TAGS: Sustainability / Natural Solutions
An Interview with Dale McCormick, Business Manager, Proprietary Products at Ingenia
Polymer processing aids (PPAs) are additives that improve the processability of polymers, especially in the extrusion process. They are used to reduce melt fracture in blown film and die buildup in extrusion which can lead to:
- poor-quality films,
- reduced output, and
- increased processing costs.
Per- and polyfluorinated substances (PFAS) are a group of chemicals that are used in a wide variety of products, including PPAs. However, they have been linked to a number of potential health risks, like cancer, reproductive problems, and thyroid disease. Thus, the packaging industry, brand owners, and regulators are moving away from PFAS materials.
The landscape of polymer processing is undergoing a remarkable transformation as Ingenia Polymers has developed and commercialized PFAS-free PPA solutions to support resin producer and converter markets. These groundbreaking solutions are poised to redefine these markets by providing safer and high performing alternatives to the traditional fluoropolymer-based polymer process aids.
In this interview, we asked Dale McCormick, Business Manager of Proprietary Products at Ingenia to explain and update us on new product development efforts to support the rapid change that the industry is making for moving away from fluoropolymer-based polymer process aids.
#1. Why are polymer processing aids used and in what applications are they most beneficial?
Polymer process aids are additives that are used to improve the processability of polymers, primarily in the extrusion process. The use of polymer process aids helps to alleviate melt fracture in blown film and die lip buildup in extrusion applications. In industry, melt fracture is also known as ‘sharkskin’, ‘orange peel’, and ‘apple sauce’. Die lip buildup is also known as plate out.
Placing a blown film over a standard graphic can illustrate the effect of melt fracture on haze and clarity. In the below picture, a melt fracture is evident on the left, while no melt fracture can be seen on the right.
PPAs are typically used in blown film, cast film, wire and cable extrusion, sheet extrusion, profile extrusion, and cast extrusion processes. An example of die build up in extrusion is shown below.
#2. Why are the packaging industry, brand owners, and regulators moving away from PFAS materials?
Specific PFAS materials such as perfluorooctanoic acid (PFOA) and perfluorooctane sulfonic acid (PFOS) have demonstrated:
- carcinogenic effects,
- toxicity in reproduction, and
- a significant danger to human health.
PFAS materials are ubiquitous, in many products that consumers use on a regular basis and are readily found in potable water at levels of concern due to the fact that they are biologically and environmentally persistent.
The Organization for Economic Co-operation and Development (OECD) developed a broad definition of per- and polyfluoroalkyl substances, and considering there are thousands of different PFAS-type chemistries in use for many different applications, it would take a massive effort and significant time horizon to test each PFAS chemical for potential toxicological effects.
Regulators are using the OECD definition of PFAS and this encompasses fluoropolymers, which have been used as polymer processing aids for decades. While the fluoropolymer industry objects on the grounds that high molecular weight polymers are of low toxicological concern, the change to alternatives is well underway in some jurisdictions and more specifically in food packaging applications.
#3. How are PFAS-free polymer process aids developed and evaluated to meet processors’ needs?
PFAS-free PPAs are developed at Ingenia through a careful review of alternative chemistries that are expected to provide similar performance benefits as existing fluoropolymer solutions that have been developed over the last five decades. The existing PFAS solutions work very well and the
development of alternatives that provide all of the same processing and performance benefits will be an ongoing process. From a processing perspective the key areas under evaluation are:
- the elimination of melt fracture,
- die buildup reduction, and
- extruder output at the same screw rpm.
In terms of film performance, the goal is to provide similar or improved haze, COF, printability, heat seal, and mechanical properties.
Steps to evaluate PFAS-free PPA solutions
- STEP 1 — Capillary rheology screening of an alternative PFAS-free PPA chemistry is the first step in our evaluations vs. industry standard fluoropolymer PPA.
- STEP 2 — Good candidates move on to blown film trials, where standard barefoot resins with a high propensity to form melt fractures are used to run time-to-clear studies.
- STEP 3 — Candidate chemistries with good time-to-clear results move to the next stage where their effect on die buildup is measured.
