Plastics Additives

Content

1) An Introduction to Plastics Additives

2) Additives
2.1 Anti Counterfieting
2.2 Antimicrobials / Biostabilisers
2.3 Antioxidants
2.4 Antistatic Agents
2.5 Biodegradable Plasticisers
2.6 Blowing Agents
2.7 External Lubricants
2.8 Fillers/Extenders
2.9 Flame Retardants
2.10 Fragrances
2.11 Heat Stabilisers
2.12 Impact Modifiers
2.13 Internal Lubricants
2.14 Light Stabilisers
2.15 Pigments
2.16 Plasticisers
2.17 Process Aids
2.18 Reinforcements

3) What do additives add to plastics?

3.1 Make Plastics Easier to Process
3.2 Make Plastics Look Good
3.3 Additives Save Money
3.4 Make Plastics Safe and Sound
3.5 Make Plastics Clean and Healthy
3.6 Make Plastics Work Longer
3.7 Additives Respect the Environment

4) Additives: A Buyers Guide

1. An Introduction To Plastics Additives

Every activity in modern life is influenced by plastics and many depend entirely on plastics
products. Imagine cars without synthetic bumper, dashboards, steering wheels and switches;
medicine without plastic hypodermic syringes and artificial hip joints. And what about
telecommunications, dependent on plastic telephones, circuit boards and cable insulation. Our
entertainment and leisure relies on the unique combination of characteristics offered by plastics
in sports equipment and clothing, CDs, video and audio tape, television and cinema - indeed you
wouldn't be able to read this over the internet without plastics!

All these plastics products are made from the essential polymer mixed with a complex blend of
materials known collectively as additives. Without additives, plastics would not work, but with
them they can be made safer, cleaner, tougher and more colourful. Additives cost money, of
course, but by reducing production costs and making products last longer, they help us to save
money and conserve the world's precious raw material reserves. In fact, our world to day would
be a lot less safe, a lot more expensive and a great deal duller without the additives that turn
basic polymers in to useful plastics.

2. Additives

2.1 Anti Counterfeiting

Function:
There are a number of ways manufacturers and brand owners can combat counterfeiting by
employing one of several or indeed multilayer anti-counterfeiting technologies. Optical
brighteners absorb ultraviolet and violet light then re-emit this energy at a higher wavelength,
normally as a blue glow.
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2.2 Antimicrobials/Biostabilisers
Function:
Help prevent deterioration of plastic materials where part of the material might be susceptible to
microbiological attack. Such attacks can cause staining, discolouration, odour and loss of
aesthetics but more importantly, loss of electrical insulating properties, hygiene and overall loss
of mechanical properties in the material.
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2.3 Antioxidants

Function:
Help prevent "oxidation", the polymer reacting with oxygen. Oxidation can cause loss of impact
strength, elongation, surface cracks and discolouration. Antioxidants help prevent thermal
oxidation reactions when plastics are processed at high temperatures and light-assisted oxidation
when plastics are exposed to UV light.

2.4 Antistatic Agents

Function:
Help to prevent the build up of static electric charge. Plastics are generally insulating and so
have the capacity to build up static charges on the surface which greatly disturb processing
procedures and can be an issue for hygiene and aesthetics.

2.5 Biodegradable Plasticisers

Function:
Used to make plastics softer and more flexible and to enhance the degradability of the product.

2.6 Blowing Agents

Function:
Form gases in the plastic to produce a foam material. The blowing agents form gases by
breaking down on heating at a pre-determined temperature and form a foam structure within the
plastic's polymer matrix.
2.7 External Lubricants

Function:
To prevent damage to plastics or the mould during processing. Applied to the material or directly
to the machine to allow processing without damage.

2.8 Fillers/Extenders

Function:
Natural substances used to improve strength and lower the cost of the material. Usually mineral-
based, fillers/extenders literally increase the overall "bulk" of the plastic.

2.9 Flame Retardants

Function:
To prevent ignition or spread of flame in plastic material. Plastics see substantial use in critical
construction, electrical and transport applications which have to meet fire safety standards either
by mandatory regulations or voluntary standards. Flame retardants are added to plastics to meet
these requirements.

2.10 Fragrances

Function:
Fragrances and deodorants for plastics are used in a variety of applications and arer products for
the home.
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2.11 Heat Stabilisers

Function:
To prevent decomposition of the polymer during processing. Processing usually results in
temperatures well above 180 deg celsius, which without the addition of heat stabilisers would
result in the plastic material literally falling apart
2.12 Impact Modifiers

Function:
Enables plastic products to absorb shocks and resist impact without cracking. Particularly
relevant for polyvinyl chloride (PVC), polystyrene (PS) and polypropylene (PP) materials.

