Adhesives & Sealants Industry May 2011

What is Responsible Tape Manufacturing? Find out on pp. 21-22.

May 2011

• Volume 18, Issue 5

•

www.adhesivesmag.com

Durable

LABELS ❯ Packaging

of Adhesives

❯ UV Curing

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GET UPDATES INTERACT NETWORK WITH PEERS AND CUSTOMERS SHARE COMMON INTERESTS

O

ne popular use for this new technology is social net-

awareness, as an online reputation management tool, for recruit-

working between businesses. Companies have found

ing, to learn about new technologies and competitors, and as

that social networking sites such as Facebook® and

a lead gen tool to intercept potential prospects.[33]
Twitter are great ways to build their brand image.

en.wikipedia.org/wiki/Social_networking_service>. These com-

According to Jody Nimetz, author of Marketing Jive[32]
panies are able to drive traffic to their own online sites while

en.wikipedia.org/wiki/Social_networking_service>,

encouraging their consumers and clients to have discussions on

there

are

five major uses for businesses and social media: to create brand

how to improve or change products or services.

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INNOVATION = VALUE COATINGS: Go ‘green’ with innovative binder and additive technologies.

ADHESIVES & SEALANTS:

Conserve energy in production and product use.

ELASTOMERS:

Formulate with alternative raw materials, and do it competitively.

YOUR CUSTOMERS DEMAND ENVIRONMENTALLY-FRIENDLY PRODUCTS. LET UNIVAR SHOW YOU HOW YOU CAN GO GREEN. Univar supplies the CASE industry with much more than a comprehensive line of sustainable ingredients — we can provide you with an innovative approach to your green formulation challenges, offering you technical expertise from concept to production. Consider Univar your partner in sustainable product development. We connect you to the latest materials and technologies, and help you bring environmentally-friendly products to market. Innovation, sustainability, expertise — it all adds up to value.

INNOVATION > TECHNICAL EXPERTISE > MARKETING > SALES > LOGISTICS > DISTRIBUTION

1.877.203.0045 | [email protected] www.univarcorp.com

IN THIS ISSUE ADHESIVES & SEALANTS INDUSTRY, VOLUME 18, NUMBER 5

15 18 21

23 26 28

DEPARTMENTS

Q&A ABOUT POLYURETHANE Scientists from the Business Development Group of Bayer MaterialScience LLC answer readers’ questions.

STICK WITH IT Finding the best label material for durable goods is no easy feat.

RESPONSIBLE TAPE MANUFACTURING The PSTC is pursuing a number of objectives to promote PSA awareness while supporting a more responsible tape manufacturing process.

OPTIMIZED PACKAGING

17

Many details should be considered when looking at multiple packaging options.

ALTERNATE PACKAGING SOLUTION Sausage packages can be considered a greener alternative because they can be recycled once dispensed.

INCREASING THE BOTTOM LINE Convenience packaging can help improve your bottom line with little to no risk.

TEACHING AN OLD STANDARD NEW TRICKS

31

A new tape option is available for manufacturers using the ASTM D 3359 crosscut adhesion test.

6

Editor’s Memo

8

Company News

11

People

12

Calendar

13

Advancing Adhesives: MACtac

16

Strategic Solutions

17

Focus On: tesa tape, inc.

41

What’s New

43

Services Marketplace

45

Classifieds

46

Ask Dr. Dave

46

Ad Index

23 What is Responsible Tape Manufacturing? Find out on pp. 21-22.

33 35 39

THE UV CURED ADVANTAGE Although UV-cured adhesives mimic the chemistries found in any other polymer, they offer several major advantages.

May 2011

• Volume 18, Issue 5

•

www.adhesivesmag.com

AN EXPLOSION-PROOF UV-CURABLE SEALANT SYSTEM

Durable

UV-curable sealant systems are an innovative solution for the production of ammunition cartridges.

LABELS

TAKING BRAND PROTECTION TO A WHOLE NEW LEVEL Using a multi-layered labeling solution can deliver protection and marketing opportunities.

❯ Packaging

of Adhesives

❯ UV Curing

Cover.indd 1

4/13/11 3:55 PM

ON THE COVER: Photo courtesy of FLEXcon.

FOR SUBSCRIPTION INFORMATION OR QUESTIONS, CONTACT: Customer Service: (847) 763-9534 ADHESIVES & SEALANTS INDUSTRY (ISSN 1070-9592) is published 12 times annually, monthly, by BNP Media, 2401 W. Big Beaver Rd., Suite 700, Troy, MI 48084-3333. Telephone: (248) 362-3700, Fax: (248) 362-0317. No charge for subscriptions to qualified individuals. Annual rate for subscriptions to nonqualified individuals in the U.S.A.: $178.00 USD. Annual rate for subscriptions to nonqualified individuals in Canada: $216.00 USD (includes GST & postage); all other countries: $228.00 (Int’l mail) payable in U.S. funds. Printed in the U.S.A. Copyright 2011, by BNP Media. All rights reserved. The contents of this publication may not be reproduced in whole or in part without the consent of the publisher. The publisher is not responsible for product claims and representations. Periodicals Postage Paid at Troy, MI and at additional mailing offices. POSTMASTER: Send address changes to: ADHESIVES & SEALANTS INDUSTRY, P.O. Box 2148, Skokie, IL 60076. Canada Post: Publications Mail Agreement #40612608. GST account: 131263923. Send returns (Canada) to Pitney Bowes, P.O. Box 25542, London, ON, N6C 6B2. Change of address: Send old address label along with new address to ADHESIVES & SEALANTS INDUSTRY, P.O. Box 2148, Skokie, IL 60076. For single copies or back issues: contact Ann Kalb at (248) 244-6499 or [email protected].

May 2011

Adhesives & Sealants Industry

Audited by BPA Worldwide.

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EDITOR'S MEMO

PROMOTING PSAs Pressure-sensitive adhesives (PSAs) can be found literally everywhere I look. Tape secures my daughter’s pictures and notes to my computer monitor, and a simple turn of my head reveals folder labels and the multiple (some might say mountainous) sticky notes without which I could not function. PSAs are so commonplace that a lot of us take them for granted. The Pressure Sensitive Tape Council (PSTC) is pursuing a number of objectives to promote PSA awareness while supporting a more responsible tape manufacturing process. I recently had the opportunity to speak with Patrick Deconinck, vice president and general manager of 3M’s Industrial Adhesives and Tapes Division, who serves as president of the PSTC. “We are trying to influence the industry that whatever is sold in the North American market should be made according to North American or U.S. environmental, workplace and quality standards,” he says. To learn more, read “Responsible Tape Manufacturing” on pp. 21-22 of this issue. This issue also includes articles detailing labels for durable goods, adhesives packaging options, ASTM’s D 3359 crosscut adhesion test, and UV curing. Please be sure to take a look at the full Table of Contents on p. 5.

PLANNING FOR 2012 It doesn’t seem possible that it’s that time of year already, but we’re beginning to plan for 2012—and we’d love your feedback. What articles were most useful to you over the last year, and what could you have done without? What new topics or technologies would you like us to cover next year? How do you prefer to receive the information we make available (e.g., print, digital, website, e-newsletters, etc.)? We strive to make ASI as useful to you and your business as possible, and your input is essential. Please send your comments and suggestions to me at [email protected], or feel free to give me a call at (330) 336-4098. I look forward to hearing from you!

Susan Sutton is Editor-in-Chief, Integrated Media for Adhesives & Sealants Industry and Ceramic Industry magazines. If you wish to send a letter to the editor, please email [email protected]. Letters must include the sender’s address, phone number and email address, when possible. Letters may be edited for space and clarity.

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CONTRIBUTING EDITORS Dave Dunn, bms North America Dan Murad, The ChemQuest Group Inc. David P. Nick, DPNA International Inc.

EDITORIAL ADVISORY BOARD Steven Gailbreath, Arizona Chemical Richard P. Muny, Chemsultants International Network Larry Owen, Franklin International Lex Reynolds, Reynolds Glue Deborah Chrzanowski, Intertape Polymer Group and PSTC Technical Steering Committee Chair

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THIS MONTH ON www.adhesivesmag.com... Online Exclusive: PSTC Week of Learning Preview Adhesive manufacturers, suppliers, tape manufacturers, tape converters, associations and industry experts will all come together May 9-13 in Orlando for the PSTC Week of Learning.

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CORPORATE DIRECTORS Daily Updates The latest industry and company news, personnel announcements, new products and more are updated daily to help you stay informed. Digital Edition ASI’s digital editions are easy to read, search and download. Site visitors can also subscribe and access the archives to view past digital editions.

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Publishing: Timothy A. Fausch

Creative: Michael T. Powell

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Directories: Nikki Smith

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Clear Seas Research: Beth A. Surowiec

Finance: Lisa L. Paulus

BNP Media Helps People Succeed in Business with Superior Information

May 2011

Semco® Packaging & Application Systems solves another packaging puzzle for the solder paste industry! Introducing the Semco® Solder Paste Jar s Ergonomically compliant threaded cap s Complies with industry requirements for viscometers and mixing equipment s Contoured to minimize waste s Cost-effective

COMPANY NEWS ALTANA recently announced it has acquired the can end sealants business for the metal can packaging market of U.S.based Watson Standard Adhesives Co. (WSAC). Through an asset deal, ALTANA primarily acquired customer relationships, products, know-how and inventories. WSAC’s can end sealants business will be integrated into the ACTEGA Coatings & Sealants division. The former WSAC can end sealant products will be produced at ACTEGA’s existing site near Philadelphia and incorporated into the ACTEGA Artística business. For more information, visit www.altana. de or www.watsonstandard.com.

Coatings and adhesives from ASHLAND PERFORMANCE MATERIALS that are marketed to North American narrow web label, tag, and wrapper converters will now also be available from Flint Group. Effective March 15, Ashland and Flint Group began a distribution and co-branding effort that calls for Flint Group to begin marketing Ashland products under a co-branded label that will carry the Flint Group trademark or trade name. The long-term agreement enables Flint to distribute Ashland’s radiation-cure, water-based and solventless laminating adhesives and coatings in North America. Flint Group will also acquire the management of some Ashland customers and will provide them with dedicated sales, technical service, and customer service support. Ashland Performance Materials is a commercial unit of Ashland Inc. For more information, visit www.ashland.com or www.flintgrp.com. AVERY DENNISON has given its business units new names to communicate their focus on market-driven solutions that help make brands more inspiring and the world more intelligent. The names went into effect March 18. The company’s largest business unit, Roll Materials, became Label and Packaging Materials to reflect the fact that its innovations in self-adhesive technology extend beyond labeling to packaging applications and solutions. Retail Information Services is now Retail Branding and Information Solutions to reflect its comprehensive suites of products and services for retailers and apparel brands. Office Products 8

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ANNOUNCEMENT FEICA ISSUES CALL FOR PAPERS FEICA, the Association of the European Adhesive and Sealant Industry, is seeking papers for the 8th World Adhesives & Sealants Conference (WAC2012), taking place September 18-21, 2012, in Paris. With the theme Creating the Future, the conference will feature four lead topics: Toward Smarter Global Regulation and Standards; Sustainability & Environment; Securing Raw Material Sourcing; and Creating Value—From Entrepreneurship, Design to Technology. An abstract must be submitted before sending a paper. Abstracts must be in English; not more than 300 words; and include presentation title, author name and job title, company affiliation, nationality, personal biography, and contact information. Abstracts are due September 2. For more information, phone (32) 2792-7517 or visit www.feica.eu.

became Office and Consumer Products to reflect the relevance of its organization and identification solutions to the home and office. Graphics and Reflective Products became Graphics and Reflective Solutions, while the Specialty Tape Division became Performance Tapes. The company’s Specialty Converting Division, which includes Industrial and Automotive Products, Performance Films, Business Media and Security Printing, is now Designed and Engineered Solutions. Medical Products, the RFID Division, and Automotive are now Medical Solutions, RFID, and Automotive Solutions, respectively. For additional information, visit www.averydennison.com. BASF CORP. has opened its new epoxy composite laboratory at the company’s technical center in Tarrytown, NY. The new laboratory combines BASF’s comprehensive technical capabilities for epoxy systems under its Baxxodur ® brand to support the development of new epoxy composite applications. It offers a range of facilities for simulating a customer’s production processes with Baxxodur resin systems and the ability to develop tailored solutions for customers’ specific process conditions. In addition, BASF has increased its technical support team with experts who provide on-site customer support. Composites based on thermosetting epoxy resin systems have become an established material for the production of modern wind turbine rotor blades. Baxxodur epoxy systems can be processed significantly faster and over a wider temperature range than conventional systems, thus increasing flexibility in production and allowing blade manufacturers to produce parts of higher quality in significantly

reduced cycle times, offering up to a 30% improvement in production efficiency. For more information, visit www.windenergy. basf.com. BAYER MATERIALSCIENCE has inaugurated a manufacturing facility for polyisocyanates at Ankleshwar in the state of Gujarat, India. With the investment of approximately @20 million (~ $27.9 million), the company wants to expand its business in India and to participate in the strong growth of this local market for coatings and adhesives. The plant will produce Desmodur® N grades based on aliphatic hexamethylene diisocyanate (HDI). The initial capacity will amount to 15,000 tons per year; it will be increased in stages in the coming years in accordance with the predicted growth for polyurethane coatings and adhesives. The plant employs 35 people and adheres to state-of-the-art standards in terms of production processes, quality and safety. For additional information, visit www.bayermaterialscience.com. THE DOW CHEMICAL CO. has announced the creation of the Performance Plastics Division, which will comprise all Dow plastics and will include the Packaging and Converting Unit that is currently part of the Advanced Materials Division. Its focus will be on high-value market-driven solutions in applications such as packaging, hygiene, food and telecommunications. Howard Ungerleider, vice president for Investor Relations, was named senior vice president for Dow and president of the Performance Plastics Division. He will join the Executive Leadership Committee (ELC) and report to Andrew Liveris, chairman and CEO. Jim Fitterling, executive vice president, adds Corporate Development to his May 2011

