Agricultural barrier films Plast09

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Conference presentation Plast 09 in Milan.

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  • Measured at 260 °C
  • LDPE = Stamylan LD2102T
  • <Use this slide for chapter intro>
  • Agricultural barrier films Plast09

    1. 1. Agricultural barrier filmsDSM Engineering PlasticsTed Brink | Application Development Engineer ExtrusionLiving Solutions for People, Planet and Profit 1DSM Engineering Plastics
    2. 2. Contents• Introduction• Agricultural barrier films - why barrier films are necessary - barrier materials - film compositions - film property improvement• ConclusionsAgricultural barrier films - Plast09 - Plastics & Agriculture Page 2DSM Engineering Plastics
    3. 3. DSM today − DSM creates innovative products and services in life sciences and materials Pharma Nutrition − active on 5 continents, more than 250 locations 11% 28% − approx. 23,000 employees Performance − approx. €8.8 billion annual sales in 2007 Materials Polymer 29% Intermediates − leadership positions in ~75 % of the portfolio Base 15% Chemicals & Materials 17% DSM Engineering Plastics € 0.84 bn sales in 2007 and 1,500 employees worldwide As a leading global supplier of quality engineering plastics we provide customer value through innovative solutionsAgricultural barrier films - Plast09 - Plastics & Agriculture Page 3DSM Engineering Plastics
    4. 4. DSM EP’s product portfolio for film applicationsAkulon® PA6 and PA66 barrier materialAkulon® XP extreme performance PA6Arnitel® TPC breathable materialStanyl® high heat resistant PA46Yparex® maleic anhydride modified polyolefinAgricultural barrier films - Plast09 - Plastics & Agriculture Page 4DSM Engineering Plastics
    5. 5. Why agricultural barrier films?Methyl bromide is being used as a fumigant in agricultureHowever, MeBr contributes to the depletion of the ozone layerApplication of a barrier film has the following effects:• reduced emission of MeBr into the atmosphere• increased effectiviness as fumigant Methyl bromide is a neurotoxic gas • odourless • boiling point: 3.6 °C • gas density: 3.4 (air = 1)Agricultural barrier films - Plast09 - Plastics & Agriculture Page 5DSM Engineering Plastics
    6. 6. The ozone hole in 2006 The largest Antarctic ozone hole recorded as of September 2006Agricultural barrier films - Plast09 - Plastics & Agriculture Page 6DSM Engineering Plastics
    7. 7. Montreal protocol 1987Reduction of methyl bromide developed countries:• 1998: 25 %• 2001: 60 %• 2003: 75 %• 2005: 100 %Article 5 countries: 100 % reduction in 2015Agricultural barrier films - Plast09 - Plastics & Agriculture Page 7DSM Engineering Plastics
    8. 8. Today’s realityObjectives Montreal will not be reached• partners granted production of 5.300 tons of methyl bromide by the USA in 2008• environmental groups revealed stock of 10.000 tons in USA• methyl bromide will continue to be used, but volumes will decrease as alternatives will become available• alternative fumigants may also require barrier films to improve efficiencyAgricultural barrier films - Plast09 - Plastics & Agriculture Page 8DSM Engineering Plastics
    9. 9. Containment of emission of fumigant• prevent emission into the atmosphere by using barrier films• injection of methyl bromide deep in the soilAgricultural barrier films - Plast09 - Plastics & Agriculture Page 9DSM Engineering Plastics
    10. 10. Barrier materials• EVOH• PA6.66 copolyamide• PA6 homopolymeer• PA6 nanocomposite• blend of PA6 and amorphous PA• Orgalloy• coated film (Al, SiO2)Agricultural barrier films - Plast09 - Plastics & Agriculture Page 10DSM Engineering Plastics
    11. 11. Properties of barrier materialsmaterial barrier price processing mechanicalEVOH +++ -- - +/-PA6.66 +/- - ++ +PA6 + + + +PA6 nano ++ - + -PA6 AmPA ++ - + +Orgalloy +/- - + +coating +++ - - ?Agricultural barrier films - Plast09 - Plastics & Agriculture Page 11DSM Engineering Plastics
    12. 12. Common film structures 3-layer structure 10 µm (L)LDPE/adhesive 6 µm (co)polyamide 10 µm (L)LDPE/adhesive 5-layer structure (L)LDPE adhesive (co)polyamide adhesive (L)LDPEAgricultural barrier films - Plast09 - Plastics & Agriculture Page 12DSM Engineering Plastics
