elastic Recovery Test Method <ul><li>Four-Step Measurement </li></ul><ul><li>Stretch the film to initial strain value at 1000mm/min </li></ul><ul><li>Hold for 10 seconds </li></ul><ul><li>Release to residual strain value at 1000mm/min </li></ul><ul><li>Hold for 3 minutes </li></ul>Drawings: courtesy of company BEUMER 0 1 2 3 4 5 6 7 8 9 10 11 0 10 20 30 40 50 60 70 Deformation (%) Stress (MPa) 1. 2. 3. 4.
  10. 10. Influence of Clearance
  11. 11. The Clearance ( d ) is a Critical Parameter <ul><li>The stretch hood must be stretched at a dimension larger than the pallet size </li></ul><ul><li>The clearance is the distance between the stretched tubing and the pallet </li></ul><ul><li>It must be added 8 times to the pallet/load perimeter: </li></ul>Strong overstretching to demonstrate the role of the clearance
  12. 12. Influence of Clearance on Initial Stretching Ratio <ul><li>Constant Load Size and Tube Dimensions </li></ul>variable clearance Variable initial stretching ratio Initial Stretching Ratio (%) 0 10 20 30 40 50 60 70 80 90 100 Clearance (mm) 0 25 50 75 100 125 150 175 200 constant load size constant perimeter constant resid. stretching ratio
  13. 13. Influence of Clearance on Holding Forces <ul><li>High Clearance equals Overstretching and Low Holding Forces </li></ul>$ Clearance reduced to 60mm: Si = 70% & Sr = 50% *For example Load size 800x1000mm, Film perimeter 2400mm and clearance 120mm: Si = 90% & Sr = 50% Common situation* ideal conditions $
  14. 14. Influence of Tube Size
  15. 15. Influence of Tube Perimeter on Elastic Recovery <ul><li>Variable Stretching Ratio @ constant Clearance* </li></ul>Initial Stress Residual Stress Stress / Strain curve Yield point Creep phase *Pallet size 800 x 1200 mm Clearance 75mm ?
  16. 16. Influence of Tube Perimeter on Economic Efficiency <ul><li>Stress vs. Residual Film Thickness After Stretching </li></ul>Initial Stress Residual Stress Large tubing = Low stretching ratio Small tubing = High stretching ratio “ Yield point” “ Creep phase” Theoretically optimized economical performace
  17. 17. Increasing Horizontal Stretching Performance 1 st Generation Modern technology Future generation
  18. 18. Influence of Film Composition
  19. 19. Typical Film Compositions used by our Customers <ul><li>Market has transitioned to 3-layer coex (typically 20/60/20) </li></ul><ul><li>Gauge (50 to 150 micron) </li></ul><ul><li>Core = Stretch Engine Skin = Enhanced Toughness </li></ul>Blend of TPO Adflex Q100F + Petrothene EVA (NA362) or LDPE (NA940) mLLDPE Starflex GM1810 or 1210
  20. 20. Improved Resistance to Tear Propagation* * Starflex GM1810 / Adflex Q100F + LDPE NA940 / Starflex GM1810 (Layers thickness 20:60:20%) )
  21. 21. Improved Puncture Resistance @ Lower Thickness* * Starflex GM1810 / Core Layer TPO Blend / Starflex GM1810 (Layers thickness 20:60:20)
  22. 22. Holding Forces vs. Film Composition* <ul><li>Constant Load Size (800x1200mm) and Clearance (75mm) </li></ul>* Starflex GM1810 / Core Layer TPO Blend / Starflex GM1810 (Film thickness 80µm; Layers thickness 20:60:20%) Higher Holding Forces Increased Versatility
  23. 23. True Stress vs. Film Composition* <ul><li>Higher Stretching Ratio = Higher True Stress </li></ul>*’Residual Stress’ divided by ‘Film Thickness on load’ times ‘Initial film thickness’ (80µm)
  24. 24. True Stress vs. Film Composition* <ul><li>Real Situation, Based on Practical Experience </li></ul>*’Residual Stress’ divided by ‘Film Thickness on load’ times ‘Initial film thickness’ (80µm) Not yet considering vertical stretching capability High Stiffness / General Purpose / Advanced
  25. 25. Application Needs
  26. 26. Stretch Hood Applications <ul><li>Petrochemical: Low stretching ratio, but strong holding forces </li></ul>Petrochemical Cement bags Building materials Beverages Appliances Petrochemical Cement bags Building materials Beverages Appliances Picture: courtesy of Company Nordfolien
  27. 27. Stretch Hood Applications <ul><li>Petrochemical: Low stretching ratio, but strong holding forces </li></ul><ul><li>Cement Bags: Low stretching ratio, dust protection but robust on packaging line </li></ul>Picture: courtesy of Company Bocedi Petrochemical Cement bags Building materials Beverages Appliances Petrochemical Cement bags Building materials Beverages Appliances
  28. 28. Stretch Hood Applications <ul><li>Petrochemical: Low stretching ratio, but strong holding forces </li></ul><ul><li>Cement Bags: Low stretching ratio, dust protection but robust on packaging line </li></ul><ul><li>Building materials: Low stretching ratio, but strong puncture & tear performance </li></ul>Petrochemical Cement bags Building materials Beverages Appliances Petrochemical Cement bags Building materials Beverages Appliances Picture: courtesy of Company Bocedi
  29. 29. Stretch Hood Applications <ul><li>Petrochemical: Low stretching ratio, but strong holding forces </li></ul><ul><li>Cement Bags: Low stretching ratio, dust protection but robust on packaging line </li></ul><ul><li>Building materials: Low stretching ratio, but strong puncture & tear performance </li></ul><ul><li>Beverages: High stretching ratio + perforated hood = robust stretching + tear performance </li></ul>Petrochemical Cement bags Building materials Beverages Appliances Petrochemical Cement bags Building materials Beverages Appliances Picture: courtesy of Company Beumer