APPLAUSE HENKEL NAMED AMONG MOST ETHICAL COMPANIES Henkel has been included in the list of the World’s Most Ethical Companies for the fourth consecutive year. The ranking, prepared by the U.S. Ethisphere Institute, recognizes companies from around the globe for their exemplary ethical approach to corporate governance and their commitment to sustainable development. The ranking names a total of 110 companies selected from thousands of applicants in over 100 countries and 38 different sectors. Henkel was recognized by a jury comprising U.S. scientists, academics, lawyers and government representatives. The multistage assessment process was based on business conduct as demonstrated in a range of categories, including social engagement, management style and innovation strength. For more information, visit www.henkel.com.

current Hydrocarbons Divisional leadership role. In addition, the Chlorinated Solvents business will move to the Performance Products and Systems Division and report to Juan Luciano, executive vice president and president of this division. Additional details are available at www.dow.com. DSM recently announced a reorganization that merges its DSM Powder Coating Resins and DSM NeoResins+ business units into a single new unit called DSM

Coating Resins. The changes were effective April 1. A subdivision will be made based on different market dynamics, which will be reflected in the organizational approach for these subdivisions. The new setup is designed to help DSM grow its position as a leading specialty resins supplier for the coatings industry. DSM Coating Resins will be led by Patrick Niels, currently business unit director of the Powder Coating Resins

unit, and will be led from Zwolle, the Netherlands. Steve Hartig, currently business unit director of DSM NeoResins+, will move to lead another unit within DSM. For additional details, visit www. dsmresins.com. H.B. FULLER CO. recently reported financial results for the first quarter ended February 26, 2011. Net income for the first quarter of 2011 was $14.4 million, compared to $19 million in last year’s first quarter. Net revenue for the first quarter of 2011 was $339.5 million, up 9.7% vs. the first quarter of 2010. Higher average selling prices, higher volume and acquisitions reportedly had a positive impact on net revenue growth by 6.8, 2.2 and 1.7 percentage points, respectively. For more information, visit www.hbfuller.com. IPS STRUCTURAL ADHESIVES recently announced it is leveraging its merger with Holdtite Adhesives Ltd. to create a new brand, expand production capacity and introduce new technologies to a broader array of markets. The expansion includes new investments in people, technology,

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COMPANY NEWS equipment and processes, thus allowing the company to expand its product portfolio of structural and engineered adhesive solutions while focusing on new product and application development. IPS Structural Adhesives has also announced plans to merge its premier brands (Weld-On, Holdtite and Macroplexx) into a single brand. The new SCIGRIP Smarter Adhesives Solutions brand brings together two global leaders in the adhesive solutions industry. For more information, visit www.scigrip.com. THE LUBRIZOL CORP. and Berkshire Hathaway Inc. have announced a definitive agreement for Berkshire Hathaway to acquire 100% of outstanding Lubrizol shares for $135 per share in an all-cash transaction. The transaction, which was unanimously approved by the board of directors of each company, is valued at approximately $9.7 billion, including approximately $0.7 billion in net debt, making it one of the largest acquisitions in Berkshire Hathaway history. The transaction is subject to the approval of Lubrizol’s shareholders and the satisfaction of customary closing conditions, including the expiration of waiting periods and the receipt of approvals under the Hart-Scott-Rodino Antitrust Improvements Act and applicable nonU.S. merger control regulations. Berkshire Hathaway and Lubrizol expect the transaction to be completed during the third quarter. After the close of the transaction, Lubrizol will operate as a subsidiary of Berkshire Hathaway. The company will remain at its Wickliffe, Ohio, headquarters and will continue to be led by its current management team. For more information, visit www.lubrizol. com or www.berkshirehathaway.com. 3M has increased its global manufacturing capacity of optically clear adhesives (OCAs) at multiple locations in Korea, Taiwan, China and Singapore. The increased capacity supports the growth of consumer electronics devices, including smart phones, tablets, touch 9:52:42 AM displays and e-readers. 3M OCAs are used in today’s consumer mobile devices for enhancing the user’s view, aesthetics and appearance of the device, as well as for touch sensor bonding. OCAs are a highly specialized adhesive-based product that offers excellent adhesion and clarity by eliminating the yellowing that can occur to various types of transparent substrates. It also enables the high-speed lamination required for mass production in the electronics industry. For more information, visit www.3m.com. OMNOVA SOLUTIONS has announced the grand opening of its new state-of-the-art specialty chemical plant at the Shanghai Chemical Industry Park (SCIP) in Caojing, China. The plant, part of a recent acquisition of ELIOKEM by U.S.-based OMNOVA Solutions, manufactures Pliocord® vinyl pyridine latex used in tires, hoses and other reinforced rubber applications for the fast-growing Asia-Pacific markets. In addition, production of OMNOVA’s complementary GenTac® vinyl pyridine latex is being evaluated for the site, as well as other specialty latices based on innovative styrene butadiene and acrylic emulsion polymerization technologies. For more information, visit www.omnova.com. UNIVAR has signed a non-exclusive distribution agreement with Cytec Industries Inc. to market and distribute its RADCURE® products to the adhesives, sealants, coatings, and elastomers (CASE) industry in Canada. “We are pleased that Cytec has put their trust in Univar to be the distributor of their RADCURE products in Canada,” said Barry Nicholls, vice president of Marketing for Univar Canada. “This

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May 2011

agreement will allow us to provide our customers with a reliable source of the highest quality UV-curable oligomers, monomers and additives.” For more information, visit www.cytec.com or www.univar.com.

PEOPLE Fisnar® recently announced the addition of ERIC CHOI to Ellsworth Corp. as managing director of Fisnar Asia. In his new role, Choi will concentrate on consolidating and growing Fisnar’s business in Asia and establishing Fisnar Asia as the global supply hub for Fisnar. Emerald Performance Materials LLC recently announced it has named BRIAN A. DENISON president of Emerald Kalama Chemical BV. In addition, Denison will continue as vice president of Operations and Health, Safety and Environmental for Emerald Performance Materials. Chemsultants International recently announced two new additions to the company. MIKE HILSTON has been named Research chemist and is responsible for contributing to new product development projects. JACK YEARY was hired as Quality specialist and is responsible for testing within the Chemsultants laboratory. Kraton Performance Polymers Inc. recently announced that HOLGER R. JUNG , Ph.D., has been hired as vice president, Sales and Marketing. He is responsible for all sales, marketing and market development activities globally for Kraton, reporting to Kevin M. Fogarty, president and CEO. Premier Industrial Supply Inc. has named GARY KRYSIAK the new senior technical director of its Research and Development group. He will establish unique formulations and chemistry, establish a larger presence in the industry affiliations, and work with customers to market Premier’s newer low-VOC products. BOGARD LAGMAN , formerly executive vice president of Charles Ross & Son Co., has been appointed regional sales manager for Asian and Middle Eastern countries for the company. Based in Manila, Philippines, he is responsible for sales management of products manufactured in Ross plants. Lagman, who has 30 years of experience in the specialty mixing and

blending equipment business, will also work directly with the company’s network of sales representatives. Plasticolors Inc. has appointed BRIAN MILLER to the position of Technical Service representative. He will provide direct technical support to customers in the thermoset composites marketplace and to internal technical programs.

NETZSCH Premier Technologies LLC has promoted RANDALL SMITH to president and STEPHEN MIRANDA to Sales director, Grinding and Dispersing for North America. The company has also promoted JOHN SNEERINGER to applications and process advisor. Visit us online at www.adhesivesmag.com for the latest industry and personnel news.

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May 2011

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COMPANY NEWS CALENDAR 18

MAY 4

Tech ManufactureXPO virtual trade show, www.techmanufacturexpo.com

9-11 Construction, Corrosion & Infrastructure Conference; Las Vegas, NV; http://www.goeshow. com/acma/CCI/ereg497293.cfm?clear 9-13 PSTC Week of Learning; Hyatt Regency Grand Cypress; Orlando, FL; www.pstc.org

U.S. EHS&S & Sustainability National Conference; Houston, Texas; www.socma.com

23-25 2011 Binding Industries Association Conference; ChampionsGate, FL; www.printing.org/ biaconference 30-6/1 13th European PLACE Conference; Festpielhaus on Lake Constance; Bregenz, Austria; www.tappi.org

A word from our customers: "Merlin's flexibility is remarkable. They stock our material and can turn on a dime when our requirements change. They always ship quickly, and more than once have responded to emergencies with next-day delivery. Nice people that are easy to work with. Overall, Merlin is an excellent supplier." B. S. Specialty polymer supplier Merlin customer for 9 years

"Merlin is extremely qualityconscious, with fast delivery and excellent attention to detail. They've given us the opportunity to be competitive on smaller orders by downpacking drums into custom cartridges. Our sales have grown steadily, thanks in no small part to Merlin Packaging." Eric Watson Purchasing Supervisor Rudolph Brothers & Co. Merlin customer for 10 years Merlin provides accurate filling of dual cartridges, syringes, pouches, mixed frozen, and many other packaging options. For fast delivery of big or small orders of quality custom packaging, call Merlin Packaging Technologies today.

JUNE 7-9

Green Manufacturing Expo; New York City; www. canontradeshows.com/expo/gmx11/ana_event. html

7-9

Green Manufacturing Expo; Toronto, Ont.; www.canontradeshows.com/expo/gmx11/ ana_event.html

19-21 Forest Products Society’s 65th International Convention; Portland, OR; www.forestprod.org/ ic65/overview.html 22-24 Digital Manufacturing – Opportunities for Manufacturing Rebirth Conference; Hollywood (Fort Lauderdale), FL; www.imiconf.com

JULY 15-15 COMPOSITES CHINA; Shanghai, China; chris. [email protected]

SEPTEMBER 13-14 Nanopolymers 2011; Dusseldorf, Germany; http:// ismithers.net/venue-details/XNAN11 15-16 FEICA Conference; Valencia, Spain; www.feica.eu 20-22 Green Manufacturing Expo; Rosemont (Chicago), IL; www.canontradeshows.com/expo/gmx11/ ana_event.html 20-22 Assembly and Automation Technology Expo; Rosemont (Chicago), IL; www.aatexpo.com 26-28 CPP Expo; Las Vegas Convention Center: Las Vegas; www.cppexpo.com/

OCTOBER 6-8

TURKCOAT COATINGS SHOW; Istanbul Expo Center; Istanbul, Turkey; www.turkcoat.com

16-18 ASC 2011 Fall Convention; Indianapolis, IN; www.ascouncil.org

NOVEMBER 1-3

2011 CHEM SHOW; Jacob K. Javits Convention Center; www.chemshow.com

9-10 The Composites Engineering Show; Birmingham, UK; www.compositesexhibition.com 21-23 Abrafati 2011; Sao Paolo, Brazil; www.abrafati2011.com.br/index_engl.html

MARCH 2012 11-16 Pittcon 2012; Orlando, FL; (800) 825-3221, ext. 203; www.pittcon.org

861 Taylor Road, Suite E

Gahanna, OH 43230 Toll-free: 888-648-7878 [email protected] www.merlinpackaging.com

MAY 2012 7-10 American Coatings Show 2012; Indianapolis, IN; www.american-coatings-show.com/en/default.ashx For a more detailed listing, visit www.adhesivesmag.com.

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May 2011

ADVANCING ADHESIVES MACtac’s InFusion product features hot-melt adhesive technology.

