Table Of ContentPVC
Formulary
2nd Edition
George Wypych
Toronto 2015
Published by ChemTec Publishing
38 Earswick Drive, Toronto, Ontario M1E 1C6, Canada
© ChemTec Publishing 2009, 2015
ISBN 978-1-895198-84-3
Cover design: Anita Wypych
All rights reserved. No part of this publication may be repro-
duced, stored or transmitted in any form or by any means with-
out written permission of copyright owner. No responsibility is
assumed by the Author and the Publisher for any injury or/and
damage to persons or properties as a matter of products liabil-
ity, negligence, use, or operation of any methods, product ideas,
or instructions published or suggested in this book.
Library and Archives Canada Cataloguing in Publication
Wypych, George, author
PVC formulary /George Wypych.--Second edition.
Includes bibliographical references and index.
ISBN 978-1-895198-84-3 (bound)
1. Polyvinyl chloride. I. Title. II. Title: Polyvinyl chloride formulary
TP1180.V 48W963 2014 668.4’236 C2014-901899-1
Printed in United States and United Kingdom
1
Introduction
There are many reasons for which researcher formulates the product and some dif-
ferences in approaches in various industries, but all reasons for working on formu-
lation belong to one of the two categories, such as:
• new product development
• product reengineering
The second is the most common in industry. In product reengineering, we
want to address new customer requirements, improve performance for competi-
tive reasons, increase product uniformity, increase production output and rate,
decrease production cost, or make production safer by application of new technol-
ogy or changing components of formulation.
Product reengineering requires less preparatory steps than new product
development because more is known about the product, which already has history
of production and performance.1 There are also disadvantages, in product reengi-
neering we already have available infrastructure (methods of doing things, pro-
duction lines, raw material suppliers, etc.), which restricts not only possible
changes but potentially freedom of thinking and evaluation.
Problem-solving theory known as TRIZ (teoriya resheniya izobretatelskikh
zadatch) was introduced in Soviet Union. It is known and used in western coun-
tries as TIPS (theory of inventive problem solving). As the name suggest this or
similar theory should eliminate some restrictions in “freedom of thinking and
problem evaluation” by using a methodology for generating ideas and solutions
for problem solving. Application of these kind of theories may be simplified (or
complicated) by the use of software, tool set, knowledge base, and/or statistical
analysis to facilitate process of functional analysis. The selection of methods is a
choice of researcher with understanding that tools do not solve the problem by
themselves. Solution usually requires knowledge of the following sequence of
reasoning: requirement → function → component → its construction → -
technology used to solve it. And this requires substantial amount of knowledge to
obtain expected results. Method of functional analysis of product reengineering
can be found elsewhere.1 “Component construction” and “technology used to
solve it” are major components of research on product formulation. Considering
that formulations may contain large number of components (or raw materials), the
effect of their interactions has to be known in order to avoid problems and unnec-
2 Introduction
essary “corrections” (addition of new raw material in order to correct damage
done to product properties by earlier selected components). Many such interac-
tions are known from literature or practice (e.g., reaction of lead stabilizers with
sulfur producing black stains), other, less common, have to be investigated.
In the new product development, many aspects of product performance, pro-
duction, and regulations have to be defined. The most elaborate systems are used
in pharmaceutical industry because of the very high cost of their research. It is
estimated that entire process from research to implementation involves over
10,000 interdependent activities.2 These activities include five principles of opti-
mal process development, such as2
• market advantage (demonstrates that product will effectively compete in
the market)
• product readiness (available information shows feasibility of product
development, expected product properties are defined, and program of
research is developed)
• program execution (research is executed, knowledge is produced to sup-
port claims of performance)
• learning and confirming (scientific learning studies form the knowledge
needed to obtain Proof of Concept)
• regulatory collaboration (requirements and constraints from regulatory
authorities in countries in which product will be sold).
