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The PolyChem Development & Marketing
TsongKai Technology

 

New Plastics Additive
Super Saving TK Series
improve the performance of
Injection, Extrusion, Blow Film/Mold

 

Customer Testimonials and Field Tests/Demonstrations 

 

 

 

The case study outlined below includes ONLY the brief summary of its individual
test background and result; please feel free to contact your local dealer if you want
to know more about how TK Series can help your unique plastic processing.

Case# 017: PVC tubes, fittings manufacturer achieves higher profit by using high percentage of the recycled and/or scrapped PVC

Customer:

anonymous

Product:

PVC tubes, fittings, pipes

Resin Type:

PVC, virgin/scrap/recycled

Process:

extrusion

Filler Type

CaCO3 or TiO2

Customer concerns:

1. significantly more surface imperfection for PVC extruded parts when recycled or scrapped/regrind resin being used.
2. looking for cost reduction in material costs, including both resin and compounding additives, etc.

Tests Brief:

1. evaluate the quality performance effect by using of TK-1
2. investigate the highest possible % scrapped PVC in place of the virgin PVC
3. investigate the TK-1 effect on the dosage of expensive compounding additives

Tests Result: 1. Customer used 25% of scrap/recycle PVC in their production and failed the quality requirements. After added with TK-1, the recycled vs. virgin ratio can be raised to as high as 50% without quality imperfections.

2. If using customer's in-house scrap/regrind PVC with TK-1; customer finds they can even use up to 100% of the scrap/regrind PVC and also require only minimal of the original compounding additives. Refer below summary for the customer's cost analysis.

Formulation

Material Cost/Kg

Virgin PVC w/o TK

Scrap PVC w/ TK

Dosage, %

$$

Dosage, %

$$

PVC Resin (virgin)

32.730

100.000

3273.000

0.000

0.000

PVC scrapped/regrind

11.440

0.000

0.000

100.000

1144.000

PW 762

244.570

1.500

366.855

0.640

156.525

TK-1

350.000

0.000

0.000

0.120

42.000

Thermo. 412

104.000

2.000

208.000

0.000

0.000

FMS

60.340

3.000

181.020

0.000

0.000

Z 298

90.370

1.000

90.370

0.000

0.000

B 4674

31.820

2.000

63.640

0.000

0.000

CaCO3 calpet

7.760

1.000

7.760

0.000

0.000

TiO2

73.440

0.200

14.688

0.000

0.000

Pig. masterbatch

450.000

0.500

225.000

0.480

216.000

TOTAL

 

111.400

4445.605

101.240

1558.525

Unit Cost of Compound; $/kg

 

 

39.907

 

15.394

Cost Saving, $/kg

 

 

 

 

24.50

Cost Saving,  %

 

 

 

 

61 %

Summary:

1. Besides that we can use 100% PVC scrapped/regrind to substitute the virgin PVC; by using TK-1, we can now significantly save the use of composite additives (stabilizers, lubricants, processing aid, pigments, etc.) which needed in the standard compounding PVC resin.

2. The overall material costs saving was up to amazing 61% per this specific production test.

Major Benefits:

1. Better dispensability and enhanced processing. In general, the more recycled resin or the more filler used, the lower extrusion rate for PVC production; TK additive helps to increase the extrusion rate and therefore improve the production throughput
2. Minimized the use of PVC virgin resin material
3. Improved gloss and elimination of surface imperfections for parts processed with either high filled compound or scrap/recycled materials

 

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