THE ACRYLIC ACID SHORTAGE Using hot-melt adhesive technology offers multiple advantages. By Mike Marasch, Senior Marketing Director, MACtac® Printing Products

he adhesives industry continues to fall victim to the cyclical shortage of acrylic acid, and the short- to mediumterm forecast for minimal, if any, added capacity indicates a continued volatility in the market. The onus for this ongoing shortage is limited global supply as much as seasonality. Despite the anticipated—and in some cases realized— improvement in the global economy, many acrylic acid suppliers are not in a position to return capacity that was rationalized in recent years due to the economic downturn. Unplanned outages throughout 2010, including facility fires, labor issues, and maintenance concerns, led to a shortage of acrylic acid monomers and, in turn, adhesive polymers. Further straining this already limited capacity is growth among other huge consumers of acrylic acid, such as diaper, paint and clear sheet manufacturers. These applications are often more strategic to acrylic acid suppliers, offering growth

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and higher profit margins than those associated with adhesive applications. The end result is limited raw material availability and rising raw material costs for adhesive manufacturers.

ADDRESSING THE SHORTAGE AS AN INDUSTRY For those adhesive manufacturers serving the labels and labeling industry, this limited availability and fluctuation in cost affects the production of labels, stamps, and other applications requiring these adhesives. As much as manufacturers work to offset and absorb costs when possible, industry-wide price increases or surcharges continue to be issued, and research and development efforts formerly dedicated to acrylic adhesive development may be minimized. However, aside from internal process improvements and supply chain diligence, some adhesive manufacturers have taken an entirely different approach to helping customers Adhesives & Sealants Industry

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ADVANCING ADHESIVES Hot-melt adhesive technology is quickly becoming a popular alternative to acrylic acid. MACtac's InFusion™ hybrid adhesive system uses this technology in the labels and labeling industry.

Figure 1. Recent Inflation Rates for PSA Raw Materials

applications. They hold up well to chemical exposure, are very durable, have clarity and color stability, and bond well to polar surfaces like metal, glass, polyesters, and polycarbonates. Some disadvantages of acrylics include poor adhesion to low-energy surfaces and lower overall adhesion compared to hot melts, unless the adhesive is highly engineered. Given these characteristics of hot melts and acrylic adhesives, hot-melt adhesives do serve as a viable—and, in some instances, superior—alternative to acrylic adhesives when used in the appropriate applications.

SUSTAINING A SOLUTION counter these increasing costs by recommending product solutions that feature an alternative to acrylic-based adhesive technology.

ENTER HOT-MELT ADHESIVE TECHNOLOGY Hot-melt adhesives are typically a mixture of a polymer (thermoplastic rubber), tackifying resins and a hydrocarbon diluent (wax or oil plasticizer), which is heated until flowable. The hot-melt adhesive is then coated on a web and cooled before being wound into a roll. Hot-melt adhesives typically exhibit high tack and peel, forming a strong bond quickly during the cooling process, and excellent adhesion to a variety of substrates and facestocks, including non-polar, low-energy surfaces such as polyethylene and polypropylene, making them suitable for packaging and labeling applications or product assembly. They demonstrate very good coatability and are lower in cost than most solventbased adhesives, including acrylics. The most advanced formats, known as 100%-solids (no water or solvent), set quickly and are heat resistant once cured. Drawbacks of hot-melt adhesives generally include processing challenges, as well as limitations performing at high temperatures (more than 150°F/66°C). They sometimes exhibit limited effectiveness when exposed to certain chemicals and ultraviolet (UV) rays. They are also more susceptible to oxidation and may darken, lose their tack and become brittle if overexposed. Acrylics provide excellent temperature, UV and oxidation resistance, and thus are often the preferred choice for outdoor 14

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For the short- to medium-term, adhesive costs will continue to rise based on availability. Added acrylic feedstock capacity is not anticipated to come on stream, and unplanned upsets in the supply chain could have major repercussions for adhesive manufacturers that have not performed due diligence by integrating operational, sourcing and formulation innovation buffers. In addition, new, higher growth/higher margin applications, such as super-absorbent polymers for diapers, will continue to assume a larger share of the existing limited acrylic acid supply. But breakthroughs in adhesive development, such as the introduction of hybrid adhesives, which maximize adhesive performance while improving conversion and processing efficiency, have led to adhesive manufacturers transitioning customers, where applicable, from an acrylic adhesive to a customized hot-melt or hybrid adhesive. These transitions are often a sustained solution when the recommended adhesive alternative offers proven performance enhancement, cost efficiencies and supply stability. By focusing research and development efforts on advancing hot-melt and new, hybrid adhesive technologies, and formulating these adhesives in-house, adhesive manufacturers may recognize certain competitive advantages such as a good cost position and the ability to more effectively customize adhesive performance to specific customer and application needs, enabling them to mitigate the effects of the shortage on themselves, customers and end users. For more information, visit www.mactac.com.

May 2011

QA &

About Polyurethane

QA

I AM DEVELOPING A TWO-COMPONENT REACTIVE ADHESIVE AND NEED SOME GUIDANCE ON POLYOL SELECTION. CAN YOU PROVIDE INFORMATION ON THE & PERFORMANCE EXPECTATIONS OF DIFFERENT POLYOL COMPONENTS? The variety of hydroxyl-containing raw materials contributes to the range of performance characteristics that can be achieved with polyurethane chemistry. Typical performance characteristics that can be varied include functionality, the components in the polyol backbone and molecular weight. Polyether polyols are made by polymerizing propylene oxide (PO) and/or ethylene oxide (EO). The functionality of the polyol is determined by the functionality of the “starter” molecule upon which the polymerization is initiated. This starter molecule is typically an alcohol or an amine. A polyol that is based solely on PO will tend to be more hydrophobic than a polyol that contains a high amount of EO. The PO-based product will have a secondary hydroxyl reactive group. It will react more slowly than an EO-capped polyol, which has a primary hydroxyl group. The polymer end group is a key factor when formulating a two-component adhesive since it has a strong influence on the curing rate of the finished product. The molecular weight of the polyol is one of most important factors influencing performance. As the molecular weight of the polyol is increased, the polymer backbone becomes softer. The typical molecular weight for tri-functional polyether polyols used to make flexible polyurethanes ranges from 3,000-6,000 g/mol. High-molecular-weight di-functional polyols most often have a molecular weight from 2,000-4,000 g/mol, but specialty types are offered with higher molecular weights (6,000-8,000 g/mol). The backbone of these materials is most often based on propylene oxide and they are frequently EO-capped. Lower molecular weight diols and triols are made with a molecular weight between 200-1,000 g/mol. As the molecular weight decreases, the polymer tends to become harder. The average functionality of the polyol blend and the isocyanate determines the crosslink density of the adhesive. A formulation that uses a high proportion of a low-molecular-weight triol will produce an amorphous polymer that is highly crosslinked and may be hard and brittle. An adhesive of this type

would not be able to absorb stresses put on the bondline during use. A balance needs to be found between molecular weight and functionality to generate an adhesive with optimum performance. —Jeffrey F. Dormish, Ph.D.

QA

I NEED A FAST-CURING, HIGH-PERFORMANCE COATING. OUR MANUFACTURING EQUIPMENT IS DESIGNED FOR HANDLING WATERBORNE SYSTEMS. WHAT CAN YOU & RECOMMEND?

UV-curing polyurethane coatings offer high performance and fast curing. As such, there has been an overall increase in the use of UV curing applications. In certain instances, traditional 100%-solids systems are now being replaced with systems built on water-based UV-cure polyurethane dispersions (PUDs). These dispersions were developed along the same lines as the more traditional PUDs, but they contain UV-active polyester, epoxy or polyether arcrylate segments in the backbone of the polymer. This new class of UV technology offers several benefits, including extremely low co-solvent formulations, high-molecularweight polymers (as supplied), extremely low oxygen inhibition and ease of developing low-gloss coatings. In addition, they offer the handling advantages of being a one-component system. With the inherent flexibility of polyurethane chemistry, one can dial-in performance characteristics tailored to market needs, from mechanical and chemical resistance to soft touch applications. Certain products can be recycled in the case of overspray. However, as with many waterborne products, one must remove water prior to the curing reaction. UV-cure PUDs are being used in many coating market areas, such as wood furniture, overprint varnishes, plastics and PVC flooring, as well as soft touch applications. UV-cure PUDs have also been found to work very well in vacuum-forming applications where a PUD-coated plastic part is dried, vacuum formed and then UV cured. Some exciting new developments for UV PUDs are in the sunshine-cure area. The polymerization is possible through the use of photoinitiators that are activated in the visible light spectrum. This technology has the potential for coating wood decks and other “outside” applications, including those in the aerospace sector. —Michael Dvorchak

ABOUT THE AUTHORS Dr. Jeffrey F. Dormish is Senior Principal Scientist, Business Development Group, Bayer MaterialScience LLC. He is responsible for the development of new polyurethane adhesive applications, with a focus on waterborne raw materials. Dr. Dormish joined Bayer in 1980. Since that time, he has held various research and application development positions of increasing responsibility, and worked in polyurethane research at Bayer AG in Germany for two years. He has a B. S. in chemistry from the University of Dayton and a Ph.D. in chemistry from the Pennsylvania State University. Michael Dvorchak is Strategic Technology manager of UV Cure Oligomers & UV PUDs Government Programs for Bayer MaterialScience LLC. He also serves as president-elect of RadTech North America. For additional information on the topics addressed or to ask another question, email [email protected] with the subject line “Polyurethane Q&A.” Any views or opinions expressed in this column are those of the author and do not represent those of Adhesives & Sealants Industry, its staff, Editorial Advisory Board or BNP Media.

May 2011

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STRATEGIC SOLUTIONS

GLOBAL PSA GROWTH TRENDS The global pressure-sensitive industry is forecasted to grow 7% per year through 2014. By Daniel S. Murad, President and CEO, The ChemQuest Group, Inc.

he pressure-sensitive adhesive (PSA) industry has rebounded well from the great recession. The industry now represents approximately 50 million square meters of coated materials and is forecasted to grow 7% per year through 2014. In excess of 50% of PSAs are produced and coated captively by tape and label manufacturers. For merchant adhesive suppliers, the merchant market is a robust $3 billion, consuming 1,000 kilotons of PSAs. Tapes represent 70% of the market, while labels and graphics represent 21% and 9% of the total, respectively. Specialty tape and medical end uses exhibit the greatest growth prospects. Protective films and paper, as well as electronic applications, are forecasted for double-digit growth. This growth readily corresponds to the explosive use of electronic devices in every aspect of our society. Medical tapes, graphics, foam tapes and double-sided tapes will offer healthy growth of 8-9% globally.

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Figure 2. End Use Growth Prospects

Geographically, the Asia Pacific region is the largest producer of pressure-sensitive materials, with a 56% share of the market (see Figure 1). Within the Asia Pacific, four countries—Japan, China, Korea and Taiwan—dominate the concentration of business; collectively, they account for 93% of the PSA business within the region. North America and Europe are roughly equal in size, at 22% and 20% of the market, respectively. These regions are quite mature and exhibit corresponding competitive dynamics at a macro level as a result. Solventborne chemistries will maintain their lead over waterborne and hotmelt PSAs over the next five years. Solventborne PSAs account for the majority of merchant adhesives, with 39% of the market. Waterborne chemistry represents 37% of the total and hot melts 18%. Combined, these three technologies represent a 95% concentration, while radiation curing and silicone technologies

Figure 1. Pressure-Sensitive Material Production by Region

account for just 5%. Within these technologies, acrylics will maintain their dominance, accounting for nearly twothirds of all raw materials used. As for substrates used in pressuresensitive materials, films dominate with 58% of the total; paper substrates make up 29%, mostly due to their use within the label industry. Foams have grown to represent 6% of pressure-sensitive material usage, while foils remain relatively flat with a 3% share of the market. In general, PSAs stand to gain significant ground over the next five years as the industry recoils nicely from the losses caused by the economic downturn (see Figure 2). Over time, the resilience of pressure-sensitive materials as clean, userfriendly technologies for the delivery of bonded materials will continue to outpace the liquid adhesive industry. Dan Murad is president and CEO of The ChemQuest Group Inc., an international strategic management consulting firm specializing in the adhesives, sealants, and coatings industries, headquartered in Cincinnati. For more information, phone (513) 469-7555 or visit www.chemquest.com.

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FOCUS ON Tapes are used on sleds and other equipment to improve aerodynamic flow. (Photos courtesy of the U.S. Bobsled and Skeleton Federation.)

