2023-01-06 / Industry news

Light Work:Advances in Foamed Sheet Technology

Foaming technology has gained popularity recently because it can help to reduce material use in products such as sheet. As long as this can be done with no loss of mechanical properties, it means that a product can be made with less material – which has both cost and sustainability advantages.

Promix Solutions says that its Microcell Technology can help to reduce raw material consumption in extrusion processes by up to 20% without losing mechanical properties.

It uses blowing agents such as carbon dioxide and nitrogen to perform physical foam extrusion on products such as sheet and film.

Until now, density reduction in physical foaming caused some loss in mechanical properties. Promix says that its technology overcomes this – making the technique more attractive to end users.

The secret of high-quality physical foaming lies in the cell structure. Tests have shown that very small, evenly distributed cells significantly improve mechanical strength. A foam with 50-micron cells has 27 times more cells than a foam with 150-micron cells – at the same density. This explains why the mechanical behaviour of microcell foams is different. There are several factors behind achieving small cells, including: dispensing the blowing fluids with very high precision – and in a supercritical stage; unique cooling and mixing equipment; special nucleation technology and improved process know-how.

In one example, a thermoformed PET tray foamed with Promix Microcell Technology showed the same mechanical top load properties as a solid tray but was 18% lighter. A non-foamed bench-mark tray – which is also 18% lighter – shows significantly reduced top load properties. This proves that the new process is an effective way to save up to 20% raw materials without affecting mechanical properties.

In addition, it reduces energy consumption. The internal and external recyclability remains intact and is equivalent to the non-foamed products.

The technology works for all types of extrusion processes including packaging films, sheets and boards and blown film. It can be retrofitted to existing extrusion lines and installed on new lines. Promix is working with a number of machine builders to do this.

 

Integral skin

Simona of Germany has developed its Celplast range of integral skin foam sheets, which are made at its centre for PVC foam products in Turkey.

The range is likely to be added to Simona’s PVC product portfolio in early 2023. Celplast is made using a semi-Celuka process – which prevents cell formation on the surface of the molten material through an immediate reduction in temperature. It produces a compact, smooth and even surface.

The result is a foamed PVC sheet that is lightweight and strong – offering good surface quality and low thickness tolerance across the entire width. This makes it suitable for design and construction applications.

 

Closed-cell

Zotefoams launched Ecozote – a range of closed-cell crosslinked foams – at K2022.

Ecozote LDR18 and LDR27 are crosslinked LDPE grades incorporating 30% post-industrial waste that comply with emerging requirements for recycled content in product protection applications. After several months of trials, the grades are available as alternatives to their Plastazote PE foam counterparts – which are made from virgin material.

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Image:Zotefoams

Zotefoams’ Ecozote closed-cell crosslinked foams incorporate 30% post-industrial waste

“LDR18 and LDR27 with 30% recycled content are part of the first Ecozote product line driving plastics circularity, with more to follow,” said Karl Hewson, director of technology and development at Zotefoams. “With Ecozote, we are building on the underlying sustainability credentials of all our block foams: lightweight, durable and foamed using nitrogen as a blowing agent.”

In addition, the company presented a range of technical block foams, spanning its Azote polyolefin foams range – including Plastazote – and Zotek high-performance foams, which are made from engineering polymers and designed for demanding applications.

Zotefoams makes its T-Fit modular foam insulation from Zotek. T-Fit is used in applications in the pharmaceutical, semiconductor and food and beverage industries.

“Sustainability is a complex topic. Often, only a detailed life cycle assessment will identify what is truly the most sustainable solution,” he added. “With Ecozote, we are building on the sustainability credentials of all our block foams.”

 

Insulation board

Trinseo has commercialised its Styron X-Tech 4660 polystyrene resins for extruded polystyrene (XPS). The material – based on patented cross-linked polystyrene technology – allows customers in the building and construction industry to reduce material consumption in foam insulation boards.

“Customers can lower foam insulation board density without compromising compression strength,” said Alain Minelli, business manager of copolymers and polystyrene.

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Image:Trinseo

Abidin Balan, Gilbert Bouquet and Luc Bosiers, of Trinseo’s polystyrene R&D team, developed Styron X-Tech 4660

With XPS insulation board, the closed cell foam structure is responsible for providing long-term durability and rigidity.

“The new material impacts this structure by introducing increased melt strength to enhance performance and allow for raw material and cost savings,” he added.

The material offers the same performance as previous formulations, with improved sustainability. It has been validated by several Trinseo partners – who have reduced the weight of insulation board by around 5%, and carbon emissions by “a corresponding amount”.

 

Source:www.filmandsheet.com

Key Words:

#Plastics, #Plastics Industry, #Foamed Sheet, #Foam Insulation Board, #PET, #PVC Foam

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