Further details of this approach can be found in referenced publication.2 In
plastics industry this principles will rarely be used in full. Some elements included
in the market advantage, the product readiness, and the regulatory collaboration
are eventually considered in very abbreviated form, which is unfortunate neces-
sity of scale to cost ratio, because it leads later to problems with warranties, prod-
uct failure, loss of customers, and high costs of replacement. It is therefore
suggested that more systematic approaches to product development are consid-
ered, especially that studies focus on understanding all variables in production
process (interaction between components of formulation, effect of quality of raw
materials, effect of technological parameters, variability of technological parame-
ters on final quality of product), and influence of various parameters controlling
products use on their performance (environmental parameters, excessive tempera-
ture and humidity, exposure to radiation, contact with other materials, mechanical
forces, different climates, etc.).
In addition to the value of the research solution, management of research
project has high importance, because the current situation in the market place
requires that research results are delivered on time. Many companies use project
management tools and methods for managing their innovations, to ensure a better
product quality, better deadlines, and lower costs.3 Recent source gives risk-ori-
ented model which helps to assess strategic decisions in new product development
projects.3 Depending on a scale of the project, a similar approach may be imple-
3
Figure 1.1. Market for PVC in 2008. [Adapted, by permission, from Carroll, W. F., Johnson, R. W.,
Moore, S. S., Paradis, R. A., Applied Plastics Engineering Handbook, Elsevier, 2011, pp. 61-76.]
mented or general approach to the research project has to be modified with under-
standing that not only solution verified by sufficient data is required but also
delivery time has to be respected.
In the development of polymeric materials, matrix polymer is the most
important raw material used. Polymers are complex materials and require exhaus-
tive consideration because many properties can be achieved by selection of poly-
mer or polymer blending can be used to obtain a special set of properties required
for application. Chapter 2 is all devoted to PVC, which is the major polymer used
in PVC Formulary. Different grades, which are available commercially are dis-
cussed to facilitate selection of polymer for different purposes. Characteristics of
polymer grades depend on the method of production, specifically on the type of
polymerization, each having strong influence on polymer morphology and com-
position. But properties are also tailored to the potential applications, variety of
which is illustrated by Figure 1.1.
Polymer properties can be further modified by the use of additives and PVC
cannot be successfully processed without additives,4 therefore Chapter 3 is
devoted to the discussion of additives. Additives used in PVC are commonly used
therefore there is a large amount of data available, therefore special monographs
on various additives exist which are referenced in Chapter 3 for further reading.
Chapter 4 contains formulations of different products arranged according to
their application. The last chapter contains a large table with physical-chemical
data on PVC.
4 Introduction
REFERENCES
1 Daniilidis, C., Eben, K., Lindemann, U., Procedia Eng., 9, 270-80, 2011.
2 Grudzinskas, C, Gombar, C. T., Principles of Clinical Pharmacology, 3rd Edition, Elsevier,
2012, pp. 487-506.
3 Marmier, F., Gourc, D., Laarz, F., Decision Support System, 56, 74-82, 2013.
4 Sastri, V., Plastics in Medical Devices. Chapter 5. Polymer Additives Used to Enhance
Material Properties for Medical Device Application. Elsevier, 2010.
5 Carroll, W. F., Johnson, R. W., Moore, S. S., Paradis, R. A., Applied Plastics Engineering
Handbook, Elsevier, 2011, pp. 61-76.
2
PVC Properties
The companion monograph entitled PVC Degradation & Stabilization contains
information on polymerization, features of chemical structure, and their implica-
tions with regard to some processing characteristics of PVC. This chapter will not
repeat this information which is important for PVC processing and thus should be
consulted in the other book.1 This chapter concentrates on other properties of PVC
which are important for its selection and processing.
2.1 COMMERCIAL TYPES AND GRADES
This section contains typical data for each commercial type of PVC, their most
common grades manufactured by major polymer manufacturers,2 methods of pro-
cessing, and typical products manufactured. Presentation of this data aims at
improving selection of particular grades for the production of different materials.