A COOL RIDE tesa tape is the official adhesive tape supplier to the U.S. Bobsled and Skeleton Team.

ate last year, tesa tape, inc. was named an official supplier to the U.S. Bobsled/Skeleton Federation Team. As the team’s only official adhesive tape supplier, tesa tape provides highly specialized adhesive tapes to optimize the team’s equipment. “tesa tape is an integral part of our sleds, as it holds the padding to the pod of the sled and helps the aerodynamic flow around the sled,” said Tuffy Latour, U.S. skeleton head coach. “Our athletes also use tesa tape on helmets and any open areas to cut down on aerodynamic drag, which can help us gain valuable hundredths of a second to get onto the podium. The adhesion of this tape is second to none and is the world leader in adhesive tapes.” The team uses tesa® 4651, a high-quality acrylic coated cloth tape. It is based on a 148-mesh woven rayon fabric backing and a natural rubber adhesive. Features include high adhesion (even on rough surfaces), excellent tensile strength and straight tear edges (longitudinal and horizontal). Easy to write on and conformable, the tape is available in eight colors (black, white, gray, yellow, blue, red, green, and brown). According to the company, tesa® 4651 is a very strong cloth tape that can be used for almost any application, including: • Bundling and reinforcing heavy pipes, profiles, etc. • Covering bore holes and other openings • Marking wires and cables

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• Labeling and color coding • Floor marking • Airtight and permanent pipe sealing • Securing sharp edges • Fixing and insulating wires • Sealing tins and tubes “As a world-class pressure-sensitive adhesive tape manufacturer, we are pleased to support the world-class athletics program of the USA Bobsled and Skeleton Federation,” said Daniel Germain, North American regional president for tesa tape.

ABOUT THE U.S. BOBSLED AND SKELETON FEDERATION The U.S. Bobsled and Skeleton Federation (USBSF), based in Lake Placid, N.Y., is the national governing body for the sports of bobsled and skeleton in the U.S. For more information, visit http://bobsled.teamusa.org.

ABOUT tesa tape, inc. For over a century, tesa tape has pioneered the development of pressure-sensitive adhesive tape technologies. This rich tradition of innovation dates back to 1882, when the company’s founder patented a method for manufacturing medical adhesive dressings. Today, the company services customers in over 100 countries around the globe and holds numerous product patents. In North America, tesa markets many diverse product lines, including double-sided fastening tapes, masking tapes and associated products, packaging tapes, duct and cloth tapes, and many specialty tape products. Visit www.tesatape.com for additional details.

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Finding the best label material for durable goods is no easy feat. By John Bennett, Vice President, Product Identification Business Team, FLEXcon ressure-sensitive labels provide critical information— from safety instructions on mechanical equipment to dosage requirements on medications. Yet creating the right labels for durable goods is no easy feat. It’s important that labels convey essential information, maintain the brand’s aesthetics and perform to exacting standards. But that’s not where label performance ends—manufacturers must deal with a host of additional requirements based on the type of product for which the label is being created.

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MULTIPLE CHALLENGES The label material, or substrate, must achieve key performance factors and functionality, such as adhering and remaining legible throughout temperature extremes, exposure to volatile chemicals, and exposure to UV light. In addition, due to the complexity of today’s retail supply chains, inventory management requirements, asset tracking and birth-to-death product tracking requirements, many labels are now printed with bar codes that must remain legible throughout the product lifecycle. 18

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Unfortunately, no single substrate will work for all applications. The performance of the label is impacted by numerous factors, including the surface to which it is meant to adhere. For example, a surface with high surface energy (easy to adhere to) may require a different adhesive than a material with low surface energy (e.g., new low-cost in-mold plastics) in order to adhere properly. Even seemingly small changes in the application surface can alter the adhesive choice. For example, while labels on snow blowers and lawn mowers have similar requirements for brand identity, warning requirements, and compliance issues, they are also very different. Snow blowers are exposed to sub-zero temperatures, which require adhesives that can perform under those conditions. Alternatively, lawn mowers are exposed to high temperatures and considerable abrasion. Thus, a label that performs well on a snow blower is likely to fail on a lawn mower, and vice versa. In addition, many of today’s applications require specific testing to comply with various agency compliance standards, such as UL, American Gas Association, military, automotive May 2011

and Nuclear Regulatory Commission guidelines. However, the process of testing labels is costly and time-consuming. Several new approaches are emerging to help tackle these complex label selection and validation challenges.

CONSULTATIVE APPROACH With so many factors involved, it can be difficult to predict label performance. After all, no single adhesive sticks to all application surfaces, no single topcoat is compatible with all print technologies, and no single liner works well for all printing or converting methods. Determining the best label construction involves a consultative approach to substrate selection, taking into consideration the application requirements, application surface, print method and more. During this process, it’s important to ask key questions, such as: • Will the product be used indoors or outdoors? • What is the application surface (material, cleanliness and smoothness)? • What will the label be exposed to? • Where on the part will the label be applied? • What is the expected product life? • How will the label be applied? • Will the label be printed and/or converted in sheet or roll form? • Will there be an overlaminate or overprint varnish?

High temperatures and solvents like oil and gasoline can cause labels on outdoor power equipment to lift or fall off.

PREQUALIFYING INK AND SUBSTRATE COMBINATIONS Durable goods manufacturers usually don’t have the time, money or inclination to certify inks and substrates for UL certification. To alleviate this challenge, UL and substrate and press manufacturers are collaborating to make the approval processes less complicated. Through this up-front process, several combinations of substrates, presses, and inks have already been UL approved, allowing printers to simply adopt these substrates and inks to produce UL-compliant labels. For example, certain FLEXcon substrates and Jetrion inks are prequalified and approved by UL for converters that need to produce a PGJI2-certified label. Manufacturers can choose from these recognized substrates and inks with the confidence that the resulting highperformance labels will meet key aesthetic and durability characteristics without an up-front investment. May 2011

Durable goods require safety, hazard, and instructional labels that can withstand temperature changes and remain readable and intact over the life of the product.

ANALYTICAL TESTING Manufacturers are also taking advantage of new testing methods that accurately predict substrate performance under a variety of environmental conditions. Temperature- and humidity-controlled ovens test the substrate’s ability to withstand considerable heat. Similarly, abrasion testing validates the product’s durability against scuffing and scratching. Cryogenic testing is ideal for testing substrate performance on products such as polymer test tubes that need to perform

*Weather-Ometer® is a registered trademark of Atlas Material Testing Technology LLC.

in freezing conditions. The system tests substrates down to -80°C, validating that bar code labels identifying blood or DNA samples are durable at extremely low temperatures. Xenon Arc Weather-Ometer® testing* exposes substrates to light, heat and humidity. Real-time weather testing is performed in a way that mimics years of outdoor weather exposure. Adhesion testing encompasses multiple test methods that evaluate peel strength, seal strength, adhesion strength, and mechanical Adhesives & Sealants Industry

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STICK WITH IT

Ampoules are exposed to rigorous conditions, and it is a challenge for labels to adhere permanently.

properties of adhesives and adhesive systems. Most importantly, end user testing includes fit-for-use-testing to ensure that the substrate fully satisfies performance, aesthetic and functionality requirements.

REAL-WORLD EXAMPLE These approaches help durable goods manufacturers make the right substrate choice, validate that the substrate will perform as needed, and help save time

and money in the process. For example, a global manufacturer of outdoor power equipment recently lowered its total applied costs for nameplate applications by using FLEXcon PSA films. Previously, the company had used a polycarbonate material based on its durability. However, the polycarbonate was costly, and the manufacturing process required to produce the sheeted nameplates was time consuming and labor intensive. The production of the polycarbonate nameplate material required a three-step process. In addition, the product had durability issues. While polycarbonate resists impact and abrasion, it discolors in the face of prolonged exposure to UV sunlight, causing the manufacturer’s nameplate to degrade over time. The company needed a solution that would improve application efficiency, extend outdoor label performance, and lower total costs without sacrificing aesthetics. To resolve these issues, FLEXcon presented the company with a pressuresensitive label solution. FLEXcon identified an ideal set of materials, with graphics printed on FLEXmark vinyl base film and protected from weathering and abrasion by DPM® CVE clear polyolefin overlaminate. The result was a textured surface similar to the more costly polycarbonate. In addition, the self-adhesive label stock eliminated the need to apply a transfer tape and could be printed flexographically in roll form, replacing the three-step operation with a single-pass process. The durability and scratch resistance of the new product construction is as good as or better than the old polycarbonate product. Less expensive materials—paired with in-line, roll-to-roll flexographic printing and overlaminating— made the new nameplate labels less expensive to produce.

CAREFUL SELECTION PAYS OFF With a myriad of factors influencing substrate performance, manufacturers can’t leave anything to chance. Taking a consultative approach to substrate selection and validating this selection through performance testing prevents costly mistakes. Moreover, choosing a pre-certified substrate and ink saves manufacturers money and speeds time-to-market by eliminating the UL approval process. For more information, contact FLEXcon at 1 FLEXcon Industrial Park, Spencer, MA 01562; phone (508) 885-8440; fax (508) 885-8355; or visit www.flexcon.com.

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Responsible Tape

Manufacturing By Susan Sutton, Editor-in-Chief, Integrated Media

The PSTC is pursuing a number of objectives to promote PSA awareness while supporting a more responsible tape manufacturing process. uch of the world tends to take pressure-sensitive adhesives (PSAs) for granted. Tape, for example, has become ubiquitous in today’s society. It’s available for myriad applications in literally hundreds of different types, widths and colors. Average consumers (and even some industrial tape users) aren’t particularly concerned about where their tapes come from or how they’re made—as long as they stick. But that might be about to change. The Pressure Sensitive Tape Council (PSTC) is pursuing a number of objectives to promote PSA awareness while creating a more responsible tape manufacturing process.

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SETTING THE STANDARD The aim of the PSTC’s Responsible Tape Manufacturing Practices program is to validate the industry’s environmental, workplace and quality goals. Following a review process, PSTC member companies can include the RTM logo on their product packaging to designate that they are a responsible tape manufacturer (see sidebar for additional program details). The PSTC’s initial goal with the RTMP program is for PSTC members to self-certify that all of their PSA tape products that are sold in the U.S. (or imported) are produced according to U.S. standards and environmental regulations. The deadline for this initial phase is January 1, 2012. The next step will be to expand the program beyond PSTC members. According to Patrick Deconinck, vice president and general manager of 3M’s Industrial Adhesives and Tapes Division, and the recently elected president of the PSTC, member companies represent the majority of sales in the U.S. “The second part of the mission, which will be more challenging, is to try to apply these responsible tape manufacturing principles to all tapes that are sold in the May 2011

U.S.,” says Deconinck. “Imports coming from emerging countries are often produced in a regulatory environment that is not as stringent as the manufacturing rules and regulations we have in the U.S. We are trying to influence the industry that whatever is sold in the North DECONINCK American market should be made according to North American or U.S. environmental, workplace and quality standards. The mission is to create a more responsible tape manufacturing process.” Deconinck hopes that the program will eventually evolve into a standard. “My vision would be that, like the electronics world has the UL certification, we have a similar certification for the tapes industry,” he says. “But that is the second part of the mission, which we’re starting to work on now.”

INCREASING AWARENESS Another of the PSTC’s main goals is to help grow the PSA tape industry. Toward that end, an important aspect of the RTMP program involves spreading the word about PSTC members’ commitment. “We are going to promote to the outside world that the members of PSTC are producing or sourcing tapes according to those RTM principles,” says Deconinck. The PSTC is also reaching out to organizations such as the Association of Mechanical Engineers and the National Tooling and Machining Association. “Our intention here is to really penetrate professional and industry associations to promote the capabilities of tapes in order to convince those people that there are alternatives to mechanical fasteners,” he explains. “We want to replace bolts, screws and rivets with tapes.” Adhesives & Sealants Industry

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RESPONSIBLE TAPE MANUFACTURING OTHER INITIATIVES Raw material availability is a major issue for the industry, especially with the turmoil in the Middle East and its effects on the crude oil market. The PSTC is working to alleviate raw materials challenges by extending membership opportunities to suppliers. “We have been taking on raw materials suppliers as members of the PSTC so there is a more close relationship between the tape manufacturers and the raw material manufacturers in order to help assure more availability of raw materials,” says Deconinck. The association is also working with ASTM and other global associations to help ensure that tape test methods and production guidelines are standardized. “We have been creating a lot of ASTM standards for tape testing,” he explains. “We are also setting up—or helping to set up with other global associations—ISO standards to make sure tapes are always made according to global standards.” For additional information regarding the PSTC and its activities, phone (630) 544-5048, fax (630) 544-5055, email [email protected] or visit www.pstc.org.

RESPONSIBLE TAPE MANUFACTURING PRACTICES PROGRAM The PSTC’s Responsible Tape Manufacturing Practices program identifies companies that commit to good environmental, sustainability and quality control practices. The comprehensive program brings together all relevant regulations, standards and practices that responsible companies follow. It then reviews company practices to validate compliance. The program’s goal is to acknowledge and raise the visibility of companies that invest in being responsible. It highlights companies that see good manufacturing practices as an integral part of the value they bring to their customers. PSTC members are required to participate in this program. To earn the right to carry the Responsible Tape Manufacturers logo, PSTC member companies must go through a performance validation review. Companies must initiate the review by completing three checklists in the areas of environmental, workplace and quality policies. The covered standards represent best business practices in the operations of U.S. pressure-sensitive tape manufacturers. Following completion of the checklists, companies complete the one-page declaration of compliance, which must be signed by the appropriate corporate officer. To validate a company’s performance, the confidential checklists are reviewed by a volunteer PSTC task force comprising regulatory and test methods committee members. To maintain confidentiality, each company has an assigned code; only that code is visible to the task force during the review process. After the program is completed, PSTC tape manufacturers selling tape in the U.S. are eligible to display the Responsible Tape Manufacturers logo to show that their tapes meet these important standards. By January 1, 2012, member company tapes sourced outside the U.S. and sold in the country will also need to meet these standards. Additional details are available at www.pstc.org.

