CALENDERING
PROCESS FOR
PVC SHEET
MANUFACTURIN
G
By Srinithi.A (2022508015)
AGENDA:
• BASIC PRINCIPLE
• PLASTIC MATERIAL AND ITS
COMPOUND
• COMPOUND FORMULATION
• COMPOUND PREPARATION
• CALENDERING PROCESS WITH
PLANT DETAILS
• PRECAUTIONS
• TROUBLESHOOTING
• ADVANTAGES AND
APPLICATIONS
Calendering
process:
BASIC PRINCIPLE
•Calendaring is the process
of squeezing a plastic melt
between two or more
counter rotating cylinders
or rolls to form a
continuous film and sheet.
• The art of forming a
plastic sheet has been
adopted from the
technique of making paper,
metal and rubber in
industries
INTRODUCTION:
Both rigid and plasticized
Compounds of PVC resin can
be used in calendaring
process.
The sheet is formed in the
range of 0.1 to 1.0 mm and
above thickness. The sheet
can be transparent, colored,
embossed, printed or
laminated form.
Calendering is still king for high-
volume PVC sheet
Plastic material
and its
Compound:
The PVC resin is generally processed
in calendaring plant, and it needs
blending, mixing and compounding by
addition of suitable chemicals called
as additives and fillers to make
compound before processing in the
calendering plant.
Other then PVC resin ABS, PE, PP and
Styrene are also used for calendering
process.
COMPOUND
FORMULATION:
• PVC resin for rigid compounds made either by the
suspension or bulk polymerization process is best in the
1.7 to2.0 relative viscosity range.
•Homopolymer grades are used alone and in
combination with 2 to 10 percent acetate copolymer.
•Heat stabilizers are needed, when heated PVC naturally
tends to degrade, first by yellowing then by turning dark
brown and losing its physical properties.
Many types of stabilizers are used, Metallic
salts, mixed metal salts, organotins and tin
mercaptides are the major categories.
Stabilizers added to a formula between 0.1
and 5.0 percent to retard degradation by
tying up hydrochloric acid (HCL) generated
by the heat of processing.
Plasticizers are used to make
PVC soft and flexible but
thereby lower melt viscosity,
modulus and transition
temperature.
Two common plasticizer
groups are in use such as
Dioctyl phthalate (DOP) and
Epoxidized soyabean oil.
Impact modifiers are used to absorb
shock to improve impact resistance
of PVC compound. The selection of
ABS, MBS, Chlorinated
polyethylene(CPE) or acrylic polymer
chosen on the basis of their impact
efficiency, clarity, weather ability
and stress whitening, as well as their
processing characteristics
Process aids assist stabilization
and increase the melt strength
of the sheet during calendering
and post processes such as
thermoforming.
Lubricants are added to
reduce the tendency of
PVC to stick to the hot
metal rolls of Calenders.
• Lubricants are either
external or internal
depending on where they
are most effective. Stearic
acid or zinc and inorganic
stearates and soaps are
classified as internal
lubricant. Paraffin and
polyethylene waxes are
external.
Coloring materials and fillers:
The pigments or dyes which can withstand
temperatures of processing at about 180°C
should be considered. Pigments which are
suitable for coloring plastic materials are
metallic salts, lead, Cadmium based and also
organic colors are used.
Inorganic materials in the form of fine powder
can be added in the Plastic compound which
helps to reduce cost and improve properties.
The popular fillers are china clay (a hydrated
aluminum silicate) and the various grades of
chalks (Calcium Carbonates). Also red mud
(hydrated aluminum silicate) is also used as
fillers. The fillers improve the modulus and the
low temperature crack resistance is reduced
FORMULATION FOR
CALENDERING
Compound preparation (Blending & Fluxing)
The resin is premixed and blended with stabilizers and other
additives by using Ribbon blender or High speed mixture.
The premixing is done up to 80°C for better absorption and
soaking of the resin.
After blending of the two compounds, it is fed to a fluxing
machine. Fluxing is done under temperature at about
150°C.Fluxing can be done in banbury mixture or a continuous
extruder
The residence time of the plastic flux at high temperature
must be limited.
Sectional diagram of ribbon
blender
• After fluxing and gelation,
either a two roll mill or an
extruder is used to form
strands or any acceptable
forms.
• Melt is maintained and
delivered to the calender at
around
140-160°C.
• The calender roll squeezes a
plastic melt into a flat sheet.
The processing
parameter needs to
be set and control
Processing parameters: are temperature,
speed, pressure and
the nip gap
CALENDER ROLLS AND ITS HEATING
ARRANGEMENT:
>>calender rolls:
They are normally made of
chilled cast iron. Calendars are
High pressure hot water
also made with steel rolls
(H.P.H.W.), This is effective
which are more resistant and
method to heat and cool the
which exhibits less deflection
calender rolls by circulating
under the pressure of the
material in the nip H.P.H.W through each roll.
>Heating system:
The hot oil can be
High pressure steam is used on circulated through the
calendaring plants. Working rolls to achieve the high
pressure range - 680-1380 KN/m operating temperature..
and a temperature range 120-
185°C.
The rolls are heated either by steam or hot oil
and roll temperature ranges from 150° to
180°C.
Calendering Fluxed material delivered to the first calendar
process with nip is regulated to form a rolling bank. The
plant details sheet passing the first nip forms another bank
between the second and third rolls, at the
final nip, the desired thickness is obtained
from the smallest bank possible to minimize
stress in the sheet.
EMBOSSING AND
LAMINATING:
To create leather like grain or other
surface structure, the hot sheet coming
from the stripper rolls is passed
between a steel roll nipped by a rubber
roll that forces the PVC into the grain.
To laminate another sheet or a fabric to
the calendared sheet, it may be nipped
against the sheet on the last calendar
roll or a laminating station may be
installed in place of the embossing rolls.
sheet
Take off
s
roll
The sheet is cooled by passing it COOLING AND WINDING
over cooling rolls then through a
thickness gauge (e.g. betaray OF THE SHEET
device) prior to being wound-up.
If the sheet is wound up too hot,
it has a tendency to shrink
during the cooling process.
The sheet is then trimmed to
required width and wound on a
tube or cut to length and stacked
as sheets.
The trimmed edges of the sheet
can be recycled
Troubleshootin
g in
calendaring
process:
PRECAUTIONS TO BE
TAKEN DURING
PROCESSING:
Preparation of stock for calendering,
conditions on the calender, the take off,
thickness measurements, and control to
windup.
Other considerations include whether the
plastic is laminated to a fabric on the
calender. Whether the web is embossed or
slit in line; what finish is required (glossy,
matt or semi-matt).
ADVANTAGES:
APPLICATIONS:
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