controlling shear to produce brilliant effect … · mineral mica is a delicate, natural, inorganic...
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CONTROLLING SHEAR TO PRODUCE BRILLIANT EFFECT PIGMENT MASTERBATCHESADVANCED TECHNOLOGY FOR SUPERIOR EFFECT PIGMENTS WITH MINIMUM DAMAGE
© Copyright 2015 - STEER Engineering Pvt. Ltd.
UNSEEN IS UNSOLD.
Gone are the days of just form and function. Consumers now
look for aesthetics as well as performance. And in today�s
overcrowded market place the competition for attention is a
fierce one. How does a packaged product stand out in a shelf
when there are ten other brands offering the same set of
benefits? How does a cosmetics manufacturer get millennials to
buy the product? How does an automobile salesman convince
his customer beyond the usual technical specifications? The
challenge of �getting noticed� is, perhaps, one of the most critical
issues that keeps manufacturers awake in today�s world.
At STEER, we have the answer to make you sleep better. As a leader in materials
transformation, we incorporate our in-depth knowledge of polymer sciences,
advanced technology and technical expertise to deliver innovative solutions that
help create the differentiation that brands and manufacturers look for. Our advanced
technology for processing special effect and mica-based pigments, helps
manufacturers create a new degree of visual engagement. Whether it is adding
lustre, sheen, glitter and sparkle, creating depth and luminescence or simply playing
with multicolour effects, our technology helps you process mica-based pigments
without damage to the extremely sensitive platelets, ensuring effective
colouration, brilliant appearance and the right visual impact and differentiation that
products and brands need to get noticed.
SPARKLE. GLITTER. SHINE. ATTRACT. AND SIMPLY DAZZLE.
Our technology for processing the extremely sensitive mica-
based special effect pigments, with minimum damage, has
helped us deliver outstanding results to leading
manufacturers and compounders of effect pigments.
TRUSTED BY SOME OF THE WORLD’S
LEADING EFFECT PIGMENT MAKERS
Mineral Mica is a delicate, natural, inorganic pigment. Coated mica crystalline
platelets, such as those used in effect pigments in thermoplastics (ex: for pearlescent
appearance), are extremely sensitive. Any alteration or change in size of the structure
will hinder effective coloration and alter the appearance of the pigments and plastics.
The biggest cause of attrition to the structure is exposure to shear during various
stages and unfortunately most of the technology available today does not
account for some or all of the following;Ÿ Efficient mixingŸ Control over shear and elimination of shear peaksŸ Efficient energy transmissionŸ Stagnation and Degradation and the resulting char formation
Moreover, selection of the right twin-screw extruder is also critical. Key
requirements include;Ÿ A deeper extruder flight depthŸ The right Screw to barrel clearance to prevent �Leakage� and subsequent damage due to shearing.Ÿ The ability to work with low-bulk density materials.
PROCESSING MICA-BASED EFFECT PIGMENTS:
UNDERSTANDING GAPS IN TODAY’S TECHNOLOGY
PROVEN INNOVATION ADVANCED TECHNOLOGYMEETS IN-DEPTH KNOWLEDGE OF POLYMER SCIENCES:MEETS
STEER’S TECHNOLOGY FOR PROCESSING EFFECT PIGMENTS WITH MINIMUM DAMAGE
Effective processing on a twin-screw extruder requires the precise implementation of different
steps involved � Wetting, Dispersion and Task Specific mixing (Distribution and Stabilisation). At
STEER, we have mastered the art of processing mica-based pigments with minimum damage,
allowing us to protect product quality, while ensuring an effective and economical product.
#1EFFECTIVEWETTING:
#2EFFECTIVEDISPERSION:
#3EFFECTIVEDISTRIBUTION &STABILISATION:
#4DEEPER ROOTDEPTH
#5ADDRESSING‘LEAKAGE’
#6LOW BULKDENSITYMATERIALS
EFFICIENT MIXING WITH STEER�S PATENTED FRACTIONAL-LOBE ELEMENTSSTEER�s patented Fractional-lobe mixing elements, address the gaps in today�s technology by allowing for mixing through elongation and laminar means in a non-filled process section. This allows for frequent splitting and recombination of the melt pool. STEER�s mixing elements have fully intermeshing and self-wiping characteristics to help with effective wetting in the intermeshing zone. Besides the shorter lead angles increase the frequency of holding.
SOLVING THE ISSUE OF SHEAR PEAKS IN THE 65-YR OLD 2-LOBE KNEADING BLOCKSSTEER�s special mixing elements reduce/eliminate shear peaks and still maintain a fully intermeshing and self-wiping characteristic. This reduction/elimination of shear peaks (through the use of multiple lobes) results in controlled energy input, improving both efficiency and effectiveness. Moreover the element geometries facilitate a controlled energy input depending on task � Simple shear for the reduction of cohesive aggregates and agglomerates, planar shear for high energy dispersion, low energy elongation.
PREVENTING STAGNATION AND DEGRADATION:STEER�s distributive mixing elements with fully intermeshing and self-wiping profile prevent stagnation and degradation and the resultant char formation. They facilitate distributive mixing characteristics while generating the right pressure. Besides, they also provide the ability to facilitate melt homogenisation prior to discharge from the extruder improving strand stability or dimensional accuracy.
