Blow Moulding

Trends, Technology & Applications

Polypropylene & Polyethylene

Dr U.K.Saroop
Reliance Industries Ltd
Parable of
Three Wise Men
 Parable of Three Wise Men:
The Green House Effect

World energy-related CO2

emissions by sector 2004:
other
8%
Transportation
Residential 20%
13%

Industry
18%
Power
Generation
41%

Total = 26.08 bln. mt

The world has warmed by 0.74°C in the last century

Will warm 0.2°C per decade

Global temperature would increase by 3°C by the turn of this century
(Source: Financial Times / International Energy Agency )

Climate Change – sparking events, that haven't

happened in 650,000 years
 Parable of Three Wise Men:
Zurich by Turn of the Century

Pressing the Panic Button –

Three Wise Men called for providing immediate solution
 Parable of Three Wise Men:
Wiseman 1: Theory of Carbon Sequestration

Carbon Capture and Sequestration
– help ameliorate global warming

By 2050, every year 5-10 billion
Tons of CO2 will be buried

Saline Aquifiers – sandstone
formations evaluated for storage

US$ 6 million project in 2004

Compressing 3,000 tons of CO2 into a supercritical fluid

Pumping it 1.6 km below surface into 2.3 mtr. thick sandstone layer

High Cost and Space requirements may become limiting

factors !
 Parable of Three Wise Men:
Wiseman 2: Theory of Hydrogen Fuel
• Transporting energy both in Electrical and
Chemical Form
• Two conduits - ~ 1 mtr. Dia.
• Electricity – through (red) resistance free
pipes made of super conducting materials
• Chilled Hydrogen as liquid (blue)
maintain temp. ~ absolute zero
• Simultaneously transmit
– 5 gigawatts of Electricity
– 10 gigawatts of Thermal Power

Technology development – a long way to go !!

Parable of Three Wise Men:
Wiseman 3: Theory of Common Sense

….. Use
more & more
Polyolefins

The question is …..

Parable of Three Wise Men:
The question is ???

And the answer is ….. POLYOLEFINS

 Parable of Three Wise Men:
Polyolefins: Environmental Value Added (A Case)

• Avg. mid-sized car in US contains $2219 of

Chemistry (Including both Chemical Products & Processing)

• Total amount of Chemistry in Automobiles US$ 31.5 bln

• Chemical products make up ~ US$ 800 of the total value
of the car
• On an avg. contains 150 kg of Plastics (8% of total wt)
• Enhancing Efficiency (West Europe Case)
• Each 4.5 kg of plastics substituted improves fuel
efficiency by 0.11 to 0.14%
• Annual fuel savings of over 2.3m t – equivalent to 9.2 m t
CO2 emissions

Polyolefins – offering hygienic, environmentally safe

products
Polyolefins
in Rigid Packaging
Rigid Plastic Packaging
Rigid Plastic
Packaging

Injection Moulding Blow Molding Thermoforming

Pails, Closures, Boxes Bottles, Jars Disposable Cups, Glasses, Punnets

Blow Moulding
Processing
Blow Moulding – Diverse Process Technologies

Blow
Moulding

Extrusion
Injection Stretch
Injection–Stretch
Blow Moulding Injection
Blow Moulding
(EBM) Blow Moulding
(ISBM)
(IBM)

Commonly used Plastics are : PP, HDPE, PVC, PC, LDPE, LLDPE, EVA,
Polystyrene, HIPS, ABS, SAN, PVC & PET
 P O L Y P R O P Y L E NE

Versatile Polymer : Designer’s

Choice
Global PP Demand
MMT

60

40
53
20 41

0
2005 2010
PP - CARG 5.4%

Source – CMAI 2006

 PP Producers in India

Plant Location Technology Process Capacity

IPCL Baroda MONTEDITION, Italy Slurry – HYHA

IPCL Nagothane HIMONT, Italy Spheripol 70,000
IPCL Baroda MONTELL, Italy Adipol 1,00,000
RIL Hazira UNIPOL, USA Gas Phase 4,00,000
RIL Jamnagar UNIPOL, USA Gas Phase 6,50,000
HPL Haldia Montell Spheripol 2,10,000

Total 1.43 Million MTA

RIL + IPCL Contribute 85% of Total PP in India

Polypropylene …
PP : Versatile Polymer……

Lightest Commodity Plastics – Density of 0.90

High strength : weight ratio

Excellent moisture barrier

Very High Filling & Service Temperature (98 deg C)

Excellent chemical , fungal resistance & ESCR

Integral hinge property

Autoclavable and can potentially be steam sterilized

PP has excellent chemical resistance & ESCR Properties.