  30. 30. Stretch Hood Applications <ul><li>Petrochemical: Low stretching ratio, but strong holding forces </li></ul><ul><li>Cement Bags: Low stretching ratio, dust protection but robust on packaging line </li></ul><ul><li>Building materials: Low stretching ratio, but strong puncture & tear performance </li></ul><ul><li>Beverages: High stretching ratio + perforated hood = robust stretching + tear performance </li></ul><ul><li>Appliances: Fast speed process + puncture resistance @ low thickness </li></ul>Picture: courtesy of Company Lachenmeier Petrochemical Cement bags Building materials Beverages Appliances Petrochemical Cement bags Building materials Beverages Appliances
  31. 31. Core Layer Blend Versatility with Starflex Skins Petrothene rich core Petrochemical Cement bags Building materials Beverages Appliances Petrochemical Cement bags Building materials Beverages Appliances Adflex rich core MODERATE STRETCHING CAPABILITY HIGH HOLDING FORCES @ LOW STRETCHING RATIO LOW BUR SENSITIVITY HIGH STRETCHING CAPABILITY (both horizontal + vertical) IMPROVED PUNCTURE RESISTANCE IMPROVED TEAR PERFORMANCE GAUGE REDUCTION CAPABILITY
  32. 32. Conclusion
  33. 33. Stretch Hood Trends <ul><li>Better, minimized clearance control </li></ul><ul><ul><li>Improved holding forces </li></ul></ul><ul><li>Gauge reduction with high-quality films on high-performance stretch hooders </li></ul><ul><ul><li>Improved Economics </li></ul></ul><ul><li>Combination of packaging line and film with stronger stretching capability </li></ul><ul><ul><li>Improved Economics </li></ul></ul><ul><li>More resilient films </li></ul><ul><ul><li>To withstand stronger stress under higher stretching conditions </li></ul></ul><ul><li>Films with improved vertical stretching-ability </li></ul><ul><ul><li>To compensate for length reduction under higher transverse stretching ratio </li></ul></ul>Stretchonomics
  34. 34. Web Tools: Free Online Calculator / Webinar
  35. 35. Resources www.basell.com ( www.lyondellbasell.com ) [email_address]
  36. 36. Thank you for your attention CRP, Adflex, Adstif, Adsyl, Akoalit, Akoafloor, Avant, Catalloy, Clyrell, Entegrity, Get in touch with, Hifax, Higran, Histif, Hostacom, Hostalen, LIPP, Lucalen, Luflexen, Lupocomp, Lupolen, Lupolex, Luposim, Lupostress, Lupotech, Lupotech, Metocene, Moplen, Purell, Pro-fax, Sholybox, Softell, Spherilene, Spheripol, Spherizone, Stretchene, Toppyl and Valtec are trademarks owned or used by LyondellBasell group companies. Adflex, Adstif, Adsyl, Clyrell, CRP, Hifax, Hostacom, Hostalen, Lucalen, Luflexen, Lupolen, Lupotech, Moplen and Pro-fax are registered in the U.S. Patent and Trademark Office Disclaimer: Before using a LyondellBasell product, customers and other users should make their own independent determination that the product is suitable for the intended use. They should also ensure that they can use the LyondellBasell product safely and legally. This document does not constitute a warranty, express or implied, including a warranty of merchantability or fitness for a particular purpose. In addition, no immunity under LyondellBasell's or third parties' intellectual property rights shall be implied from this document. No one is authorized to make any warranties, issue any immunities or assume any liabilities on behalf of LyondellBasell except in a writing signed by an authorized LyondellBasell employee. Unless otherwise agreed in writing, the exclusive remedy for all claims is replacement of the product or refund of the purchase price at LyondellBasell’s option, and in no event shall LyondellBasell be liable for special, consequential, incidental, punitive or exemplary damages. The statements in this presentation relating to matters that are not historical facts are forward-looking statements. These forward-looking statements are based upon the current beliefs and expectations of management, and are subject to significant risks and uncertainties. Actual results could differ materially based on factors including, but not limited to, availability, cost and price volatility of raw materials and utilities; supply/demand balances; industry production capacities and operating rates; uncertainties associated with the U.S. and worldwide economies; legal, tax and environmental proceedings; cyclical nature of the chemical and refining industries; operating interruptions; current and potential governmental regulatory actions; terrorist acts; international political unrest; competitive products and pricing; technological developments; our ability to implement our business strategies; access to capital markets; and other risk factors. Additional factors that could cause results to differ materially from those described in the forward-looking statements can be found on the Investor relations page of the LyondellBasell Industries' website ( www.lyondellbasell.com ) and in the Lyondell, Equistar and Millenium Annual Reports on Form 10-K for the year ended December 31, 2007, and quartely reports on Form 10-Q for the quarter ended June 30, 2008.

×