1. BOPP Films, Automotive Bumpers and PP Nonwoven Fabrics Three Case Studies for product and productivity improvements through tailored Additive solutions. INTERFACES ’05, Hungary September 2005
Wolfgang Voigt
Ciba Specialty Chemicals Inc.

2. Case Study # 1: Enhance BOPP Properties
Challenge: Production of BOPP Films is highly sophisticated and optimized, but faster processing and need to down gage brings PP resins to their limits.
Task:
Upgrading the efficiency of the Stabilizer systems, in order to meet the requirements of modern process technologies and end use properties

3. Ciba® IRGASTAB ® BOPP
State-of-the-art BOPP Base Stabilization System for superior Processing and Properties

4. Requirements for Additives In BOPP Film
Film processing :
Maintain processing window
Rework quality
Cost effective
Film performance :
No influence on color
Give excellent optical properties
No loss of mechanical properties
Packaging performance :
Organoleptic
No change in film shrinkage
Maintain surface adhesion/reactivity

5. BOPP Film Trends BOPP process and film trends : Increasing line speeds
(>500m/min)
Increasing line width
Decreasing film thickness
Increasing film modulus
Improved organoleptics
Improved printability / metallization

6. BOPP Film Trends PP producers modify polymer
structures to meet these requirements :
Random copolymers
Bimodal PP
Stereoregularity, ...
Enhanced stabilizer technologies are required to achieve the highest performance
Maintain polymer structure
Consistent process performance
Enhanced film physical properties

7. IRGASTAB® BOPP for Superior Performance
IRGANOX® B High Performance Phosphite Blend

8. Commercial BOPP Film, Reel End Colour
IRGASTAB®BOPP(1000ppm) IRGANOX®B215(1500ppm)

9. Customer confirmation of improved performance……..
Customer Experience Analysis
Customer confirmation of improved performance……..
Based on 20 micron film manufactured on 8m stenter.
Annual saving estimated to be 4% of manufacturing costs.

10. Ciba® IRGASTAB® BOPP
Is the state-of-the–art Base Stabilization System for BOPP resins, providing significant property and process advantages at a competitive price.

11. Case Study # 2: Nonwoven Fibers
Increasing
Line speed
Machine Width
Challenge: Discoloration of peroxide concentrates and unsatisfactory properties of nonwovens
Task:
Provide easy-to-use concentrate, enhance nonwoven barrier properties and improve storage

12. The Novel Polymer Modifier for Polypropylene Nonwovens
Ciba® IRGATEC® CR 76
The Novel Polymer Modifier
for Polypropylene Nonwovens

13. Ciba® IRGATEC® CR 76 A novel polymer modifier for PP nonwovens
provides
Outstanding barrier properties of meltblowns & SMS
Enhanced mechanical properties of meltblowns
Broader bonding window for spunbond nonwovens
Cost saving potential
Customer friendly product form and safety in use

14. Excellent Storage Stability
IRGATEC CR % peroxide 10% peroxide
0h, 80° C
50h, 80° C
500h, 80° C
Extrusion: twin screw, l/d = 42, 100 rpm, Tmax = 175° C, 4 kg/h, N2
Peroxide: commercial concentrate based on 2,5-dimethyl-2,5-bis-
(tert-butylperoxy)-hexane

15. Outstanding Meltblown Nonwovens
Standard PP MF 25 as raw material for 25 g/m2 meltblown
Up to 2 times higher
liquid barrier
Either 4 times higher
tensile or elongation

16. Controlled Vis-breaking Technology
Standard Grade
(e.g. MFI 25)
IRGATEC CR 76
T = 250°C – 300° C
Meltblown Grade
(e.g. MFI 1200)
Great control of MFI by adjusting either concentration and / or temperature

17. Ciba® IRGATEC® CR 76 Ames test: not mutagenic (OECD 471)
Skin Irritation: not irritant (OECD 404)
Skin Sensitization: not sensitizing (OECD 429)
Cytotoxicity: no cytotoxic (MEM Elution L929, “Grade 0”)
Ciba® IRGATEC® CR 76
Form: Granules
Packaging: 2 x 20 kg in box

