|
|
The
world first polymer-specific masterbatch for rigid PVC is aiming
to change the European coloured PVC compound market.
An innovative material believed to be the world's first polymer
specific colour masterbatch for rigid PVC could be poised to change
the PVC compound market in Europe. Vynacol
is based on patented PVC colouring technology that is used to make
it as easy to colour PVC as any other plastic material. The masterbatch
has the potential to turn the PVC processing market inside out by
allowing processors to cash-in on the benefits of lower polymer
costs, reduced stock holding and production flexibility. Universal
and polymer specific masterbatches for flexible PVC have been available
for many years but they have never work reliably in rigid PVC. There
are many reasons for this: PVC is a complex material that is highly
sensitive to the introduction of additives. For example, a universal
masterbatch may be unsuitable in rigid PVC because the carrier lubricates
the compound. Processors of the material have always had to find
just the right grade for their particular plant and application.
Consequently these are literally thousands of PVC formulations on
the market with varying amounts of additives and different levels
of compounding; all developed to meet the specific performance and
processing requirements, or both. In these circumstances is it expecting
too much for a universal to work effectively in every grade? Conversely,
polymer specific masterbatches for flexible PVC contain plasticisers.
Although this does not present compatibility problems when used
in rigid PVC, you are, in effect, adding plasticisers to a polymer
chosen specifically for its unplasticised characteristics. This
in turn can lead to application failures due to plasticiser migration
and changes in physical properties in the final product. What
makes Vynacol different is that it works well both in rigid and
flexible grades without any of these inherent compatibility and
homogenization problems. The free-flowing granular product overcomes
all the traditional difficulties associated with adding colour to
rigid PVC via the masterbatch route." Additionally,
grades can be tailored to suit individual manufacturing processes.
This is important because PVC has never been the easiest of materials
to work with, a formulation that runs well on one machine may present
processing difficulties on another, even identical, manufacturing
plant.
SECRET
FORMULA Perhaps
not surprisingly the formulation and manufacturing techniques used
to produce this new masterbatch are closely guarded secrets, but
the company does say they are based on existing polymer technology
and involve specially modified manufacturing plant. Ingredients
have been selected for good weatherability and excellent colour
aging characteristics. Further enhancements to outdoor performance
are possible by adding UV stabilizers and absorbers while suitable
approved pigments allow the masterbatch to meet all European food
contact, packaging and EN71 (toy) criteria. Generally
dispersed at recommended dosage of 1-2% and can be used in filled
as well as unfilled grades. Depending on thickness and opacity required,
dosing in excess of 8% is possible with no effects on processing
or physical properties. In fact the product can improve and enhance
the characteristics of the base PVC; these are cited as ease of
processing, improved weld strength, increased ductility, increased
strength (especially at low temperatures), and high gloss finish.
SLOW
START Following
its UK launch in July 2000 initial market response to Vynacol was
tentative, but over the past year sales have risen dramatically
and now account for over 600 tonnes per annum for the Welsh manufacturer. There
were several reasons for the guarded reactions at first shown by
UK PVC processors. After 30 years of managing without a 100% reliable
masterbatch for rigid PVC the market had, understandably, been predisposed
towards precoloured compounds. So when we came up with a product
that worked in both PVCu and PVCp the first reaction was one of
skepticism. However, once a few processors trailed it word got around
that Vynacol worked effectively and orders started to roll in. Given
that PVC is one of the most versatile and adaptable plastics used
worldwide - the British Plastics Federation estimated consumption
in the UK of 728,000 tonnes in 2001 - the market potential for colouring
PVC with Vynacol polymer specific masterbatch is huge. "These
are exciting times, as the full potential for Vynacol is begun to
be realised in Europe" |
 |
