Basf Linked In Presentation
- 1. Presented by Doreen Becker Technical Marketing Manager BASF Effect Pigments for Plastics Effect Pigments in Plastics
- 2. Overview Introduction: overview of effect pigments Features and benefits of product lines for plastics Common resins employed in processing Challenges of using effect pigments in plastics Styling for trend and color forecasts Real-world examples and finished products
- 3. Effect pigments Pearlescent pigments White pearlescent mica-based pigments such as MagnaPearls Interference pigments Mica-based pigments that change color on the flop angle Metallescent pigments Mica-based pigments have metallic and pearlescent effects Borosilicate-based pigments Glass flake pigments that have color travel and transparency Special effect pigments Dynacolors, Black Olive, Mark-It etc
- 4. Pigment structure Mica Mica TiO 2 or other metal oxides With optional absorption colorant layer Substrates Mica Borosilicate Al 2 O 3 SiO 2 Graphite Others? 50 nm TiO 2 50 nm TiO 2 500 nm Mica
- 5. Metal oxide coated mica pigment \/ \/ \/ Metal oxide coated mica O O O O O M M M M >700 C O O O O O O H H H H H H M M M
- 6. Oxide thickness determines interference color TiO 2 TiO 2 Mica TiO 2 TiO 2
- 7. Titanium dioxide coated mica by reflectance microscopy Gold Red Violet Blue Green
- 8. Absorption color depends on oxide color and thickness Mica Bronze Fe 2 O 3 Fe 2 O 3 Mica Russet Fe 2 O 3 Fe 2 O 3
- 9. Iron oxide coated mica by reflectance microscopy Bronze Russet
- 10. Mica versus metallic pigments Reflectance of a pearlescent and metallic flake pigment in a transparent resin Pearlescent pigment transparent platelets Metallic flake pigment opaque platelets
- 11. White pearlescent pigments MagnaPearl® Highest luster pigments (blue shade) Least mica undertone contribution Developed for plastics packaging industry Particle sizes MP3000= 2-10 microns (high hiding) MP2000= 5-25 microns (velvet effect) MP1000= 8-48 microns (satin effect) MP 5000= 14-95 microns (sparkle effect) MP8000= 5-80 microns MP4000= 15-150 microns (glittery effect)
- 12. Interference Pigments Lumina® Colors (D Fraction) Higher, purer chroma 6-48 microns Hi-Lite Super pigments (Z Fraction) Older coating technology Lower chroma, more pearly 6-48 microns Mearlin® Micro-Pearl pigments Small particle size, 2-24 microns
- 13. Metallescent Pigments Combines a metallic appearance with the softness of pearl Silver Gold/Brass Bronze Copper Russet
- 14. Firemist ® pigments Firemist ® 5-300um 5 microns thick High transparency No flow lines Firemist ® Super pigments 5-60 um 0.5 microns thick Smooth appearance
- 15. Special effect pigments Black Olive ™ pigment Mica-based product that imparts a dark silvery effect Used in men’s packaging, electronics, styling tint Dynacolor ® pigments Interference mica pigment with additional organic layer Used in kid’s packaging and other brightly colored applications Mark-it ™ Laser marking pigment Provides high-definition marking for barcodes and graphics-YAg
- 16. Special effect pigments Mearlite ® pigments (UFI) Bismuth oxychloride pigments 2-25um sized crystals Imparts a very white lustrous appearance to plastics Used in high-end cosmetic packaging
- 19. Common resins employed in processing Styrenics: GPPS, K-resin for bottles Polycarbonate: PC/ABS for compacts, PC for closures,clear packaging and lenses Polyolefins: LDPE for pinch tubes, PP& HDPE for closures and blowmolded bottles Polyester: PET & PETG used for bottles and films
- 20. PVC Products: Pinch tubes, closures and blowmolded bottles, calendered film (flexible) Vertical blinds, capstock, trim etc (rigid) Effect Pigment loading 5.0% or more in Banbury (batch process) or two roll mill 5.0% in 20mil flexible films (from concentrate) 1.0% in injection molded pieces Flexible concentrate up to 20% in a twin screw extruder Additives Add pigments incrementally, Generally not needed Mineral Oil or phthalate (1g in 1000g batch) for dry blends Plateout Decrease loading of pigment and or plasticizer Extrude films more slowly to achieve better contact with rolls or use air knife
- 21. Solid Surfaces Polyester Corian Polyester & Quartz Zodiac PMMA Aristech
