Science of Plastics Instructor Guide

1. Science of Plastics Instructor Guide

2. Science of Plastics Introduction General Characteristics of Plastics Technical Make-up of PVC Resin Review Questions & Answers PVC Compound Recipe Variables The End Recipe: Ingredients and Processes Review Questions and Answers Session Outline

3. Objectives At the end of this session, you will be able to: • Describe key scientific elements and terms for making vinyl • Define how PVC (PolyVinyl Chloride) compound is made • Describe the key ingredients & steps for creating the PVC that JELD-WEN uses in their extrusions

4. Listening Questions Listening Questions • Name three of the many properties of plastic. • What is polymerization? • What is a monomer? • What is a polymer? • PVC stands for what chemical name? • What two chemicals are used to eventually create VCM? • Who performs the testing and grading for the PVC Resin? • Does JELD-WEN mix their own PVC? Vinyl compound pushed out from a die

5. The Benefits of Window Grade PVC PlasticsProperties • Lightweight • Water Proof • Chemically Resistant • Varieties of Colors • Does not Rust or Rot • Opaque • Lower Density than Metal • Moldable - Extrudable

6. Question Answer the question. Name 3 of the many properties of plastic. • Answer: • Lightweight • Water Proof • Chemically Resistant • Varieties of Colors • Does not Rust or Rot • Opaque • Lower Density than Metal • Moldable - Extrudable

7. The Benefits of Window Grade PVC Plastics Plastics • Responsible • Safe • Efficient • Recyclable • Economical • Durable • Innovative • Versatile

8. The Benefits of Window Grade PVC PlasticsResponsible Responsible • Life Cycle Assessment (LCA) • Worker Safety • Recycling • Landfills

9. The Benefits of Window Grade PVC PlasticsSafe Safe • Fire Retardant • Low Toxicity • Food Grade Ingredients

10. The Benefits of Window Grade PVC PlasticsEfficient Efficient • Energy Efficiency • Thermal Efficiency • Water & Air Infiltration Resistance • Reduced Material Use • Efficient Products

11. The Benefits of Window Grade PVC PlasticsRecyclable Recyclable • Post - Industrial • Post - Consumer

12. The Benefits of Window Grade PVC PlasticsEconomical Economical • Production • Distribution • Installation and Function • Disposal

13. The Benefits of Window Grade PVC PlasticsDurable Durable • Building and Construction • Resource Conservation • Low Maintenance

14. The Benefits of Window Grade PVC PlasticsInnovative Innovative • Processes • Applications Gates - Christo

15. The Benefits of Window Grade PVC PlasticsVersatile Versatile • Form and Appearance • Function

16. JELD-WEN & PVC • PVC or polyvinyl chloride is the plastic used to create JELD-WEN’s vinyl extrusions • JELD-WEN recycles vinyl by-products to reduce environmental impact and costs • By understanding how PVC Resin and PVC Compound is made, you will be able to ensure quality of the extrusion during the entire manufacturing process

17. Plastic Composition: Molecular Structure • Polymerization is a chemical reaction in which two or more monomers combine to form a polymer of repeating structural units. • Monomers are the repeating structural unit, and are typically hydrocarbons, silanes*, or amides*. • Polymers are a chain of either a single type of monomer or several types arranged in a repeating pattern.

18. Question Provide a definition. What is a polymer? • Definition Dimensions • Plastic is made of long chains of carbon molecules. • Products that are made of long carbon chains are called polymers.

19. Question Define the following term: What are monomers? • Definition Dimensions • Plastic is made of long chains of carbon molecules. • Products that are made of long carbon chains are called polymers. • A monomer can be chemically bound as a unit of a polymer. • Monomers are repeating structural units and are typically hydrocarbons, silanes, or amides.

20. HOW IS PVC MADE? PVC Industry Ethylene EDC VCM PVC Chlorine PVC Products PVC PVC Converter Industry

21. Question Answer the question. What is the abbreviated chemical name for polyvinyl Chloride? Answer PVC

22. Question Provide a definition. What is polymerization? Answer Polymerization is a chemical reaction in which two or more monomers combine to form a polymer of repeating structural units.

23. Question Answer the question. What two chemicals are used to eventually create VCM? Answer Ethylene & Chloride

24. PVC ResinIndustrial Standards Resins • Are engineered for specific uses • Are made of different monomers • Have industry standards they must meet • Have standards that include but are not limited to color, density, weight, gravity, and/or bulk JELD-WEN does not make PVC Resin

25. Question Answer the question. Does JELD-WEN make their own PCV Resin? Answer No. JELD-WEN buys their PVC Resin from a supplier.