The data are presented in a tabular form to aid retrieval and comparison.
Considering that different processing methods require information on differ-
ent properties (e.g., paste-forming grades need information on their rheological
properties in composition with plasticizers which is not needed in the case of
grades for production of rigid products), the type of information differs between
grades.
Properties which are common to all types or require direct comparison are
dealt with in the second part of this chapter.
2.1.1 GENERAL PURPOSE RESINS
2.1.1.1 Suspension
Table 2.1 provides examples of the data from some producers of suspension PVC.
Table 2.1. Properties of commercial grades of suspension PVC.
Property Unit Range of values
Apparent bulk density g l-1 390-590
Sieve analysis %
retained on 0.063 mm sieve 70-97
retained on 0.250 mm sieve 1-5
Mean particle diameter μm 100-150
6 PVC Properties
Table 2.1. Properties of commercial grades of suspension PVC.
Property Unit Range of values
Volatiles content g kg-1 1.5-4
Residual monomer (VC) ppm 0.01-1
Relative viscosity − 1.6-3.55
Inherent viscosity − 0.51-1.6
K number − 50-99
Porosity cm3 g-1 0.17-0.51
Manufacturers Anwil, Axiall, Formosa Plastics, Ineos, OxyChem, Shin-
Etsu, Solvay, Vestolit, Vinnolit
Grades Evipol SH5730, SH6030, SH6520, SH6521, SH6530,
SH6630, SH6830, SH7020, SH7020M, SH8020, Formo-
lon, 608, 614, 616K, 622, 622F, 622R, 622S, 622W, 676,
676H, 680, 680H, 685, 690, 690F; Norvil S5736, S6030,
S6261, S6550, S7050, S8060; OxyVinyls 155, 155F, 185,
185F, 190F, 195F, 200F, 216, 216S, 220F, 225, 225P, 226F,
240, 240F, 255, 255F, 280, 310, 355, 450F, 500F; Polanvil
S-58, S-67HBD, S-70; S-58, S60, S-67, S-70; Solvin
250SB, 257RF, 258RD, 260RF, 263RB, 264GC, 264PC,
266SC, 266SF, 267RC, 271DF, 271GA, 271PC, 275SC,
460SL, Vestolit S 6058, S6558, S 6858; Vinnolit C 100 V,
C 12/62 V, C 65 V
Method of processing blow extrusion, blow molding, calendering, extrusion,
injection molding
Special properties abrasion resistance, consistent particle size distribution,
crystal-clear articles, dielectric properties, early color heat
stability, excellent dry flow characteristics, food grade,
freedom from gels, good fusion properties, high bulk den-
sity, high flow, high porosity, improvement of gelation
abilities, low contamination, low fines, low fish-eyes, matt
surface finish, mechanical strength, medical grade, melt
homogeneity, narrow particle size distribution, outdoor
grade, permits molding of complex articles, rapid absorp-
tion of plasticizers, transparency
Typical products automotive components, blood bags, bottles, cable insula-
tion, cable sheathing, cosmetic bottles, canalization tubes,
domestic appliance components, drainage tubes, electrical
ducts, electrical housings, fittings, flexible profiles, floor-
ing, foam profiles, food packaging, footwear, medical tub-
ing, pharmaceutical packaging, pipes, plasticized film and
sheet, plasticized hoses, polyblends, pressure pipes, purge
compound, rigid articles, rigid foam, rigid films and
sheets, rigid profiles, sewage pipes, siding, venetian
blinds, window frames, wire & cable
2.1 Commercial types and grades 7
2.1.1.2 Mass
Table 2.2 gives data on commercial grades of mass polymerized PVC.
Table 2.2. Properties of commercial grades of mass PVC.