Easily recyclable
PP - A Versatile Polymer
…With the widest Performance Envelope
Izod impact at RT, J/m2
600
Optimum impact-
impact-stiffness balance

400

200

0 1000 2000
Flexural modulus, MPa
Polypropylene…

• Reliance Manufactures & Markets three main types of

Polypropylene under the Brand Name “REPOL”
 Homopolymers : Have high heat resistance and good rigidity,
making them suitable for a vast range of applications;
 Copolymers: which are made by incorporating different
monomers, are extremely resilient materials and have wide
uses in automotive and industrial applications.
 Random copolymers : which are made by introducing ethylene
links into the polymer chain, tend to have improved optical
properties, making them ideal for applications such as
packaging where transparency is required.
Polypropylene…..

PP – Material of Choice for Blow Moulding Apllications

 Very low density

 High stiffness
 High surface hardness
 Very good chemical resistance & ESCR
 Very Good Contact clarity & gloss
 Very low water absorption & transmission
 Good resistance to high temperature
 Elastomer modified grades for low temperatures toughness
 Ideal for smaller containers
 Guidelines for Processing PP : Blow Moulds

 Material of Construction :
Mild Steel
Aluminium
Beryllium Copper
 Essential requirements on the mould :
 Adequate cooling, preferably along the contours of the cavity
 Cooling of thicker areas of the article like neck, top and
bottom pinch-offs
 Proper alignment of the two halves
 Typical Construction of a EBM Moulds
– Venting : air vents & sand blasted mould surface to be
provided on mould to allow air to escape
 Pinch Off Design
– Pinch off land of 1.2mm recommended for PP as compared to
2.4mm for PE.
Guidelines for Processing PP : M/c Parameters

• For blow moulding applications, PP with MFI between 1 to

3 dg/min. should be used.

• Screw with L/D>20 and compression ratio >2 should be used

• Melt temperature should be between 180 & 220°C

• Adequate venting of mould is required for good container

surface finish

• Hot wire cutter should be used for parison transfer

• Adequate mould cooling for faster cycles and better clarity

Guidelines for Processing PP : M/c Parameters

 Processing Temperatures
 Feed Throat : 170 - 190°C
 Melt Temp. : 180 - 220°C

 Mould Temperatures
 Blow mould temps. : 20°C
 Adequate mould cooling for faster cycles and better clarity
Reliance PP Blow Moulding Grades :

MFI
Grade Type Special Characteristics
(dg/min)
H020EG Homopolymer 2.0 Good rigidity and processability

R019MZ Random Copolymer 1.9 Low odour, contains clarifier

Medical Grade Suitable for I.V.Fluid
SR20NS
Random Copolymer 1.9 application
SR20NC Random Copolymer 1.9 Low odour, contains clarifier
Suitable for Clarified PP_ISBM
SRM100NC Random Copolymer 10.0 application
C015EG /
MI 1530
Impact Copolymer 1.5 High impact copolymer
Clarified Polypropylene (cPP)
Additivated Random Co-Polymer

Opportunity Knocking
cPP Consumption : as a Percentage of Total PP

India vis-
vis-à-vis Global Average
7.5 %

3.1 %
Strive to Meet Global Average
PP Random Copolymer

Incorporation of Ethylene in PP
• Chain regularity disturbed.
• Decrease in crystallinity and rate of crystallization.

• Restrict the size of crystalline aggregates.

• Better clarity.

Use of Clarifier (Nucleation)

• Large number of crystallites having size less than wavelength of light.
• Effect : Better clarity and high stiffness.
Nucleated vs Clarified PP

Nucleators and clarifiers induce

formation of smaller spherulites
that scatter less light.

Inorganic Nucleators : Larger than the wavelength of light.

Sorbitol-based Clarifiers form a fibrous network within the resin that makes the
crystallites smaller than the wavelength of light.
(Source: Milliken Chemical)
Polypropylene Morphology

Standard PP Nucleated PP

100 microns
Photomicrographs - cross-polarized light
Characteristics of Clarified PP :

• Glass like transparency

• Excellent moisture barrier & Chemical resistance

• Higher continuous use ambient temperature

• Hot fill ( upto 98 Deg C), Retortable &

Microwaveable

• Excellent balance of stiffness , flexibility

• Live Hinge property

• Excellent ESCR property

• Cost effective

Clarified Polypropylene (cPP) ideally suited for Modern Life Style

Applications of cPP

Bottles and containers for :

• Mineral water • Cream
• Cough syrup • Baby feeding bottle
• Sterile fluid
• Shampoo
• Syrup & Squash
• Face powder
• Mouthwash
• Lotion • Tooth powder
• Ketchup
Blow Moulded Applications of cPP