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ASI07094Chemquest.indd 1

May 2011

6/23/09 10:38:58 AM

A burst seal pack divides two different materials by an interior barrier in a plastic pouch. (Photo courtesy of Andpak Inc.)

Many details should be considered when looking at multiple packaging options. By Eugene Geisz, Sales and Market Development, PPG Industries, Semco® Packaging & Application Systems

requently sold as multi-component materials, adhesives increase joint strength, reduce weight and aid in protection from adverse environmental conditions. But how are adhesives applied to the desired substrate, what types of packaging options exist to dispense adhesives, and what types of adhesive packaging are available for the end user?

F

KIT BASICS Multiple packaging options exist for applying adhesives to substrates. The manufacturer or distributor may supply kits in bulk or “proportioned kits” that are supplied in containers designed to facilitate the combining and mixing of their contents. In these instances, part A and part B of the adhesive are packaged separately and supplied as a kit. One of the containers typically includes enough head space to accommodate the other component, with a little extra room for mixing. Accordingly, the materials (particularly those with a simple mix ratio, such as 1:1 by volume) could be successfully proportioned and mixed by hand. In theory, the metering is done at the factory, and the only thing the operator needs to do is follow the mixing instructions. However, problems exist when hand packaging or using bulk containers. Hand mixing can introduce air, and judging material volumes—as opposed to weight—could cause difficulties that May 2011

might result in operator errors. Operators could also intentionally adjust the mix ratio to compensate for a production condition and add “a little extra” catalyst or hardener to speed up the cure, thus inadvertently affecting the functionality of the adhesive. In addition, the repeated opening and closing of the containers could contaminate the material or compromise its shelf life. Another issue that is specific to proportional kits occurs when the operator leaves material stuck to the inside of the “emptied” container after pouring the contents. The result is wasted material and the potential for an off-ratio mixture, because an inadequate amount of catalyst is left for the remaining quantity of sealant. Off-ratio or improper mixing adversely affects the adhesive’s performance. To eliminate the potential of mix ratio or operator errors, a variety of practical solutions are available to users of multicomponent materials when the application requires a limited amount of material to be mixed and applied. Specialty packaging options are supplied with the intent of dynamic or static mixing, as well as other user-friendly kit options.

DYNAMIC MIXING In a dynamic mixing scenario, the adhesive components meet in a mixing chamber and are homogeneously combined by a mixing element. Dynamic mixing provides the user with a high shear Adhesives & Sealants Industry

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OPTIMIZED PACKAGING

An injection kit contains the catalyst inside a valve mixing rod, while the base is inside the cartridge. All of the material inside the kit is mixed within the package. (Photo courtesy of Semco® Packaging & Application Systems.)

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In a barrier kit, the catalyst and base are separated by an aluminum foil barrier formed over the mixing head. (Photo courtesy of Semco® Packaging & Application Systems.)

Side-by-side cartridges are a mix-ondemand system in which the individual components are packaged into separate cartridges. (Photo courtesy of Sulzer Mixpac USA Inc.)

force, which is required for a range of materials—from thin liquids to heavy pastes—with high mix ratios and varying viscosities. Dynamic mixing can be accomplished with injection- and barrier-style kits, both of which can accommodate any ratio of material. Commonly made of polyethylene, these kits are supplied in various sizes (e.g., 1, 2.5, 6, 8 and 20 oz, and 1/10 gal). Labor-intensive tasks like the measuring and handling of materials are completely eliminated, thereby preventing the possibility of material contamination. When properly performed, this method also dramatically reduces operator exposure to chemicals and fumes. In addition, the package ensures accurate proportioning of materials, since the pre-measured components are stored in separate compartments within the cartridge. Barrier and injection kits are used for specific material ratios. The barrier kit is used for compounds with a volumetric ratio of more than 10 parts per 100, while the injection kit is used for ratios of less than 10 parts per 100. In a barrier kit, the catalyst and base are separated by an aluminum foil barrier formed over the mixing head. An injection kit contains the catalyst inside a valve mixing rod, while the base is inside the cartridge. All of the material inside the kit is mixed within the package. The semi-translucent package allows for visual inspection that a thorough mix has been achieved. After the components are thoroughly mixed, a nozzle is attached and the material

is either manually or pneumatically dispensed with a handheld gun. Many nozzle options are available for specific applications. For automated dispensing applications, adapter heads are attached to dispense the material using needles. There are no intermittent uses of this package, and all of the material must be dispensed within the materials’ working or pot life. Mixing energy for these types of kits is generated through either manual or mechanical means. To optimize the mixing effect and obtain a consistent mix between kits, the rotational speed can be controlled and varied electronically. These types of dynamic pre-weighted packaged kits offer many advantages: • Correct ratio • Guaranteed mix with a wide range of materials • Minimized exposure to chemicals • Capable of handling many different materials (such as polysulfides, epoxies, polyurethanes, etc). • Internal package mixing system • Can be sized to the job (e.g., different cartridge sizes and filling levels) • Convenient application • No special storage required • Capable of handling unique ratios • Good packaged product shelf life • Clean, healthy and safe work environment • No risk of material contamination during the mixing process May 2011

ADDITIONAL OPTIONS

The new generation of syringes is designed with thick walls for high-pressure dispensing. (Photo courtesy of Semco® Packaging & Application Systems.)

STATIC MIXING The next type of package involves static mixing, which incorporates a method for delivering two streams of materials into a static mixer. No shear action is involved, even as the materials are continuously being metered and passed through numerous splits throughout the tube. Because there is a chance that the materials will not be sufficiently mixed, the metering of the individual components to the mixer is crucial. As the streams move through the mixer, the non-moving elements continuously blend the materials. If one component enters the mixer before the other, it will pass through the mixer on its own and result in an improper ratio of the material, which will affect the product quality or characteristics. Complete mixing is therefore dependent on many variables, including the fluid properties, tube inner diameter, the number of elements, and the elements’ design. Depending on the volume and mix ratio of the material, static mixing systems incorporate the use of side-by-side or coaxial cartridges, or dual syringes. Sideby-side cartridges are a mix-on-demand system in which the individual components are packaged into separate cartridges. Commonly used cartridge sizes include 50, 200 and 400 ml, with mix ratios of 1:1, 2:1, 4:1 and 10:1 (by volume). The materials in the cartridge are forced through the dispensing end into the static mixing nozzle. As the metered materials pass through the tube, each element splits the stream into multiple streams to achieve a mixing effect throughout the entire length of the nozzle. May 2011

Again, mixing nozzle designs comprise a series of mixing elements inside a tube. An extrusion gun extrudes the material through a static mixer, which also serves as the dispense nozzle. The static mixer is disposable, thus enabling the intermittent use of this type of package. A coaxial (or universal) cartridge is a static mix system that features properties similar to those of the side-by-side cartridge, but uses two individual cylinders (one within the other) to separate the reactive material until it’s used. The coaxial cartridge is typically available in 75-380 ml sizes, with mix ratios of 1:1, 2:1, 4:1 and 10:1 (by volume). The universal cartridge was designed to fit a standard caulking style or 1/ -gal cartridge that is available in 1:1, 10 2:1 or 10:1 mix ratios (by volume). An extrusion gun is used to simultaneously push the pistons and deliver properly rationed material into a static mixer that also acts as the dispense nozzle. This system enables intermittent use by virtue of its disposable/ replaceable static mixer. Another static mix system involves sideby-side syringes, which are designed for lowto medium-viscosity adhesives with limited ratios (generally 1:2 and 2:1 by volume). This package features a dual plunger that empties both syringe barrels simultaneously. The only task remaining is to ensure proper mixing of the dispensed material using a stick or spatula. Alternatively, side-by-side syringes can be equipped with an attachable static mix nozzle to mix the material as it is dispensed.

Other packaging options are available based on consumer needs and demands. For example, the syringe was originally intended for medical applications. Though the medical syringe was not designed for pneumatic applications with the precise dispensing of small shots that require repeatability and high accuracy, technological developments have modified the syringe for industrial applications. The new generation of syringes is designed with thick walls for high-pressure dispensing, as well as a radius on the luer-lock end to permit air-free filling. In addition, the luer-lock connection allows material to be dispensed using needles and a luer-slip outlet for the direct application of industrial materials. Made of polypropylene, these small syringes are supplied in various sizes, including 1, 3, 5, 6, 10, 20, 30, 35, 55 and 60 cc. Syringes are complemented by a range of pistons or stoppers to facilitate various applications, materials and viscosities. These small syringes are ideal for one-part or pre-mixed and frozen material application, and can be dispensed either manually or pneumatically. Another example, the divider bag, contains parts A and B in a plastic sleeve with a spline separation. To mix the materials, the operator removes the spline and kneads the materials together within the sealed plastic pouch. Similarly, a burst seal pack divides two different materials with an interior barrier in a plastic pouch. The interior barrier bursts open after the operator applies pressure to one side of the package. After kneading the material thoroughly, the corner of the pouch is cut open to squeeze out the material. (This method may not provide adequate mixing with some materials because of variations in viscosity, material ratio and operator handling.)

PACKAGING CHOICES It is important to consider many details when looking at multiple packaging options. However, end users should remember that no single kit solves all problems; each kit offers its own advantages and disadvantages. The operator must decide on the type of kit that works best based on the material properties and application requirements. A proper analysis should therefore be undertaken before choosing the appropriate adhesive package. For additional information, contact Semco® Packaging & Application Systems, a division of PPG Industries, at 12780 San Fernando Rd., Sylmar CA 91342; phone (800) 237-6649; or visit www.semcopackaging.com.

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Sausage packages are often considered a greener alternative because they can be recycled once dispensed. By Eric Traxler, Sales Manager, Contract Packaging, Accumetric LLC

ausage packaging is quickly gaining interest in the marketplace, primarily due to growing environmental concerns. Sausage packages are often considered a greener alternative because they can be recycled once dispensed. European governments and agencies have developed regulations seeking to enforce the incorporation of greener materials and solutions, and the use of sausage packaging has become widely adopted as a result. As domestic regulations change, sausage packages will become more common in the U.S.

S

WHAT IS A SAUSAGE? A sausage package comprises aluminum foil formed into a cylinder with adhesive tightly packed inside and sealed with an air-tight clip. As the sausage is dispensed, the foil film 26

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crumples in a fashion that leaves little to no material residue behind. One of the main advantages of sausage packaging is all that remains once the sausage is completely dispensed is a small recyclable aluminum disk, much like a crushed soda can. Depending on the geographic location, recycling can be very expensive for traditional adhesive cartridge systems, usually due to the amount of adhesive left behind in the cartridge or pail that could not be dispensed. Sausage packages can be considerably less expensive per ounce than conventional cartridges packages, mainly due to the cost of consumable materials. Savings as high as 60% over standard cartridges can be achieved. Sausages can be packaged into varied configurations and sizes, generally in the 10-30 oz range in

diameters from 16-65 mm. Since the film is supplied on a continuous spool, manufacturers can make “on-thefly” packaging changes with relative ease. This added flexibility allows manufacturers to package several different sizes of sausages without having to absorb expensive product changes or additional packaging component inventory. Since the filling process generally entails less air entrapment, sausages tend to enjoy longer shelf life than conventional packages. However, a good rule of thumb when determining the best size for a sausage package is that the length should be at least 2.5 times the diameter. New dispensing equipment is constantly being developed for this technology, but it is a good idea to select a size that accommodates May 2011

readily available dispensing equipment. For example, one new package is available in a 300 ml sausage and can be dispensed out of a reusable plastic cartridge that is compatible with standard 10 oz dispense guns. Two-component sausage guns are also available, which enable many twocomponent adhesives to be sausage packed, including epoxies. Some dispensing manufacturers can also design custom tools to meet specific packaging needs. The main disadvantage to the sausage package is that, once the material is cut and loaded into a gun, it must be completely dispensed and/or emptied. Sausages cannot be capped and stored for another use; they have to be used within the materials’ curing parameters. It is therefore critical that the material is sized appropriately so the consumer is not left with excess material and disposal issues. In addition, it can sometimes be messy when removing the dispensed film material from the gun. Most materials can be packaged into a sausage, but some low-viscosity materials become problematic because most sausage machine equipment fills horizontally.