26. Properties • Properties of plastic are determined by the lengths of the plastic molecule and the specific monomer present. • Elastomers or rubbers are plastics that are composed of long twisted molecules which stretch and recoil like a spring.

27. Review Questions What do we remember?

28. PVC Compound Recipe

29. Why a Recipe? Pure PVC ResinIS NOT Useful • Poor Heat Stability • Sticks to Metal Parts • Poor Impact • Poor Weather Ability • Pale Yellow • Semi Opaque

30. Question Answer the Question Why is pure PVC Resin not useful? • Poor heat stability • Sticks to metal parts • Poorly receives impact • Poor weathering • Pale yellow • Semi opaque

31. Formulating a Recipe What is formulating? • Formulating is the modification of a pure PVC resin by adding other chemicals that will offset the undesirable properties. • The end product of formulating is therecipe. • Each recipe is engineered for a specific end use like windows or pipe.

32. Question Fill-in-the-blank.Additives, Modification, Properties What is formulation? Formulation is the _______________of a pure PVC Resin by adding other chemicals or ____________ that will offsetundesirable _____________. modification additives properties

33. Question Fill-in-the-blank The end product of formulating is called a _________. recipe

34. Compounding High Intensity Blending or Compounding • The process of mixing all the ingredients • Uses very specific equipment and follows very specific rules or steps that are part of the recipe

35. Review Question Fill-in-the-Blank High intensity blending or ________________ is the process of mixing all the ingredients and using specific _______________ in a recipe. compounding steps or rules

36. Additives Overcoming Poor Heat Stability • Add heat stabilizer • Liquid tin type • Level range from 0.8 parts to 1.5 parts Overcoming Sticking to Metal • Lubricant package of 2 to 4 different lubricants • Improves melt flow characteristics & surface gloss

37. Additives Overcoming Poor Weatherability • Add ultraviolet block & absorber • Example: White pigment Titanium Dioxide • Provides base for white & improves opacity • Improves melt strength • Improves modulus (stiffness of the finished profile) • Levels used depend on where the windows are being sold

38. Question True or False? An additive is a chemical that offsets a positive property of a plastic. Answer: False An Additive is a chemical that offsets a negative property of a plastic. For example, The filler, calcium carbonate which is also known as chalk or limestone is used to improve melt strength.

39. Additives Process Aid • Improves Process Ability Impact Modifier • Improves Strength • Emproves Ductile Characteristics Drop Test Results Drop Dart Lab Test

40. Additives Fillers Are Used to Improve • Melt strength • Stiffness of the window profile • Reduces costs slightly • Most common: Calcium carbonate (chalk or limestone) • Levels vary from 0 to 5 parts

41. Matching B. Heat Stabilizer D. Lubricant A. Titanium Dioxide C.Fillers like calcium carbonate known as chalk or limestone.

42. The Recipe: Ingredients & Processes

43. Question Can you substitute one additive for another additive in a standard recipe and still manufacture a successful profile? Answer: Probably Not Any change in the formulation of a recipe will impact the performance of the end product.

44. 7 Step PVC Compound RecipeStep One Step One • Add resin • Mix at high speed until it reaches 140º F 140º F

45. 7 Step PVC Compound RecipeStep Two Step Two • Add a Heat Stabilizer -often a liquid tin type • Mix until 160º F 160º F

46. 7 Step PVC Compound RecipeStep Three Step Three • Add the lubricants • Make sure the lubricant is evenly coated onto the resin • Mix until 180ºF 180º F

47. 7 Step PVC Compound RecipeStep Four Step Four • At 180ºF, add the process aid and impact modifier • The process aid helps fusion during the extrusion process • The impact modifier improves the poor impact properties of pure PVC • Mix until 210º F 210º F

48. 7 Step PVC Compound RecipeStep Five Step Five • Add Titanium Dioxide, which adds opacity, white color and resists ultraviolet yellowing • Add Filler, which will help to reduce costs & improve melt strength • Add color pigment package • Mix until 220º FNOTETitanium dioxide and calcium carbonate are very abrasive and are added last to avoid excessive wear to the processing equipment. 220º F

49. 7 Step PVC Compound RecipeStep Six Step Six • At 220º F the blend has reached the desired process temperature • Now the mixture is dropped into the cooler/blender where it will be slowly agitated and cooled to 120º F • The end products looks and feels like suger Note The cooler blender is normally 2 to 3 times the size of the blender. This allows the mixing of the blends. 120º F

50. 7 Step PVC Compound RecipeStep Seven Step Seven • The completed blend is now transferred to the storage silo. • PVC compound is now ready to ship to JELD-WEN