Property Unit Range of values
K number − 57-65
Apparent bulk density g l-1 620-700
Sieve analysis %
retained on 0.063 mm sieve 10-95
retained on 0.200 mm sieve 0.2-2
Plasticizer absorption g DOP/100 g PVC 18
Volatiles content % 0.3 max
Manufacturers Formosa Plastics Corporation
Grades Formolon B-57, B-60, B-60S, B-62S, B-65
Method of processing calendering, coating (extender lowering viscosity), dip-
ping, extrusion, fluidized bed coating, injection molding,
powder coating
Special properties good gelation, high apparent density, high brilliance, high
plasticizer absorption, low fish-eye content, matt finish,
narrow particle size distribution, transparency
Typical products bottles, coated fabrics, containers, expanded profiles, floor
coverings, foils, profiles, pipes, rigid films, rigid plate,
sheets, wall papers, window profiles
2.1.2 DISPERSION RESINS (EMULSION, MICROSUSPENSION)
Table 2.3 gives data on commercial grades of emulsion PVC.
Table 2.3. Properties of commercial grades of emulsion PVC.
Property Unit Range of values
K number − 59-86
Apparent bulk density g l-1 300-580
Sieve analysis %
retained on 0.063 mm sieve 0.2-85
retained on 0.200 mm sieve 0-30
Mean particle diameter μm 40-50 (paste-forming 5-25)
Viscosity (60 phr DOP) Pas at 1.5 s-1 7-55 (pseudoplastic) 3.5-6.5 (Newtonian)
Viscosity (60 phr DOP) Pas at 45 s-1 4-11 (pseudoplastic) 3.5-4.5 (Newtonian)
Volatiles content % 0.05-0.5
Elongation at optimum TS % 340-425
8 PVC Properties
Table 2.3. Properties of commercial grades of emulsion PVC.
Property Unit Range of values
Optimum tensile strength MPa 17.6-24.0
Light transmittance % 68-86
Gloss % 61-93
Gelation temperature oC 61-91
Manufacturers Formosa Plastics, Ineos, Solvay, Vestolit, Vinnolit
Grades Formolon 10, 24A, 24C, 25, 28, 34, 38, 260, 1071, KVF,
KVH, NVA, NVW; Pevikon P11, P1412, P15, P1510,
P2170, P602, P682, P709, P737; SolVin 173GB, 178GI,
367NC, 370HD, 372HA, 373MC, 373MH, 373ND,
374MB, 375MD, 386NB; Vestolit E 6007, E 7004, E 7012
S, E 7031, E 7037, E 8001, E 8019, P 1300 K, P 1351 K, P
1352 K, P 1353 K, P 1357, P 1382 K; Vestolit E 6007, E
7004, E 7012 S, E 7031, E 7037, E 8001, E 8019, P 1300
K, P 1353 K, P 1353 KR, P 1382 K; Vinnolit E 67 FF, E 67
ST, E 68 CF, E 68 FO, E 68 SA, E 69 VS, E 70 CQ, E 70
G, E 70 LF, E 70 TT, E 74 CC, E 75 HV, E 75 SK, E 80 TT,
EP 6060, EP 6953, EP 7060, EP 7091, EP 7555, P 3468, P
4472, P 5078
Method of processing calendering, casting, coil coating, dip coating, extrusion,
film by Luvitherm process, lamination, mechanical foam-
ing, organosol coating, paste processing (foaming, fabric
coating), reverse roll coating, rotational molding, rota-
tional screen printing, slush molding, spraying, vacuum
forming
Special properties abrasion resistance, blending with suspension or mass
PVC reduces blocking and electrostatic charge, clarity,
dilatant flow, fast expansion, good deaeration, good
embossing characteristics, good storage stability of pastes,
heat stability, high impact strength of film, large particle
size, low emulsifier content (free flowing blending compo-
nent in extrusion), low moisture absorption, low odor, low
static charge and surface resistance, low volatiles in a fog-
ging test, matt surface, pastes have Newtonian properties,
pseudoplastic flow, rapid fusion, rapid gelation, release
properties, tear resistance, tensile strength, very fine cellu-
lar structure