18. Case Study # 3: Automotive Bumpers
Challenge: Paint curing systems are sometimes interacting with Light Stabilizers:
Task:
Develop a non interactive system

19. The Novel, Non-Interactive Light Stabilizer for Automotive Bumpers
Ciba® TINUVIN® XT 850
The Novel, Non-Interactive Light Stabilizer for Automotive Bumpers

20. Key Trends – Exterior (1)
Styling of exterior parts make the difference
But almost all are painted parts (80%) :

21. Key Trends – Exterior (2)
Or with two-tone bumper fascia (partially painted)

22. Key Trends - Regulations
Increased Aesthetics Durability
Degradation controlled up to 10 years
More stringent requirements for weatherability.
Facilitate future recycling
Rationalization of the number of resins used toward PP/TPO
Phase-out of PVC in interior applications toward PP/TPO
Reduction of VOC (Volatile Organic Compounds)
Lower Solvent (1K paint) or waterborne paint systems
paint adhesion becomes much more critical

23. HALS undergoes reactions with acids ...
ROO·
R=O + ROH R·
[Oxidation] R N O O·
cyclic
stabilization
mechanism R N R*
R* = - H
- CH3 R* H
Acid [H+] R N+ X
... TINUVIN® XT 850 does not.
-> conventional HALS become ineffective
-> acids become ineffective

24. A paint adhesion success : Customer A
Application : Partially painted exterior TPO parts
Issue : Poor Paint adhesion as conventional HALS interfere with paint cure in acid-catalyzed 1K systems
Solution : Blend based on TINUVIN XT 850 as non-interacting UV system
Effect : Durable „two-tone “ TPO bumpers with no paint-adhesion issues
Benefit : Made Customer A the leader in partially-painted applications for a regional market

25. TINUVIN XT 850... avoids paint adhesion failures
Stabilizer system
Taber scuff
[% removed]
Aggressive
adhesion test
0.4 % Standard HALS
0.2 % UVA
100 %
Fail
0.4 % TINUVIN® XT 850
0 %
Pass
1- component base coat (acid catalyzed) +
1- component acrylic clear topcoat (acid catalyzed)
Samples:
2 mm injection molded plaques
Natural reactor TPO contains: 0.05 % CaSt

26. ... outperforms in bright colors
Stabilizer system
Gloss Retention
at 2500 kJ/m²
at 3000 kJ/m²
0.4 % Standard HALS
0.2 % UVA
53 %
26 %
0.4 % TINUVIN® XT 850
74 %
70 %
Samples:
Weathering Conditions: SAE J 1960
PP/EPDM samples contain: 15 % talc % CaSt % IRGASTAB FS 301
color: % Pigment Red 177

27. avoids mold deposit
XT 850
Tin 791
Simulation of mold deposit caused by reaction with acids:
Reaction of additives with stearic acid in hexane:  Best performance by TINUVIN XT 850

28. Summary
TINUVIN® XT 850 is the product of choice when non-interacting properties, and low basicity are required, besides very good UV light stability.
CIBA® TINUVIN® Xt 850 creates UV weatherable applications for all Polyolefin-based systems in which interactivity can be an issue :
Partially-painted parts coated with 1K acidic-catalyzed paints
Formulations containing any other acidic components
Irganox PS 802
Stearic Acid

29. Conclusions
Development of today’s Plastic Additive solutions is increasingly focused on very specific requirements and applications like
helping polymers to keep the pace with state-of-the-art equipment (BOPP Extrusion Line speeds):
CIBA IRGASTAB BOPP
making polymers fit for new environmental challenges (solvent free paint systems are more critical in terms of adhesion  need for non-interactive systems):
CIBA TINUVIN XT 850
Modifying polymers for improved properties and higher flexibility in raw materials (better barrier properties, higher storage stability):
CIBA IRGATEC CR 76