2.13 Internal Lubricants

Function:
Used to improve processability of plastics by increasing the flowability. Internal lubricants
improve the melt flow of material by lowering the viscosity and heat dissipation (also see
Processing Aids)

2.14 Light Stabilisers

Function:
Used to inhibit the reactions in plastics which cause undesirable chemical degradation from
exposure to UV light.

2.15 Pigments

Function:
Tiny particles used to create a particular colour.

2.16 Plasticisers

Function:
Used to make plastics softer and more flexible.

2.17 Process Aids

Function:
Used to improve processability of plastics by increasing the flowability. Internal lubricants
improve the melt flow of material by lowering the viscosity and heat dissipation (Also see
Internal Lubricants) High-polymeric processing aids also improve flowability of PVC
compounds.

2.18 Reinforcements

Function:
Used to reinforce or improve tensile strength, flexural strength and stiffness of the material.
Often fibre-based.

3) What do Additives Add to Plastics?

3.1) Additives Make Plastics Easier To Process

Making things out of plastics is like

playing a game with molecules. The aim
is to re-organise them into new shapes
without their changing colour, sticking to
the mould, or doing anything that could
spoil the finished article. Additives help
with all these problems. In fact,
processing plastics without additives is
virtually impossible.

Consider the range of plastics available

and the wide variety of plastic objects in
every day use. From fizzy drinks bottles
and carrier bags to window frames and
computers, it is clear that there are many
different ways of forming plastics. Most
of these processes involve melting
polymer powder or granules inside a
heated tube. This 'melt' is forced through
a shaped die, injected into a mould, or
rolled or blown into flat film. The ease
with which this is done depends on the
physical and chemical properties of each
plastic material, and can be improved
through the use of certain additives
known as PROCESS AIDS.
Process aids become liquid during the
moulding process and form a liquid
around colour particles so that they mix
better. Other additives make the
individual polymer particles adhere more
to each other inside the tube so that they
melt quicker. This means that the
moulding temperature can be lower
which saves energy and prevents or
minimises heat damage to the plastics.

Certain plastics can be difficult to

process because they become viscous
and sticky when they melt.
LUBRICANTS help reduce viscosity by
creating a film between the mould and
the polymer melt, and by lubricating the
polymer particles against each other.
More intricate shapes can be moulded
and the moulding temperature can be
lowered. Most plastics have to be
processed at over 180oC, a temperature
which unfortunately can sometimes spoil
the colour and weaken or embrittle the
plastic. However, these effects can be
prevented or minimised by additives
known as ANTIOXIDANTS, which are
special compounds such as Vitamin E,
which help protect the plastic under
hostile conditions. Other additives called
HEAT STABILISERS help stop plastics
from decomposing during processing.

3.2) Additives Make Plastics Look good

What is it about plastics objects that

catches our attention? Its shape? Its
usefulness? Its colour? Plastics are
coloured using two main methods. The
surface can be painted or printed after
moulding, or additives called
PIGMENTS can be incorporated before
or during moulding. With this method,
colour pigments can create all sorts of
decorative effects that go all the way
through the object and of course, will
never wear off. This property, coupled b
with the range of moulding techniques
available, gives designers today a
tremendous freedom when working with
plastics.

Pigments are tiny particles which have to

be evenly mixed into the polymer in its
molten state. Colourists specialise in
scientifically devising shades suitable for
all types of situations. Through a skilful
manipulation of additives, plastics
components can be colour matched with
parts made from other materials such as
wood, metal and fabrics, cars radios and
kitchen appliances all use this technique.

Different pigment formulations co-

ordinate plastics with other materials, as
in the Land Rover Discovery (BASF).

Fashion is a word that not only covers

clothes and accessories, but also
includes, tableware, kitchenware and
office equipment. In all these areas,
pigments enable plastics to offer an
endlessly variable palette of colours, as
vivid as any other media. Colour in
plastics also has many non-decorative
functions. It can be used to cut down
light to protect the contents of a package,
for example in medicine bottles. It can be
used as an important danger signal. Often
it is used simply to protect and conceal,
as in dashboards, machine housings and
pipes. To make an opaque moulding,
pigments are chosen that absorb or
scatter light very well. The most
common, cost-effective way of creating
solid colour is to use carbon black or
titanium dioxide. Carbon black absorbs
light, whereas titanium dioxide, with its
high refractive index, scatters light,
producing a very high level of whiteness
and brightness. It is part of a range of
inorganic pigments and is mixed with
other colours to create pastel shades.
Organic pigments are also good for
making bright colours.

3.3) Additives Save Money

There are two vacuum cleaners in a shop.