    13. 13. Adhesive or tie resin (DSM Yparex)• no adhesion between PE and PA in coextrusion• MAH-g-PE is commonly used to realise adhesion between PA and PE• physical adhesion between MAH-g-PE and PE• chemical reaction between MAH-g-PE and PA O O + H2N + H2O O N O OAgricultural barrier films - Plast09 - Plastics & Agriculture Page 13DSM Engineering Plastics
    14. 14. Requirements agricultural barrier filmsRequirements• British Pest Control: 1 gram MeBr per m² per hour• French ministry of Agriculture: 0.2 gram MeBr per m² per hourAgricultural barrier films - Plast09 - Plastics & Agriculture Page 14DSM Engineering Plastics
    15. 15. Coextrusion blown film processAgricultural barrier films - Plast09 - Plastics & Agriculture Page 15DSM Engineering Plastics
    16. 16. Film processing• thin film• large machines• large bubble diameter• compromise in material use: - LDPE needed for bubble stability - PA6.66 to realise low polymer temperature• PA6 good alternative to PA6.66 but higher melting point• rheology of PA differs from PEAgricultural barrier films - Plast09 - Plastics & Agriculture Page 16DSM Engineering Plastics
    17. 17. LDPE and LLDPE for barrier filmproperty LDPE LLDPEbubble ++ +stabilityimpact + ++strengthpuncture + ++resistanceAgricultural barrier films - Plast09 - Plastics & Agriculture Page 17DSM Engineering Plastics
    18. 18. Viscosity curves of LDPE and PA6 10000 melt viscosity [Pa.s]. 1000 LDPE Akulon F132 100 No proper viscosity match 10 0.01 0.1 between PE and PA6 1 10 100 1000 shear rate [1/s]Agricultural barrier films - Plast09 - Plastics & Agriculture Page 18DSM Engineering Plastics
    19. 19. Standard materials result in interfacial instability Rheology mismatch PA6 and LDPE processing window 10000 viscosity 1000 PA6 LDPE 100 10 0.01 0.1 1 10 shear rate [1/s] 100 1000 leads easily to problems Poor elasticity and viscosity match creates wave effect resulting in poor optical properties and quality risk wave length uniform thickness wavy interfaceAgricultural barrier films - Plast09 - Plastics & Agriculture Page 19DSM Engineering Plastics
    20. 20. The Akulon XP solution Minimizes differences in melt viscosity and elasticity of coextruded materials Result: widening of processing window 10000 Akulon XP Akulon XP shows shear-thinningviscosity [Pa.s] 1000 behaviour: • less motor power at 100 LDPE high rpm MFI 1.9 • higher zero shear viscosity 10 • lower Tpol at high 0.01 0.1 1 10 100 1000 output shear rate [1/s] wide processing window Agricultural barrier films - Plast09 - Plastics & Agriculture Page 20 DSM Engineering Plastics
    21. 21. Akulon XP for agricultural barrier film - trialTrials in a 3-layer conceptObjective:replacement PA6.66 to reduce costs and/or improve propertiestotal film thickness: 25 µmCOPA layer: 6 µmPE outerlayers: 60 % LLDPE, 30 % LDPE, 10 % Yparex 9403bubble diameter: 5.8 meter (BUR 2.1) Yparex 9403 DSM’s tie resin MAH-g-PEAgricultural barrier films - Plast09 - Plastics & Agriculture Page 21DSM Engineering Plastics
    22. 22. Akulon XP for agricultural barrier film - resultsReplacement of PA6.66 with Akulon XP36-E1:• LDPE could be omitted while maintaining bubble stability and improving mechanical properties or• bubble diameter could be increased from 5.8 to 7 meter (BUR 2.8) or• thickness PA layer could be reduced from 6 to 5 µm while maintaining mechanical and barrier propertiesAgricultural barrier films - Plast09 - Plastics & Agriculture Page 22DSM Engineering Plastics
    23. 23. ConclusionsAkulon XP PA6 in agricultural barrier films results in:• improved bubble stability• improved mechanical properties• improved output (larger BUR)• cost reductionAgricultural barrier films - Plast09 - Plastics & Agriculture Page 23DSM Engineering Plastics
    24. 24. THANK YOU FOR YOUR ATTENTIONMore information:Ted BrinkApplication Development ExtrusionDSM Engineering PlasticsTel: (31)464767831e-mail: ted.brink@dsm.comwww.dsmep.comwww.akulon.comwww.yparex.comVisit us at Hall 20, booth D31Living Solutions for People, Planet and Profit 24DSM Engineering Plastics

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