HOW TO PACKAGE? Packaging material into a sausage can be achieved through several paths. If you do not have access to the packaging equipment or do not want to make the large capital investment, outsourcing to a contract packaging company is recommended. Manufacturers should take several steps before intro ducing a sausage package to the consumer. Regardless of the material going into the package, it is industry standard to go through an evaluation period to determine if there are any negative factors relating to the material, film, shelf life and/or stability. To expedite this process, an accelerated aging test can be used to determine the material’s interaction with the film over extended periods. A packager or manufacturer will typically run multiple lab samples to complete the evaluation tests. This is also gives the manufacturer time to evaluate the completed product and make any necessary changes to artwork or graphics before production begins. Film can be ordered with artwork, or limited graphics can be applied during production, in some circumstances. May 2011

Sausages can provide a very simple adhesive package if the application is a fit. They can be packaged in diameters of 16-65 mm, with theoretically no limit on length, though manufacturers must consider what equipment is readily available to the consumer (e.g., dispensing guns and nozzles). Sausage packages are becoming more common

because they offer valuable green benefits over traditional packaging. However, the application must meet certain criteria in order for sausages to be a true fit. For more information, contact Accumetric LLC at 350 Ring Rd., Elizabethtown, KY 42701; phone (800) 9282677; fax (270) 765-2412; email sales@accumetricinc. com; or visit www.accumetricinc.com.

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Adhesives & Sealants Industry

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INCREASING THE BOTTOM LINE

Convenience packaging can help improve your bottom line with little to no risk. By Jamie Ellsworth, President, KitPackers

oes your company only offer your adhesive or specialty chemical products in bulk containers? Do you rely on selling more poundage year after year to increase your profits? Are you seeing shortages and higher pricing for your raw materials? Are you looking at a significant capital investment to increase your capacity to produce more pounds? Are you looking for a way to differentiate your product offering from that of your competitors? If your answer to any or all of these questions is yes, then you may want to look at offering your products in smaller, more customer convenient packaging. Selling your adhesive in smaller convenience packaging can greatly increase your profit per pound and eliminate the need to continually increase your poundage production and sales. Table 1 illustrates how an adhesive manufacturer supplying a 1:1 ratio epoxy system in 5-gal pails (100 lb net weight per kit) can increase its sales and profitability by providing its product in smaller packages. Selling your product in even smaller packages (e.g., 3-30 cc premixed and frozen syringes, or 3-30 g two-component pouches) would further increase your profits. The increased profit holds true for one-component packaging as well, though less dramatically. The smaller the

D

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package, the greater the improvement in sales, profit per pound and total bottom line profit. However, this scenario does not fully account for the higher margins that can be realized by supplying differentiated convenience packaging.

GETTING STARTED It is possible to start enjoying higher profits with little or no financial risk through the use of a qualified contract packager. You must choose a packaging partner that is willing to work with you through a sequence of start-up steps. The first step is for the contract packager to provide samples of various packages for evaluation in order to determine the best package options. Intermediate quantities of the new package will then need to be provided for market introduction or launch. Finally, the contract packager will need to be able to quickly deliver larger volumes as the new package gains market acceptance. You could decide to offer convenience packaging on an individual, case-by-case basis, or you could add the package as a standard product offering. In either case, using a contract packager eliminates your investment in packaging equipment, as well as the need for packaging materials. In addition, little or no investment in finished goods inventory is required. May 2011

Table 1. Three Scenarios for Supplying Kits of a 1:1 Ratio Adhesive System (100 lbs total net weight per kit) 2 x 5 gal Kit End-user price

87 x 400 ml Cartridges (side-by-side)

696 x 50 ml Cartridges (side-by-side)

$5.25/lb

$25.00/cartridge

$6.00/cartridge

Extended end-user price (full order)

$525

$2,150

$4,176

Manufacturer margin

45%

50%

50%

Manufacturer profit

$2.36/lb

$12.50/cartridge

$3.00/cartridge

Extended manufacturer profit (full order)

$236.25

$1,087.50

$2,088

Taking advantage of new opportunities with a quick production turnaround is vital. A contract packager should be able to provide you and your sales force with small-run quantities (for customer testing) on demand. The contract packager should also be able to respond quickly with quotes and samples for new opportunities, and offer short turnaround times when the custom packages are ordered. Packaging to order reduces shelf life risks and inventory costs, which are common in small-run situations. Before adding new convenience packages to your line, a market analysis or customer survey can be used to determine what packages your customers would like. Convenience packaging can provide customers with significant cost reductions through processing savings and/or reductions in waste by sizing packages to match their usage patterns at an assembly station. Customers with small usage patterns on one or many workstations profit by using adhesives packaged in containers that are scaled to their operations. You may have customers that are buying from you in bulk and “downpacking” the product into convenience packaging. In those cases, the valueadd that you can provide for your customers through pre-packaged systems is significant. Down-packing from bulk to convenience packaging requires specialized equipment and techniques that are typically outside the core competencies of manufacturers using adhesive products.

CONTRACT PACKAGER QUALIFICATIONS Providing adhesives and other specialty chemicals in convenience packaging can entail risks, particularly at the beginning. Will the product have May 2011

Convenience packaging can be offered on an individual, case-by-case basis, or as a standard product offering.

the same shelf life as its original bulk counterpart? Will customer complaints increase due to packaging and dispensing issues? These risks can be minimized by partnering with a contract packager that has experience and expertise with your product chemistries in the same (or similar) convenience packages. The contract packager can assist with accelerated shelf life studies and help avoid the potential pitfalls surrounding a new package. In addition, the contract pack-

ager can help you choose the right package for an application and provide testing to ensure that the product dispenses properly to meet your customers’ needs. The contract packager must also have a robust quality system, with ISO 9001:2008 certification as a minimum requirement. This ensures that the packaging specifications you jointly develop are followed for each and every package, and your customers can rely on consistent quality. A thorough on-site Adhesives & Sealants Industry

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THE BOTTOM LINE

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audit of your prospective contract packager (with a threebatch qualification process) is recommended for any potential contract packager. Lead times and freight costs should also be considered when selecting a contract packager. Variables could include lead times for supplied material to the contract packager, as well as the geographic location of the contract packager relative to your customers and sales channel (especially if drop shipments are contemplated). It is important that the contract packager has technical experience and longevity in the marketplace; look for positive indicators such as solid growth and financial strength. In addition, they need to be current on regulatory compliance and have the ability to provide all of the required documentation and certifications. The contract packager should have the technical expertise needed to provide product support, with a staff that includes engineers and chemists along with testing lab capabilities. Finally, the packaging partner must provide top-notch sales support and customer service to help meet delivery requirements.

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Selling your adhesives or other specialty chemicals in smaller convenience packaging can be an excellent way to improve your top and bottom lines with little to no risk or investment. You can increase profits by adding customer value through packaging without capital outlays and resource allocation to a packaging operation. As your packaging needs grow, choosing the right contract packager is key to a quick and successful product launch, as well as an ongoing, on-time supply of quality packages. For more information, contact KitPackers at N117 W18711 Fulton Dr., Germantown, WI 53022; phone (866) 322-8322; fax (262) 253-5919; or visit www.kitpackers.com.

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May 2011

A new tape option is available for manufacturers using the ASTM D 3359 crosscut adhesion test. By Robert L. Hester, Vice President of Operations, M.E. Taylor Engineering Inc., SEMicro Division

STM D 3359, commonly called the crosscut adhesion test, is one of the most used standards in the ASTM library. Despite the fact that the original standard is over 30 years old, this test method is still extensively used for the qualitative assessment of a coating’s adhesion in industries ranging from automotive to manufacturing. In Method A, a razor blade is used to cut an X in the coating. In Method B, a multi-toothed blade is used to score parallel lines through the coating to the substrate. A second series of parallel lines are scored through the coating at 90° to the first set to create a cross-hatch grid pattern. After the cuts have been made using either method, a 3-in. strip of tape is applied to the grid and subsequently removed. This strip is then examined to estimate how much, if any, of the coating was removed from the substrate. For Method B, the tape is then compared to an X-cut classification chart to determine the coating’s classification rating (see Figure 1).

A

TAPE BACKGROUND The strength and consistency of the tape used can dramatically impact the outcome of the test. If a user performed the test with Scotch tape, a given coating would probably yield 5B (unless the coating was very weak). If duct tape was used to perform the test, however, it might yield 0B. While certain applications may require a special tape, this is acceptable in the standard as long as the tape used is agreed upon between all interested parties. However, it is important to use the same tape for the life of the testing program. If a user were to change tapes midway through the program, the results obtained with the new tape could not be compared to previous tests. Over the years, the tape that has been suggested for use with ASTM D 3359 has changed several times. One of the original tapes suggested for use with the standard was a 3M product that was later removed from the standard at 3M’s request. The company had informed the committee that its tapes were manufactured to a minimum adhesion value but could actually have a much higher strength. The lack of consistency in adhesion would make it a poor tape to use with the standard. May 2011

Some time later, ASTM was informed that Permacel’s P-99 tape was being used extensively by the testing community. Until its recent discontinuation by the manufacturer, this tape was suggested for use with the standard for many years.

DEVELOPING A SOLUTION A solution for current users of the standard has been developed by the SEMicro Divison Figure 1. X-Cut of M.E. Taylor Engineering Inc. Classification Chart The company first obtained several samples of Permacel P-99. Although the adhesive strength of the tape was published in Permacel’s technical data sheet at 52 oz/in., the test method that obtained the published value and the dwell time of the tape were not listed. The dwell time is important because users of ASTM D 3359 are required to remove the tape in 90 ± 30 seconds from application. In many cases, pressure-sensitive adhesives become stronger the longer they are left applied. The rolls of P-99 tape were sent to an independent third party, Chemsultants International of Mentor, Ohio, for testing. Chemsultants performed 10 different peel tests on the tape and reported an average strength of 61.0 oz/in., with a standard deviation of 1.3. (Note the difference from the published value of 52 oz/in., which was most likely due to the tests’ dwell time.) The next step in the process involved contacting an adhesive formulator and requesting a product with a synthetic rubber adhesive similar to the Permacel product and with an adhesive strength of as close to 61.0 oz/in. as possible. After substantial research, it was determined that no off-the-shelf product had an adhesive value within 20% of the adhesive value of the Permacel product when used with a 90-second dwell time. A difference of 20% is unacceptable, as this could result in a different classification rating from the Permacel product for the same test. Adhesives & Sealants Industry

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TEACHING AN OLD STANDARD NEW TRICKS

ASTM D 3359 TEST PROCEDURE Score the coating using the proper blade and tooth spacing for the application. Brush away any excess material.

Using the tab, remove one of the test strips from the booklet.

Apply the test strip to the hatched area and wait approximately 90 seconds.

Again using the tab, remove the test strip from the surface with a smooth, continuous motion.

SEMicro developed a new product, called CHT tape, to take the place of Permacel P-99. To keep the comparisons consistent, this tape was also sent to Chemsultants for testing. The results show that its adhesive strength average is 58.6 oz/in. with a 1.7 standard deviation, representing a 3.9% difference to the Permacel product and providing users with consistency for the life of their quality program. The standard 60-yard rolls of Permacel P-99 were rarely fully used by testers before the shelf life of the product required disposal. (The effect of shelf life on the adhesion of the product cannot be overlooked; an expired roll was also sent to Chemsultants for testing and averaged 64.4 oz/in., with a standard deviation of 3.9.) In addition, the product included no liner and was wound on itself, so laps of the tape were required to be removed and discarded at the beginning of the testing day. The new version of the tape is sold in booklets of 50 test strips that measure 3.5 in. A blank 0.5-in. tab on the end of each strip makes them easy to remove from the booklet, apply to the coating and subsequently remove without the user having to pick at the tape edge (see sidebar). The booklets are also lighter and easier to carry, less costly to ship, and easier to store since they take up less space. Each strip is on a liner, so no tape needs to be discarded and all of the tape can be used. The booklets are also about half the cost of a roll of tape and include a copy of the ASTM classification rating system.

IMPROVED TESTING

Compare the test site to the images on the back of the booklet to determine the coating’s classification rating.

Although ASTM D 3359 is qualitative in nature and not meant to be extremely accurate, it is still very popular in the adhesion testing community because it is fast and easy to perform. Since the test is used in some industries where consistent quality is important (e.g., automotive), a proper alternative must be available for those who had used Permacel’s P-99 product. The CHT product from the SEMicro Division was developed in a scientific manner and made many improvements along the way. For more information, contact the SEMicro Division of M.E. Taylor Engineering Inc. at 15817 Crabbs Branch Way, Rockville, MD 20855; phone (301) 975-9798; fax (301) 975-9653; email [email protected]; or visit www. adhesiontesting.com.

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May 2011

Although UV-cured adhesives mimic the chemistries found in any other polymer, they offer several major advantages.

By Brian Eustace, General Manager, American Ultraviolet West/Lesco Division

onding technology has advanced from glass, steel and mechanically fastened products to multilevel polymer materials and superior ultraviolet (UV) curing methods. With the continued movement toward more compact devices, the need to reliably bond smaller and smaller compounds has never been greater.

B

The UV curing process is a photochemical reaction in which free-flowing molecules, excited by UV radiation, link to form solid polymer chains.