- 22. Processing challenges- Injection Molding & Blow Molding Flow Lines Caused by poorly designed molds Flow lines enhanced by color and effect pigments Solutions Change label placement Mold design or redesign Reduce sharp angles of molded piece Reduce mold openings or pins Center gating rather than edge gating Hot runners or static mixers Use CAD programs to predict where flow lines will emerge Processing changes Slower injection speeds Lower injection pressures
- 23. Processing challenges- Injection Molding & Blow Molding Flow Lines (continued) Processing changes Reduced clamping pressures Increased mold temperatures Longer residence time (curing) in the mold Formulation changes Larger particle sized pigments Less opaque pigments More transparent resins Lower pigment loadings
- 24. Processing challenges- Injection Molding & Blow Molding Splay Incompatibility of additives or letdown resins Excess moisture Dry pigments and resin prior to processing Overloading of pigments Add less than 2% of effect pigments Poor resin clarity Moisture Incompatibility of additives or letdown resins Splay from gated edge
- 25. Processing challenges- Injection Molding & Blow Molding Streaked bottles Poor dispersion Raise processing temperatures Increase screw speed Use an olefin screw if possible Dirty equipment Mandrel becomes clogged with charred resin or pigments Molder isn’t thoroughly purged from prior resin Weld line failure & stress fractures Moisture Incompatibility of additives or letdown resins Wall thickness Pigment selection Streaked bottle Clean bottle
- 26. Mechanical Solutions-Injection Molding Metering Screw Design L/D ratio-smaller ratio is better Screw length to outside diameter (20:1) Profile- use a longer transition and shorter meter Length of each zone (10:5:5) feed:transition:meter Channel depth of meter zone Deeper channel is better for effect pigments Compression ratio- lower compression ratios are better Depth of feed channel:depth of meter channel Helix angle-larger helix angle is better Pitch of screw flights
- 27. Processing challenges-Extrusion Loading limits Dusting Strand breakage Processing temperatures Throughput limits Pigment damage
- 28. MagnaPearl ® X Series High performance pigment High performance white pearlescent pigment Developed for the master batch industry Pigment is encapsulated in a proprietary preparation Appearance benefits Unique performance attributes Approved for food contact applications Engelhard’s high performance effect pigments improve manufacturing efficiency & reduce costs
- 29. MagnaPearl ® X2100 High performance pigment Increased throughput 50% improvement vs untreated product 25% improvement vs competitive products Enhanced visual appearance Less damage to pigments from extrusion Reduction in processing additives Reduces dusting Improves feed flow Reduces strand breakage Increased loadings Greater than 35% Reduced processing temperatures Easier cleanup and purging Experiments *Not attainable 35 160 MagnaPearl ® X2100 35 N/A* MagnaPearl ® 2100 25 160 MagnaPearl ® X2100 25 100 MagnaPearl ® 2100 Loading % pigment Throughput Grams/minute Sample
- 30. Mechanical solutions-extrusion Twin screw extrusion Allows for higher pigment loading Yields higher throughput 2 feed system Allows for higher pigment loading Less pigment damage Better dispersion Screw design and Static Mixers Low shear design Distributive rather than dispersive mixing Distributive Mixing (elongational flow)* Dispersive Mixing (shear flow)* *Courtesy of Rauwendaal Extrusion Engineering
- 31. Blending Guide for Effect Pigments For Polypropylene 1% Pearlescent pigment 0.125% Mineral Oil or DOP 1% LDPE Wax or other plasticizer For ABS 2% Pearlescent pigment 0.125% Mineral Oil or DOP 0.125% Magnesium Stearate For Polystyrene 0.5% to 1.0% Pearlescent pigment 0.125% Mineral Oil or DOP 1% LDPE Wax or other plasticizer Blending Procedure Blend resin and oil for five minutes Add the wax or stearate Add the pearlescent pigment Tumble for 20 minutes
- 32. Styling for trend and color forecasts Packaging Trend Trendance (Teletronics/Interior Automotive)
- 33. Real-world Technical Experience Technical Services Color/Effect matches Resin compatibility issues Customer requests Styling Product updates and offsets Plant and production trials Industries Served Concentrate Houses Molding and Extrusion Customers Other raw material suppliers Electronics, packaging and appliance designers
- 34. Interested in an Innovation Session for your products? Contact Information Doreen Becker Office: 914-737-0985 x 227 Email: doreen.becker@basf.com