Oral care products

Baby Feeding Bottles Shampoo bottles

Skin care products I.V.Fluid Bottles Food applications

 HIGH DENSITY
POLYETHYLENE
Polyethylenes : Characteristics
• Represents a family of resins prepared from the
polymerization of ethylene gas using a variety of
catalysts

• Density, melt index, crystallinity, degree of

branching and cross-linking, molecular weight
and molecular weight distribution can be
regulated over wide ranges. Further modifications
are obtained by copolymerization, chlorination,
and compounding additives.
Processing Of HDPE

• Extrusion Temperatures :
– Melt temperatures in the range of 175 - 205ºC are
recommended.
– Normally, temperatures of s190 - 205ºC will result in
optimum ESCR properties.
– No premium in stress crack resistance can be expected
by increasing melt temperatures above 215ºC.
• Mould Temperatures :
– Mould temperatures should be preferably 20ºC to
minimize cycle time. The cycle time also depends upon
mould design and atmospheric conditions.
– Mould temperatures should not be too low as this
would lead to mould sweating.
PE Application Portfolio
0 .9 6 0
IM (In d u s t ria l &
0 .9 5 5 G P B M (P e s t ic id e , R a ffia & H o u s e h o ld )
HM F & HM BM
C o s m e t ic s , L u b e & MF
Caps
0 .9 5 0 E d ib le o il
H M P ip e s c o n t a in e r )
0 .9 4 5
W & C
0 .9 4 0
< - ------ ----- -----D e n s i ty

0 .9 3 5
RM
0 .9 3 0

0 .9 2 5
IM & M B
B lo w n F ilm ( G P ,
0 .9 2 0 Cast
M ilk & L a m in a t io n EC
F ilm
) & D rip la t e r a ls
0 .9 1 5

0 .9 1 0

0 .0 1 0 .1 0 .3 0 .5 1 3 10 20 30 50
M e l t F l o w I n d e x ----- --->
Applications of HDPE

• Edible oil
• Chemicals
• Petro Products (Lube Oil)
• Pharmaceuticals
• Pesticides
• Cosmetics
• Toys
• Automotive Parts (Arm rest, windshield
washer bottle)
Applications Of Polyethylene

Bottles Edible Oil Containers

Milk Bottles

Pesticide Containers Lube Oil Containers

HDPE Blow Moulding Grades
Grade MFI Density Special Characteristics Typical Applications

Indothene 1.2 Bimodal MWD, Good flow Small vol. Containers and GP
0.954
54GB012 (I5) and ESCR. containers preferably upto 5 L
Indothene 1.0 Broad MWD, Very good 5-30L containers for lube oil,
0.950
52GB010 (I5) swell and impact edible oil, adhesives etc.
Relene Good melt strength and General purpose containers,
0.3 0.956
B56003 rigidity jerry cans (Upto 15L)
Relene 0.45 Good melt strength, Medium volume containers,
0.952
TB50004 (I5) Swell and ESCR liners, sheets, air ducts etc.
Good melt strength and
Indothene 0.45 Medium volume containers,
0.952 swell, impact - stiffness
52GB003 (I5) liners, sheets, air ducts etc.
balance
Broad MWD, good swell,
Indothene 0.40 Large containers, L-ring drums,
0.952 melt strength & Impact
52GB001 (I5) liners & barrels upto 240L
strengh
RIL Partnership
Role of Business Development Group

 Evolution of concept

 Explore / Identify new market

 Identify Modern technology

 Identify Entrepreneur / Investor

 Downstream development

 Nurturing new application / Promotion / Market extension

 Securing Approvals From Testing Agencies & End-

End-user

 Regulations / Mandation for driving Growth

Sector Management
• Bulk Packaging

• Rigid Packaging

• Flexible Packaging

• Automobiles

• Lifestyle & Appliances

• Textiles & Fibers

• Pipe & Profiles

• Downstream Development

Concept to Commercialisation
A Vital link amongst
M/c Mfg. - Business - Converter - End User

Machinery
Manufacturers Extensive support from

• PAT – Technical Support

• Nodal Agencies
BD • Govt. Agencies – for Spec in

End Users Processors

Concept to Commercialisation
We believe in Building Strategic Relationships

• Between business enterprises and their vendors

• Converting basic needs into commercially viable technology
• Helping produce useful products

Research
Institutions

End Users Business Machinery

Development Manufacturers

Polymer
Processors
 In short…...

Mould Maker & M/c Mfrs

• Concept Marketing
Existing Customers • Product Identification
• Market Survey
New Entrepreneur • Feasibility Studies
RIL • Development
State Ind. Dev. Corp. • Implementation
• Supply chain
OEM / End Users • Nurturing new Devp

Standard / Specs.

360°° Support - Complete package of Value Added Services

to Customers & Entrepreneurs