PROCESS HISTORY UV-curable inks and coatings were first introduced in the 1960s as an alternative to solvent-based products. Conventional heat and air drying were originally achieved through solvent evaporation, which shrinks the initial application of coatings by 50% and creates environmental pollutants. Since UV curing avoids the use of solvents, however, it results in zero environmental pollutants, no loss of coating thickness, higher productivity in a shorter amount of time, and a reduction in waste. UV curing involves 100% solids in a fluid state. The UV curing process is a photochemical reaction in which free-flowing molecules, excited by UV radiation, link to form solid polymer chains. Small amounts of May 2011

chemicals known as photoinitiators act as catalysts, allowing the UV-curable adhesives and coatings to solidify or cure the instant that the UV light hits them. No hazardous substances are released during the UV curing process. The volatile organic compounds (VO Cs) found in the noxious, flammable solvents used by conventional coatings, adhesives

and inks are completely eliminated. The environment benefits from the fact that the amount of liquid applied before the curing process is the same amount remaining after the curing is complete: no leftovers, no VOC emissions and no compliance problems. UV curing is now a multi-billiondollar industry and constitutes about 4% of the industrial coating market. Adhesives & Sealants Industry

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THE UV-CURED ADVANTAGE It is currently used in many industries, including automotive, electronics and graphic arts.

BENEFITS When UV light penetrates through a substrate and causes the liquid-tosolid chemical reaction, UV adhesives can cure materials to glass, stainless steel, or other difficult-to-bond substrates. Although UV-cured adhesives

mimic the chemistries found in any other polymer, they offer several major advantages. For example, the chemical bonding reaction happens very quickly, and high-quality UV ink goes farther than solvent-based ink. As a result, UV curing can increase throughout four times over solvent-based processes. Cleanup time practically disappears, so the time available for production is increased significantly.

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UV adhesive bonds display a range of physical properties that are similar to those of thermal or airdried adhesives. As soon as they are cured, UV adhesives display a number of crucial physical properties (e.g., high tensile strength and desirable elasticity) between the substrate and the adhesive. For example, UV adhesives can feature a high compression modulus, which determines the amount of stress the material will exhibit under strain, and a low elastic modulus, which ensures the adhesive’s stretchability. UV light replaces the use of thermal sources that can color adhesives in undesirable ways. They are beneficial for medical device applications because the excitation of their photoinitiators occurs in the UV region, which prevents some adhesives from yellowing. Curing mechanisms that operate in the visible light region, in contrast, include yellow photoinitiators—an undesirable characteristic that can affect the adhesive’s color. UV dryers also take up less space than traditional dryers, so manufacturers can use the extra space for more revenueproducing equipment. UV technology uses less energy, which translates to a significant cut in operational costs. In addition, the technology does not pollute the inside or outside of the facility. A cleaner workspace means healthier employees and a “greener” environment.

stick to outdated business and

TECHNOLOGY ADVANCES

production models.

UV light-emitting diode (LED) curing has been developed to offer an advanced, high-performing curing technology. UV LED technology offers multiple advantages compared to traditional lamps: it is mercury-free; does not generate ozone; and allows for accelerated production speeds, lower production costs and reduced energy use. While traditional mercury-based UV curing lamps dominated the market in the past, more efficient and environmentally friendly UV LED technology is now becoming a superior alternative for spot, flood and conveyor curing formats.

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For additional information, email beustace@auvco. com or visit www.americanultraviolet.com/curing_ solutions.

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May 2011

UV-curable sealant systems are an innovative solution for the production of ammunition cartridges.

ltraviolet (UV)-curable adhesives and sealants have been used successfully in numerous applications due to their excellent high-strength bonding to a variety of substrates, as well as their aesthetically pleasing finish. Their quick curing times are ideal for high-speed, high-volume production lines. In such demanding production lines, selecting the appropriate UV-curable sealants, applicators and UV-curing equipment is important for the proper implementation of a UV-curable sealant process. Additional considerations may be necessary in order to comply with specific product safety regulations. Implementing a UV-curable sealant system for a high-speed, high-volume ammunition production line can be challenging, but the benefits outweigh the drawbacks.

By Peyman Dehkordi, Ph.D., President, Digital Light Lab; and John Lennox, President, LennoxGentle Automation, Inc.

BACKGROUND

May 2011

U

The history of bullets dates back thousands of years, when cast lead bullets were used with slings. The modern bullet’s history begins sometime after 1249, when gunpowder was used to fire projectiles from the open end of a tube. Modern small arms ammunitions, or cartridges, are used in a variety of firearms ranging from pistols and shotguns to rifles and heavier automatic weapons (such as machine guns).1 The term “bullet” is loosely used to describe the cartridge, but it mainly refers to the actual projectile. The proper components and terminology are projecAdhesives & Sealants Industry

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AN EXPLOSION-PROOF UV-CURABLE SEALANT SYSTEM tile, case, primer, and propellant or gunpowder, as shown in Figure 1. A bullet’s manufacturing process begins with the production of each individual component.2 The assembly process loads the propellant into the case and attaches the projectile to the case. The projectile is then sealed into the case by the use of a pitch- or bitumen-based sealant, which is applied to the mouth of the case before “crimping” the projectile or bullet into it. This messy and problematic sealant process typically provides a shelf life of about 10-20 years. Modern advancements in sealants—especially UV-curable sealants—can provide a much better controlled joint and can extend the shelf life to approximately 30-35 years. In the new age of UV-curable sealants, an ammunition case can be waterproofed by applying a UV-curable sealant to the joint between the brass case and the projectile of an ammunition cartridge after the ammunition cartridge is fully assembled and crimped. The UV-curable sealant penetrates, or “wicks,” into the joint by capillary attraction and is then cured by proper exposure to a UV radiation source. The completed, sealed ammunition cartridge is then presented to an accept/ reject system, and all acceptable cartridges are passed down an out-feed chute to tote carts for packaging. Any reject components are directed to quality assurance personnel for disposal. This type of production process can apply to a variety of cartridges (e.g., 5.45 mm, 5.56 mm, 7.62 mm, .308 cal, .338 cal, .50 cal, 20 mm and 30 mm).

CHALLENGES Modern high-speed ammunition production lines can operate at production rates in excess of 150 cartridges per minute. Several challenges are associated with the UV-curable sealant process for such a high-speed production line. These challenges can be grouped into the following categories: • Selection and application of the UV-curable sealant • Specification and implementation of the UV-curing system • Verification of sealant application and UV curing Selecting a UV-curable sealant is important, as it has to adhere to the required waterproofing. It also has to feature fast-curing attributes to comply with the production line speed. The proper amount 36

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Figure 1. Various Sized Cartridges and Their Components

of the sealant (i.e., width, thickness, sealing, adhesion and physical properties) may be established off-line to ensure thorough waterproofing and other relevant properties. Since the cartridge is moving at such a fast rate, accurate and precise application of the sealant to the circular joint between the case and projectile is often difficult. It can be accomplished by first applying a proper amount of sealant to the joint. The round is then rotated to ensure correct distribution and capillary “wicking” of the sealant into the joint. T h e U V- c u r i n g e q u i p m e n t specifications are driven by the UV-curable sealant, production speed, production line specifics, safety and regulatory requirements. The UV-curable sealant usually contains a photoinitiator, which determines the required UV wavelength and minimum UV radiation energy (measured in J/cm 2). In a highspeed production line, the required UV power is determined by: Energy (J/cm2) = Power (W/cm2) x Exposure Time (Seconds) A higher production rate obviously results in a shorter exposure cycle; therefore, a higher power UV system may be required. For a given UV-curable sealant and production rate, the required UV power may be computed. Additional on-line, at-speed testing may be needed to verify the

UV power and proper cure. Alternatively, analytical testing methods may be incorporated to establish the relationship between the sealant cure rate, sealant thickness, UV power, and exposure cycle.3 Due to ever-increasing production throughput, UV equipment is usually challenged to provide the highest possible UV output. The UV radiation output is usually most powerful at the UV lamp aperture. Therefore, a close placement of the UV sources to the cartridges is desired. However, one has to consider and manage the amount of heat transferred from the UV source to the cartridges via radiation, conduction, and convection as a result of this close proximity to the explosive material. Additional regulatory compliances also need to be considered. For example, UV equipment is generally required to be installed directly on the out-feed end of an ammunition load and assembly machine; these are considered a Class 2 Division 1 Group E, F, and G hazardous environment. (Note: Class 2 refers to ignitable metal, carbon, or organic dust. Division 1 classifies the substance as hazardous under normal conditions. Group E contains aluminum and magnesium alloys; Group F refers to carbon, coke and coal; and Group G includes flour, grain, wood, plastic and chemicals.) Therefore, additional safety considerations should be made for the UV-curing equipment to comply with the required regulatory compliances. May 2011

Figure 2. Excited Cartridge with Various Sealant Applications

As one may expect, the proper application and UV curing of the sealant is a very important step in the ammunition manufacturing process. The UV-curing process should include an inspection system to examine the complete periphery of the joint for the sealant ring application, placement and continuity. The system should also inspect the proper sealant application for each manufactured cartridge at full production speed.

SOLUTIONS The application of the sealant is performed at the “sealant apply” station, which consists of a precision, pneumatically operated, normally closed pinch valve. May 2011

The precision dispensing valve features micrometer control over flow (the amount the valve opens and closes), ensuring the accuracy and repeatability of operation. The precision valve is connected to a 1-liter pressurized reservoir that holds the sealant in its own container; no cleaning is required during sealant fill. The production of a shot size with a time/pressure dispensing system has four requirements: • The period and accuracy of the time the valves are “opened” • Repeatability of the pressure on the material in the reservoir • Repeatability of the pressure supplied to the valves • Controlled viscosity of the sealant

A combination of these four factors can be manipulated to produce the desired repeatable volume of dispensed material at high speeds. The first three elements are controlled by the pressure regulation system and repeatability of the timing system. The round is rotated under the precision valve system, and the sealant “bead” is accurately dispensed into the joint between the projectile and case. The UV-curing equipment is usually based on either traditional arc lamps or UV-LED technologies. A careful comparison between these technologies points to UV-LEDs as a more appropriate solution for this application. Arc lamps can be more powerful than UV-LED systems. However, most of the arc lamp optical output is spread through the UVA (315-400 nm), UVB (280-31 nm), UVC (200-280 nm), visible and infrared range of the spectrum. In general, the photoinitiators in the UV-curable sealant are sensitive to UVA and, in some cases, more sensitive to the small range in the UVA spectrum. Therefore, the electrical-to-UVA optical conversion of arc lamps is not as efficient as UV-LEDs, which have a narrow concentrated UV energy spectrum. In addition, the majority of the electrical power to the arc lamp is converted to heat, which is radiated along with the UV signal. In contrast, UV-LEDs offer electrical-to-optical efficiencies as high as 22%, provide a narrow energy spectrum, and do not radiate any other unwanted signals (e.g., IR or heat) toward the curable material. The required UV power is determined by the type of UV-curable sealant, as well as the production line speed. Multiple offthe-shelf arc lamp systems may be used to deliver the required UV radiation. However, various analysis and experiments indicate that the cooling of multiple arc lamp systems with close proximity to the material is difficult, expensive, and complex to implement. Therefore, the arc lamp systems have to be placed in cooling cabinets and may require light guides to transfer UV to the cartridges. This introduces additional inefficiencies and possible maintenance issues due to UV solarizations. UV-LED systems, however, may be placed directly next to the cartridge, with simpler cooling systems and without any light guides. In addition, UV-LED systems are easier to control; they can be rapidly switched on and off without damaging the lamp. Adhesives & Sealants Industry

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AN EXPLOSION-PROOF UV-CURABLE SEALANT SYSTEM

The AccuCure Lightbar provides a narrow, 10 cm focused UV beam that emits an optimized radiation pattern for the UV-curable sealant at the case and projectile joint.