1.71 DO/DISTEER�s OMEGA 1.71 DO/DI (the new standard in compounding) or the deeper root depth, draws more of the resin into the screw root and away from the shear forces that occur when the melt contacts the barrel wall.
One of the biggest causes of damage to the pigment is shearing that can occur when plastic containing the pigment, �leaks� back into the trailing screw channel. This occurs when the screw-to-barrel or screw-to-screw dimensions are large enough to allow leakage of the polymer. With STEER�s OMEGA 1.71 DO/DI co-rotating twin-screw extruder the �Barrel to Screw Gap and Screw to Screw Gap� are maintained at less than 0.25mm to have fully wiping effect rather than shearing effect.
STEER�s OMEGA 1.71 DO/DI co-rotating twin-screw extruder provides manufacturers the ability to work with shear-sensitive and low-bulk density materials, making it the ideal equipment of choice for working with mica-based pigments. Moreover, the patented conveying elements increase throughput by 5x while reducing the attrition that can occur with standard conveying elements.
STEER’S PATENTED SPECIAL ELEMENTS ARE AVAILABLE ONLY WITH STEER PLATFORMS
FOR FURTHER INFORMATION ON THE TRIALS OR TO WORK WITH US WRITE TO [email protected] OR VISIT STEERWORLD.COM
EQUIPMENT:Ÿ STEER�s Do/Di=1.71 Technology platform
OMEGA 40H; L/D=44Ÿ Special Design Elements by STEERŸ Loss-in-Weight FeedersŸ Strand pelletizer
MATERIALS:Ÿ 70% LLDPE, 30% PigmentsŸ Iridion 305 Solar GoldŸ Iridion 305 WM10 (PEWax dispersion)Ÿ Iridion 305 Pearlets PO (70% MB in PE)Ÿ Antioxidant, Additives�.
PROCESSING:Ÿ Three Screw Designs; �Standard� Hi-Shear
& �Optimized� Special ElementsŸ Screw RPM fixed @ 600 for all trialsŸ 170-230C
TESTING:Ÿ Microscopic Examination at MERCK as
per MERCK Standard Procedure
THE PROOF IS IN THE PIGMENTSTRIALS CONDUCTED AT STEER’S APPLICATION DEVELOPMENT CENTER IN BENGALURU, INDIA
FOR FURTHER INFORMATION ON THE TRIALS OR TO WORK WITH US WRITE TO [email protected] OR VISIT STEERWORLD.COM
“STANDARD” HIGH SHEAR DESIGN
“OPTIMIZED” USING STEER SPECIAL ELEMENTS – SIDE FEED
Pigment Top Cut = 60microns, Top Cut in Compounded Masterbatch = 28microns
Pigment Top Cut = 60microns, Top Cut in Compounded Masterbatch = 60microns,
�OVERSIZE PARTICLE DETECTED INDICATING LEAST PARTICLE DAMAGE�
ADVANCED TECHNOLOGY FOR PROCESSING MICA-BASED PIGMENTS WITH MINIMUM DAMAGE
DEEPER ROOT DEPTH FOR REDUCED SHEAR FORCES | BARREL TO SCREW GAP AND SCREW TO SCREWGAP’ < 0.25MM TO PREVENT LEAKAGE | ABILITY TO PROCESS LOW-BULK DENSITY & SHEAR-SENSITIVE
MATERIALS | BETTER ENERGY DISSIPATION | HIGH VOLUME, HIGH TORQUE
STEER’S OMEGA 1.71 DO/DI CO-ROTATING TWIN-SCREWEXTRUDER — THE NEW STANDARD IN COMPOUNDING
ADVANCED TECHNOLOGY FOR PROCESSING MICA-BASED PIGMENTS WITH MINIMUM DAMAGE
EFFICIENT MIXING THROUGH LAMINAR / ELONGATION MEANS | ELIMINATION OF SHEAR PEAKS WHILEMAINTAINING A FULLY INTERMESHING AND SELF-WIPING CHARACTERISTIC | EFFECTIVE DISTRIBUTION
& STABILISATION WITHOUT STAGNATION OR DEGRADATION
STEER’S PATENTED SPECIAL ELEMENTS
RFV Elements
SFV Elements
FME Elements
DSE Elements
FKB Elements
OSE (wave) Elements
5 10 GLOBAL OFFICES, SATELLITE OFFICES
APPLICATION DEVELOPMENT CENTERS3
STATE-OF-THE-ART FOUNDRY FOR SPECIAL STEEL1COUNTRIES SERVED39
EMPLOYEES500+
PATENTS 33
350000 ELEMENTS SOLD
EXTRUDERS INSTALLED470
Satellite Office
Application Development Center
Global Office
Countries Served
Foundry
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STEER is a creator of materials platform technology that effectively transforms and functionalises materials in the fields of plastics, pharmaceuticals, food & nutraceuticals, biomaterials and biorefining. Founded in 1993 by Dr. Babu Padmanabhan with a vision to steer a new world, STEER today has 5 global offices and 10 satellite offices, serving over 39 countries and employs over 500 gifted engineers, scientists and technicians across the globe. With 33 patents for breakthrough innovations, STEER is committed to the design, creation and implementation of advanced platform technologies, components, elements, peripherals and applications that help our customers, and the world at large, to move forward.
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