They both look attractive and offer the
same attachments, but one is on special
offer. Unknown to the customer, the
cheaper appliance has been made from
plastics components that contain no
additives. Does this make any
difference? What are additives for
anyway? Is the cheaper machine better
value?

Without an IMPACT MODIFIER, the

vacuum cleaner will crack if it is bumped
around the furniture and skirting boards
in the usual way. But since it would
contain no pigments, it would already
look drab and dirty. More worrying
would be the lack of FLAME
RETARDANTS, for if an electrical spark
causes the plastics housing to catch fire,
it will burn dangerously without being
able to extinguish itself. And this vacuum
cleaner is the one on special offer? The
other model may cost more, but in the
end will prove to be more cost effective.
The additives that assist the moulding of
plastics, such as lubricants, process aids
and heat stabilisers, can cost many times
more than the polymeric raw material,
and although only small amounts are
used, they are nevertheless essential and
greatly enhance the final performance of
the finished article.

Other additives such as MINERAL

FILLERS like chalk, talc and clay, are
naturally occurring substances and are
cheaper then the raw polymer. However,
they are not necessarily used to reduce
cost but for the benefits they give to the
basic material: talc and chalk increase
rigidity, clay improves electrical
properties. Mineral fillers also increase
the thermal conductivity of plastics so
that they heat up and cool down quickly,
meaning shorter mould cycle times and
more articles produced at lower cost.
When a small saving of 0.5p per
moulding may not sound much, but if it
involves producing several injection
mouldings every few seconds this 'small'
saving can amount to many tens of
thousands of pounds over a year. There is
a wide variety of additives available to
help reduce costs.

3.4) Additives Make Plastics Safe And Sound

Good design in plastics includes the art

of combining the inherent safety
properties of plastics, such as
unbreakable materials, with appropriately
designed product features. Rounded
edges, child resistant closures and tamper
evident seals are examples. Even greater
safety factors can be built in through the
use of additives.

Most people are probably not aware that

all our major plastics are similar in
composition to natural polymers such as
wood, wool, silk or cotton. They are all
based on organic molecules which can
catch fire and burn. In some cases this is
not a problem, but in other situations it
could mean life or death. the building
materials that are used to construct our
homes, schools and public buildings
must be protected against fire by law,
which means they must nor ignite or
spread flame. Depending on the type of
plastics material and the likely hazard,
there are many FLAME RETARDANT
additives available to help satisfy this
requirement.
Tough crash helmets and colour coded
occurred regularly when pulleys
overheated, causing serious warning
lights are produced with additives
(Shell).

An excellent example of lives saved by

flame retardants in plastics is the
conveyor belt in coal mines. For many
years fires occurred regularly when
pulleys overheated, causing serious
accidents and deaths. But when belting
made from PVC containing high levels
of flame retardants was introduced in the
mid-1950s, these accidents stopped.

An increasing amount of plastics is found

in cars today. These man made materials
are often selected for their safety value.
Dashboards and bumper not only have to
look stylish and work well, but must also
prevent injury by absorbing and
dissipating the force of any impact. The
additive type used in this case would be
an impact modifier. Pigments are
additives usually chosen to make plastics
look more attractive, but they can also
increase the safety factor, such as the
special colour-coding for electrical
wiring. Designer often use colours to
accentuate the controls on machines and
day-glow pigments prevent many road
accidents: runner and cyclists wear
reflective fabrics and strips, while road,
rail and building site workers can easily
be seen in their fluorescent helmets and
jackets.
3.5) Additives Make Plastics Clean And
Healthy

Hand in hand with advances in medical

science, plastics have become an
important medium for raising standards
of hygiene to the high level we now
enjoy. Throughout our lives, plastics help
prevent disease and prolong active
healthiness. PVC, for example, with its
low toxicity, flexibility, clarity and
sealing properties, all achieved through
additives, has become one of the most
important plastics in medicine.PVC
tubing, blood transfusion sets and
disposable packs of equipment have
helped create an easier and healthier
lifestyle. Additives have allowed the
development of a sealed system of PVC
tubing and bags which separates blood
into its constituents without the need to
open the equipment. This has led to a
whole new field of blood component
therapy. Plasticsed PVC medical bags
help save lives.

To prevent plastics materials from

becoming hard and brittle at low
temperatures, or soft and sticky at high
temperatures, additives are used to
'design' the plastics for its specific end
use. Today plastics containers can be
transferred from freezer to microwave
and remain virtually unbreakable and
safe in all conditions.

