The Mixing Process PVC
The Mixing Process PVC
The Mixing Process PVC
TECHNICAL
I N F O R M AT I O N
PLASTICS
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1. Introduction
PVC processing first requires a compounding process [1, 2], in which the PVC is
mixed with additives such as stabilisers,
lubricants, fillers and pigments to produce
a dry blend. It is important not only that all
components of the formulation should be
homogeneously mixed, but, in the ideal
case, that all components should bind to
the PVC particles.
In our experience, a number of problems in
processing can be traced back to agglomeration and separation resulting from an
inadequately compounded dry blend.
Poor mixing of the components is difficult
to correct subsequently and is often the
cause of problems such as fisheyes and surface flaws in semi-finished products.
Mix
Heat to 50C
Add lubricant
Mix
Heat to 70C
Add stabilisers
Mix
Heat to 90C
Mix
Heat to 120C
The vortex assists the homogeneous distribution of additives, while ensuring self cleaning of the mixing vessel and mixing
blade [4].
Mature
for 24 h
Add fillers/pigments
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2. Hot/Cold Mixing
The most widely used process for preparing the dryblend PVC is discontinuous
compounding in a two-stage heating/cooling mixing process [3, 7]. In this case, the
PVC powder and additives are first heated
to about 120 C in a hot mixer and then
cooled to about 40 C in the cooling chamber.
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At about 50 C, add the one-pack stabiliser system. The low-melting lubricant that this contains will liquefy,
disperse homogeneously and bind to
the PVC particles together with the stabilisers.
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In the best case, this yields a mixture of virgin PVC particles without additives and
PVC particles containing twice the amount
of additives than that produced in a conventional (single batching) mixing process.
In the worst case, the additives are not
completely adsorbed by the PVC grains
(because the available surface area is too
small), and some of them remain in the dry
blend as separate fractions.
In both cases, differences in density between the particles may lead to separation
during storage, conveying and metering
[6]. This results in poor homogeneity and
has a negative effect on the subsequent
process [10], leading to inhomogeneities in
the final compounding [1, 2], variations in
the gelation of the PVC, and therefore to
poorer quality of the semi-finished product.
3. Troubleshooting during
Mixing
In uPVC processing, the numerous problems that may occur can have entirely different causes. Problems must therefore
always be dealt with on a specific case-bycase basis. Often, there is no obvious relationship between the processing problems
and the PVC compounding process. Table
1 lists some typical problems that arise
from inadequate mixing. Omya also offers
technical support.
4. Literature
[1] Krger, E., Aufbereiten von PVC,
Dissertation, Aachen, 1985.
[2] cpm GmbH, Grundstzliches und Problemlsungen fr die PVC-Extrusion, Grossefehn, 2000.
[3] Langenberg, H., Design of Heating Mixers
for Plastics Compounding, Kunststoffe/Plast
Europe 76 (1986) 5, pp. 406-409.
[4] Pahl, M. H., Mischen von Schttgtern,
in: Schttguttechnik in der Kunststoffindustrie, VDI-Gesellschaft Kunststofftechnik, Dusseldorf, 1998.
[5] Pahl, M. H., Solid-State Mixing of
Plastics, Kunststoffe/Plast Europe 76 (1986)
5, pp. 395-405.
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Problem
Causes
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Solutions
Inhomogeneities/agglomerates during
the feeding of liquid components
The information contained in this Technical Documentation relates only to the specific material designated herein and does not relate to use in combination with any other material or in any process. The
information provided herein is based on technical data that Omya believes to be reliable, however Omya makes no representation or warranty as to the completeness or accuracy thereof and Omya assumes no liability resulting from its use or for any claims, losses, or damages of any third party. Recipients receiving this information must exercise their own judgement as to the appropriateness of its use,
and it is the user's responsibility to assess the material's suitability (including safety) for a particular purpose prior to such use (March 2009).
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