Masterbatch for stronger, thinner films

Granic, a leader in the production of plastic concentrates with mineral fillers, has developed a new high-performance masterbatch using Vistamaxx ™  performance polymers from ExxonMobil Chemical. Granic 1522 masterbatch uses Vistamaxx polymers as a carrier resin for calcium carbonate (CaCO₃) to deliver significant performance and processing benefits.  

Looking to develop a new masterbatch to complement its existing product portfolio, Granic, a division of the GCR Group in Spain, contacted ExxonMobil Chemical to learn more about Vistamaxx polymers.  

ExxonMobil Chemical demonstrated that by using a Vistamaxx polymers-based CaCO₃ masterbatch in film formulations instead of a typical linear low density polyethylene (LLDPE) or polypropylene (PP)-based masterbatch, mineral filler loadings could be increased without sacrificing key mechanical properties.
 
Also highlighted were the benefits for end-use applications, such as high density polyethylene (HDPE) shopper bags, HDPE garbage bags and PP raffia (slit) tape and bags. These benefits include increasing the concentration of recycled material, making the bags thinner, or improving performance, such as dart impact resistance.  

With such a strong value proposition for customers, Granic developed a new high-performance  masterbatch, Granic 1522, which uses Vistamaxx polymers as a carrier resin.
“Granic 1522 masterbatch has significant benefits. Using Vistamaxx as a carrier resin in the masterbatch  enables increased productivity, reduced energy consumption and improved mechanical properties,” said  Victor Oliva, Commercial Director and R&D manager of GCR Group.

Successful sales
Since its introduction, Granic® 1522 masterbatch has been well accepted in the marketplace and the company has been successful in generating new sales.
 
One customer, a leading producer of polyethylene (PE) packaging materials for the converting industry, is producing stronger, thinner garbage bag films by adding Granic 1522 to its existing HDPE resin formulation. The  masterbatch also delivers better processing and lower costs.

Adding Granic 1522 masterbatch to the existing HDPE resin formulation delivers the following key advantages: enhanced dart impact despite thinner film structure; improved thickness tolerance for better processing and less material use; and cost saving opportunities.

The commercial garbage bag film produced by this customer which includes 20% Granic 1522, exhibits twice the impact resistance and is 16% thinner than the original film.  
 

High-performance  masterbatch, Granic 1522 uses Vistamaxx polymers as a carrier resin for stronger films.


Better processing
As well as performance improvements, the thickness tolerance of the film is improved. A more consistent film thickness leads to better, smoother processing that requires less adjustments.

The company also benefits from significantly lower costs because, optimising the formulation using Granic 1522 masterbatch, uses less material through thinner films. “Our customer is delighted with the new film formulation as it provides a stronger, thinner film with better overall garbage bag performance for consumers,” said Mr. Oliva. “It is an innovative solution that aligns with their wish to become a market-leader in certain defined market segments”.

 “We are very excited about the market potential for Granic 1522 and are targeting key applications,” Mr. Oliva added. “These include shopper and garbage bags, raffia tapes and bags, and thermoforming/ blow moulding where increased filler loadings and improved toughness can make a big difference to customers.”

Granic® is a GCR Group brand owned and it is among the European leaders and a worldwide reference in the development, production and marketing of mineral masterbatches. The division develops high-quality, high-dispersion calcium carbonate and talc masterbatches which are known worldwide for the possibility of dosing them in high concentrations in polyethylene (PE),polypropylene (PP), polystyrene (PS) and Acrylonitrile Butadiene Styrene (ABS) plastic formulations becoming a replacement for virgin polymer. Granic products offer excellent cost-effectiveness. They are formulated free of heavy materials; they are not abrasive and are suitable for an enormous variety of applications, including food contact. The division’s current production capacity is 220,000 tonnes/year.

For its part, ExxonMobil Chemical offers its Vistamaxx™ propylene-based elastomer (PBE) for both compounders and end-product manufacturers. For compounders, Vistamaxx PBE can deliver reduced inventory as it serves as a universal carrier in polyethylene (PE) and polypropylene (PP) compounds, excellent dispersion of additives and pigments to help with quality consistency, low temperature compounding for heat sensitive additives, blowing agents and flame retardants, high CaCO3 loading level in filler masterbatches which can allow plastics fabricators such as PP raffia woven bag manufacturers and PE blown film extruders, to increase the let-down ratio of these low cost fillers.  For end-product manufacturers, Vistamaxx PBE can deliver excellent film tear and impact properties at higher masterbatch ratios for lower costs, outstanding weld line and impact strength for blow molded containers, high filler loadings for pipe extrusion while maintaining flexibility, excellent anti-fibrillation performance, less yarn breakage and dusting problems for monofilaments in PP raffia bags, and food regulation approval, as well as excellent organoleptic performance.