Polythene, and later polypropylene,

inspired a post-war revolution in
kitchenware. Now we have something
even more versatile and good-looking -
Clingfilm - which can prevent micro-
organisms spoiling fresh or cooked
foods. To do this the polymer is
formulated with suitable additives such
as plasticisers and non-toxic stabiliser
systems. The plasticiser makes the film
very clingy so that bacteria cannot get
into the food, yet the film can also be
permeable so that oxygen and water
vapour can pass through for safer
storage.Most plastics are by nature
insulators, and this property has
encouraged the development of a myriad
of electrical products which are safe and
a pleasure to use: telephones, shavers,
hairdryers, radios, TV sets and food
processors. Their plugs, sockets and
wires are of course all insulated with
plastics as well. However, being non-
conductive, static can build up in plastics
which attracts annoying dirt and dust.
The additive that helps to counteract that
problem is known as an ANTI-STATIC
AGENT.

3.6) Additives Make Plastics Work Longer

Many natural materials decay with age -

even granite erodes over the years. In the
world of plastics measures are being
taken to protect products from the effects
of time. In extending the life and service
of plastics, the unseen protection given
by additives can result in materials which
lead to new products for even more
demanding situations. Imagine the
conditions that plastics are subjected to -
heat light, electric current, water
weathering, cold, and knocks and kicks
of continual use in the home, office
factory or field. Effectiveness is critical.

Cars are good examples. The next time

you are out in a car, take a look at the
exterior and interior and under the
bonnet. Not only will you find more
components than ever before made of
plastics, but many of them - from
bumpers and wheel trim to steering
wheels and door panels - have to endure
long exposure to the elements, as well as
flying stones, scrapes, knocks and wear.
Look at the engine with its plastics
mouldings, cables and tubes. Conditions
are tough, temperatures are high, yet
plastics components still have to - and do
- work effectively. In all these cases the
longer life additives are silently at work.

Non-fading pigments will help

these Spectrum stadium seats to hold
their colour for many years (Hille).

Children's toys and garden furniture,

packaging and flooring are just some of
the products that form the backdrop to
our lives, and it is hard to overestimate
the rough treatment they have to endure.
In sports stadiums, more and more
spectator seating is moulded in brightly
coloured plastics, and playing surfaces
are often made of synthetic fibres. All of
these are exposed to the weather, day and
night, summer and winter, but a
combination of LIGHT STABILISERS,
UV ABSORBERS and
ANTIOXIDANTS ensure constant high
performance. Natural materials usually
have to be finished off after manufacture
with paints and lacquers. plastics enjoy
the advantage of incorporating before or
during the moulding process the
additives that prolong their useful lives
for many years.
3.7) Additives Respect The Environment

We all tend to think that plastics

consume energy. In fact plastics actually
help to save energy in many different
ways. For example plastics in cars save
European motorists some six billion
litres of fuel per year. This is because
plastics have replaced heavier metal parts
and inspired designers to create wind-
cheating aero-dynamic shapes that cut
down on fuel consumption. Without
additives to give plastics strength and
durability, this would not be possible.

When certain plastics are moulded at

around 220oC, particular additives called
BLOWING AGENTS break down to
form gases such as nitrogen, carbon
dioxide and water. These gases, trapped
in the plastics, turn the material into
foam, thus increasing the insulation and
energy absorption properties and
reducing weight. These foams can be
seen in everyday use such as protective
food packaging, cushioning in sports
shoes and in automobile parts where
lower weight saves fuel.

Three stages in the life cycle of time

controlled degradable mulching film:
begin the growing season,
partlydegraded film after harvesting and
the film after ploughing. (Prof. G Scott,
University of Aston)
Throughout the world crop yields are
boosted by plastics film laid over the soil
to trap heat and moisture. Tomato
production, for example, can be
increased by 300%. But what happens to
the plastic sheet at the end of the growing
season? Additives have been developed
that allow the sheet to capture the sun's
warmth during the growing season but to
break up as soon as the harvest arrives.
The sheets disintegrates due to the action
of sunlight and the fragments can be
ploughed into the soil where the soil
bacteria quickly breaks them down into
carbon dioxide and water. In areas of
predictable climate, this process can be
timed to an accuracy of within seven
days. Where plastics cannot be reused or
recycled, biodegradation could offer a
clean, safe method of disposal.

Plastics waste disposal can cause

problems, especially as plastics are
usually mixed up with other types of
waste such as paper, metals and food. For
recycling they really need to be sorted
into individual polymer types such as
polythene, polystyrene or polyvinyl
chloride, otherwise they have no strength
if remoulded and may literally fall apart.
This is an area in which additives called
COMPATIBILISERS can help. They act
like chemical adhesives, sticking the
different waste plastics material together
so that a reasonable amount of cross-
blending can be accepted. Mixed plastics
waste can be remoulded into fencing,
pallets and road markers, thus saving
valuable timber. All this comes from a
waste product that would other wise have
been buried in a landfill site. Additives
are vital for reprocessing waste plastics
into useful second generation products.