- STEP 4 — If a PFAS-free PPA candidate has good performance in terms of melt fracture elimination and reduction of die buildup, film property testing is completed to ensure film properties will be at par with expectations. With similar use levels (ppm) of PFAS-free PPA alternatives, downstream processes where machinability, printing, and sealing take place are typically unaffected. However, indicator testing is completed at the pilot scale to ensure the product is viable prior to commercial trials.
- STEP 5 — Additional film structures are produced at the pilot scale containing common additives used to provide other film properties. These additives such as anti blocks, slip agents, and UV HALS may have an antagonistic effect on the PPA performance and could disqualify a potential PFAS-free PPA from the final stage of testing, in which Ingenia works with key partners on commercial scale production evaluations at their sites. Using feedback and test data from commercial partners, products can be further optimized.
#4. How do you ensure your PFAS-free product offerings are truly PFAS-free?
Ingenia’s PFAS-free PPA masterbatches are not formulated with any per- or polyfluorinated substances (PFAS) and to the best of our knowledge none of our raw materials are formulated using PFAS. Ingenia works with outside labs to complete testing for fluorine content to address questions about non-intentionally added substances (NIAS). Two common methods of testing for fluorine are:
- oxygen/parr bomb, with a detection limit of 50 ppm and
- neutron activation, with a detection limit of 10 ppm of fluorine.
Both methods are used to evaluate prepared standards containing low levels of fluoropolymer PPA. Ingenia monitors the commercial production of lots of our PFAS-free PPA masterbatches for fluorine content by periodically testing for fluorine content by neutron activation.
#5. What refinements can we expect in terms of performance and applications for Ingenia’s PFAS-free PPA masterbatch offerings?
The initial development focus for Ingenia was to prepare a PFAS-free PPA for blown film application and our
IP1170 product has been a commercial success, supporting many customers who were early adopters of PFAS-free PPA technology. IP1170 does have some limitations in terms of regulatory approvals in certain food packaging films, so we have looked to broaden our focus to more globally compliant solutions.
Our most recent commercial offering,
IP1171, has broad regulatory compliance in food packaging applications. This grade also shows reduced die buildup in extrusion applications. We expect to see improved benefits with it in cast films, bi-axially oriented films, sheet extrusion, and profile extrusion and are in the process of evaluations in these applications.
Reduction of Die Lip Buildup
#6. Why are you offering more than one grade of PFAS-free PPA?
I don’t expect a one size fits all solution. While that would be ideal, there are many variables at play, like:
- Melt fracture avoidance is important in blown film applications but is not even created in cast films.
- Die buildup is of greater processing concern for other extrusion applications versus blown film.
- Also, in some extrusion applications, high thermal stability is of greater importance.
Differences in rheology and polymer type lead to different outcomes in terms of PPA performance. Ingenia is developing additional grades to further maximize specific performance attributes and assess their performance in different polymeric systems. Just as the fluoropolymer industry developed several generations of PPA products with tailored properties to improve the performance of specific applications, I expect the PFAS-free PPA industry to do the same.
Download Brochure - Introduction to PFAS-free PPA Solution with Broad Regulatory Compliance
VIEW ALL POLYMERIC PROCESS AIDS BY INGENIA
About Dale McCormick
Dale McCormick is the Business Manager for Proprietary Products at Ingenia Polymers. His focus is to develop and grow the company’s masterbatch business with advanced technology products, supporting the growth of more sustainable plastic products through the INCIRCLE® and INBIO® branded solutions that Ingenia offers. Target applications include the key market segments of food and consumer goods packaging, while he also has responsibility for all masterbatch products, across a variety of end markets.
Together with the Ingenia R&D, Sales, and Manufacturing teams, Dale brings Ingenia’s proven strengths to the market, combining Ingenia’s deep and specialized application knowledge with proven manufacturing capabilities and best-in-class customer service support to provide efficient, cost-effective, and sustainable solutions for each customer application.
Through his background at Amcor, Spartech and Ingenia, Dale has developed broad commercial and technical expertise in R&D, technical service, manufacturing, sales, product and market management. He holds a bachelor of science degree in applied chemistry from Brock University and resides in Ontario, Canada.