Typical arc lamp system lifetimes are in the range of a few hundred to perhaps a thousand hours, while the lifetimes of UV-LED systems are usually of a much higher magnitude. In addition, UV-LED systems typically enjoy a longer life, as they may be switched off when the production line is in stop/go mode. UV-LED systems also

reduce downtime and scheduled preventive maintenance because they require less frequent replacement than arc lamp systems. Arc lamps also usually contain toxic material and are not as environmentally friendly as UV-LEDs. The AccuCure Lightbar from Digital Light Lab provides a narrow, 10 cm focused

CONSULTING BY “DR. DAVE” Adhesives and Sealants-Technology, Applications and Markets

Dr. Dave Dunn writes the monthly “Questions and Answers” column in Adhesives & Sealants Industry magazine, and is a unique source of both technical and management consulting for the adhesives and sealants industry. Technical Consulting • Formulation advice • Sourcing information • New developments • Application development • Application troubleshooting • Problem solving Market Research • Opportunity analysis • Customer surveys • Mergers and acquisitions • New developments • Market analysis • Industry structure • Competitive intelligence • Key trends

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Technology Focus • Anaerobics • Cyanoacrylates • Reactive acrylics • Epoxies • Hot melts • Gasketing Market Focus • Industrial • Automotive OEM • Automotive aftermarket • Medical • Construction Management Consulting Innovation can be planned and managed to meet the strategic goals of a company. We have concentrated on integrating the R&D functions of companies into their strategic plans and putting systems in place to continuously measure the effectiveness of investments in R&D.

www.adhesivesmag.com

About the principal… Dr. Dave Dunn is President of F.L.D. Enterprises, which is located near Akron, Ohio, USA. He is a former Vice President and Director of Loctite Corporation and has consulted for many adhesives and sealants manufacturers and users in both North America and Europe. He is the author of several books and many articles, including the recent book Adhesives and Sealants-Technology, Applications and Markets, published by Rapra Technology Ltd. (www.polymer-books.com). F.L.D. Enterprises Inc. 242 Trails End Aurora OH 44202 Tel. 330-562-2930 FAX 330-247-1690 e-mail [email protected] web site www.fldenterprises.com

UV beam that emits an optimized radiation pattern for the UV-curable sealant at the case and projectile joint. To comply with Class 2 Division 1 Group E, F, and G hazardous environment regulation standards, the unit is fitted with a type Z purge and pressurization protection system in the form of a sealed and pressurized enclosure. The system is directly mounted on the production line and minimizes any UV losses. The AccuCure Lightbar features a modular architecture to enable various production line speeds. For example, multiple units can be cascaded together to provide a longer UV radiation pattern and accommodate higher production throughput. After curing, an automated, vision-based system inspects each cartridge’s joint periphery for the sealant ring application, placement and continuity. The inspection system, which contains a UV light source, high-speed camera, image acquisition, image processing algorithm and processing electronics, can inspect of all of the cartridges synchronized to the production throughput. The UV source excites the fluorescing material in the sealant, which makes it easier to detect and inspect. Figure 2 (p. 37) shows a UV-excited image of several cartridges with different sealant applications.

HIGH-SPEED SUCCESS High-speed ammunition production systems based on UV-curable sealants and UV-LED curing systems are already in use in full production settings. A UV-curable sealant, accurate dispensing, UV-LEDs, and automated-inspection technologies—coupled with innovative designs—are the key enablers for the success of these systems in ammunition production lines. For additional information, contact the authors at: • Digital Light Lab, 9041 Executive Park Dr., Suite 100, Knoxville, TN, 37923; phone (865) 694 -7892; fax (615) 5231430; email [email protected]; or visit www. digitallightlab.com. • Lennox-Gentle Automation, 400 Corporate Circle, Suite C, Golden, CO 80401; phone (303) 762-0500; email John@ lgautomation.com; or visit www.lgautomation.com.

REFERENCES 1. Hakley, F.W., History of Modern U.S. Military Small Arms Ammunition, Macmillan, 1967. 2. Bames, Frank C., Cartridges of the World, 6th ed, DBI Books, Inc., 1989. 3. Dao, Tien, Roye, Nick, Hedman, Kaj, Dehkordi, Peyman, “The Effect of UV Intensity on the Cure Profiles of Developing Networks, A Case Study for Determining Optimized UV Curing Intensity,” RadTech Report, p. 15, July/August 2009.

May 2011

Using a multi-layered labeling solution can deliver protection and marketing opportunities. By Steve Delepine, Vice President of Business Development, BrandWatch Technologies ever has brand protection been more important or more challenging than in today’s business environment. Counterfeiting is one of the biggest challenges brand owners and manufacturers face. The U.S. Federal Trade Commission (FTC) and Interpol’s World Customs Organization estimate the global counterfeiting problem to be upward of $600 billion per year. In addition to the billions of dollars in lost revenues, counterfeiting threatens brand and product integrity, corrupts supply chains, taints product pedigree, and increases the risk of liability for brand owners in case of consumer injury or death. Given the growing landscape and increased sophistication of counterfeiters, the use of a single security solution to secure and validate is no longer enough. Brand owners and manufacturers that put all of their time and effort into deploying a single overt solution are likely to find that they are using an incomplete system. For example, packaging that can be reused or resealed needs more than a single layer of security. Rather than authenticating the product inside the container, companies that put their focus on a single area such as the

N

May 2011

outside label are merely authenticating a container that can later hold adulterated or fake materials. If the ultimate goal is to deliver a legitimate product from the manufacturer to a consumer and to protect consumers from counterfeit goods, then brand protection requires more than a single layer of security imprinted on the outside of a box. It requires a multi-layered solution that features overt, covert, track and trace, and forensic elements to prevent counterfeit products mixing with legitimate items while assuring customers that the products they are buying are genuine. Multiple layers of protection and the infrastructure to validate authenticity can not only provide comprehensive brand protection, but also deliver many cost-saving and marketing benefits. In fact, when used correctly, brand security can actually be a profit center. Integrating security with marketing and customer loyalty programs can move brand security into value-added payback, spurring additional customer interaction that can enhance customer loyalty and result in additional sales opportunities.

WHAT CONSTITUTES MULTILAYERED BRAND PROTECTION? Multi-layered brand protection includes a combination of security elements such as industry and regulatory compliance, information technology systems to provide track and trace capability, and enforcement mechanisms that initiate internal and external response teams. It uses technology that incorporates overt, covert, track and trace, and forensic security (see Figure 1, p. 40). Overt technologies can be seen and include bar codes, specialty inks and labels, intaglio printing, holograms, watermarks, and tamper-evident film. Track-and-trace systems are unique product identification solutions that can be applied covertly and overtly to individual products, cases, pallets, or shipping containers. The unique markers can be scanned at any point in the supply chain. Information is then uploaded to centrally located data management systems. Brand owners and enforcement teams can access these information systems at any time to track and authenticate their products at any point in the supply chain, from production to the retail shelf. Covert technologies are solutions that are not visible to the human eye. These may include specialty inks, Adhesives & Sealants Industry

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TAKING BRAND PROTECTION TO A WHOLE NEW LEVEL Figure 1. Layered Security Solutions

nanoencryption, and taggants that are integrated into the packaging or product, and can only be read with proprietary readers or detectors. Forensic solutions are difficult to replicate. Forensic technologies can be tailored to meet the individual needs of customers and are exclusive to a product or brand.

purchased the product and from where. With a back-end track-and-trace system in place to capture data along the supply chain, serialization can also prevent product diversion or errant distribution, as well as fraud.

BENEFITS OF MULTI-LAYERED BRAND PROTECTION PROGRAMS

A solid brand protection

A multi-layered brand protection program not only combats fraud and provides the ability to validate product authenticity, but also adds the capability to integrate push-pull marketing efforts that enhance customer engagement and reduce costs associated with product recalls and fraud.

program does more than

Product Recalls/Fraud It is difficult to go a day without reading about a new product recall. In 2010, for example, the Consumer Product Safety Commission recalled 230 infant and child products (a 68% increase over 2009). Other industries, from pharmaceuticals to electronics and automobiles, have also faced significant recall challenges this past year. Companies that incorporate layers of security and leverage new track-and-trace technology can actually limit the amount of product they have to recall. Batch or product serialization helps manufacturers authenticate their products throughout the supply chain. When integrated with a marketing component, the serialization component can identify who actually 40

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create confidence.

Once entered online or via smartphone, the winery can provide the customer with additional product information, as well as methods for interaction with the brand such as accessing recipes and wine/food recommendations. Leveraging these layers of security creates a proactive system that helps brand owners know who their customers are while providing validation technology that can help manufacturers identify problems with the supply chain down to a single bottle. If a unique ID is checked in California and then checked two hours later in France, the system has built-in alerts that are sent to the manufacturer to help them proactively enforce their brand protection in real time. Layered security solutions also provide different levels of knowledge for the appropriate audience. A scan of a secure label can help brand owners know where a product is in the supply chain or provide a distributor with validation that a product is authentic. In addition, entering a code into a smartphone can provide consumers access to additional product information and interaction opportunities with the brand. Consumers want to know they are getting what they pay for, and by incorporating brand protection with marketing initiatives, brand owners can include their customers in the validation process and engage them on an entirely new level.

A SOLID PROGRAM Marketing Opportunities Many product manufacturers do not have a direct connection to their consumers because products are distributed through a complex supply chain before they ultimately end up on retail shelves. Modern security solutions actually make it possible for brand owners to create a previously unattainable two-way exchange of communication. For example, multi-layered integrated labels for wine and spirits provide stateof-the-art forensic protection, as well as a means for consumers to provide direct feedback to the brand owner. A unique forensic identifier provides the distributor and consumer product authentication that is impossible to replicate. A unique serial number on the label can also be crossreferenced via the Internet or a mobile device with an authentication database that can validate an individual bottle.

In the world of business today, it’s all about the brand. This includes brand protection, enhancement, profitability, strategy and sustainability. All of these can be significantly impacted by an effective brand security program that involves a thorough evaluation of a company’s security needs, followed by the design of customized, multi-layered security strategies that will protect products throughout their lifecycle, enhance the customer experience, and deliver multiple levels of knowledge and validation. A solid brand protection program does more than create confidence; it can help drive customer loyalty, providing additional opportunities for direct customer interaction and sales. For more information, visit www.brandwatchtech.com.

May 2011

WHAT’S NEW RAW MATERIALS ASHLAND AQUALON FOAM-CONTROL AGENTS

To serve the needs of waterborne paint formulators, Ashland Aqualon Functional Ingredients, a commercial unit of Ashland Inc., has developed four new Drewplus™ foam-control agents based on mineral oils and hydrophobic components. Versatile and flexible in use, the new foam-control formulations are specifically designed to ensure a long-lasting foam control in waterborne architectural paint systems, the company reports. Drewplus L-1500 and L-1600 are 100% active, zero-VOC foamcontrol agents designed for various pigment concentration paints and suited for dosing in the grind stage. L-1311 is designed specifically for use in waterborne emulsion paints and plasters, and is formulated to control foam at any point during manufacturing, packaging, or application of the paint. Phone: (31) 10497-5817 Web: www.ashland.com

ISP IN-CAN PRESERVATIVE

Nuosept® BIC is a high-performing, formaldehyde-free in-can preservative offered as a “drop-in” replacement to formaldehydecontaining preservatives previously used in Europe for protection against microorganisms. The water-based, zero-VOC preservative contains three active substances (BIT, IPBC, CMIT/MIT) that reportedly work synergistically to preserve products against a variety of microorganisms. Engineered with quick kill activity, Nuosept BIC will be marketed as a universal biocide for wetstate preservation, with the added benefit of plant hygiene. The material is commercially available in Europe for formulators of coatings, adhesives, ready-mix building materials and construction chemicals that seek to market Ecolabel-compliant products without compromising the quality of wet-state preservation. Web: www.ispcorp.com

NatureShield 30 is an emulsion of tung oil that provides a tough, highly water-resistant finish that does not darken noticeably. It produces water beading and holdout in exterior wood stains and sealants, and is also used because of its light golden tint. NatureShield 31 is an anionic emulsion of natural oils and waxes that can provide water resistance and water beading in topical wood coatings. NatureShield 40 is a filmforming natural oil emulsion used to provide water resistance and moderate scratch and mar resistance in both wood and concrete coatings. Phone: (513) 793-7766 Web: www.michelman.com

NUSIL SILICONE ADHESIVE

NuSil Technology LLC has introduced EPM2890, a thermally conductive, non-corrosive silicone adhesive. The adhesive can provide moderate heat transfer between electrical components and their heat sinks. In addition, EPM-2890 exhibits less than or equal to 1% weight loss when heated for 30 minutes at 275ºC to withstand lead-free solder reflow. EPM-2890 is a one-part white silicone adhesive that will room-temperature vulcanize, with moisture, in 72 hours. It can be used as an adhesive or sealing, caulking or potting material in electronics applications that require minimal volatility to avoid condensation in sensitive devices. For applications in which adhesion is important (e.g., bonding for ruggedizing LCD displays), EPM-2890 offers 100 psi minimum primer-less adhesion on aluminum. It provides enhanced thermal conductivity at 0.6 W/(mK) for applications in which stress relief during thermal cycling and heat management are desired. Web: www.nusil.com

H.B. FULLER PACKAGING ADHESIVE

According to this company, Advantra Encore ™ is a new custom-designed, proprietary technology platform that can transform hot-melt performance. The adhesive can reportedly provide superior performance to metallocene-based packaging adhesives. The new adhesive is designed for exceptional bonding on a range of challenging substrates, including coated stocks and high-recycled-content board. Due to its aggressive hot tack, it can grab and hold quickly to prevent pop-opens with highmemory board. The adhesive also offers the potential to switch to lower cost boards that are challenging to seal. Web: www.hbfuller.com/advantra-encore

MASKING TAPE

NATURAL OIL EMULSIONS

May 2011

FORMULATED ADHESIVES

INTERTAPE POLYMER GROUP

MICHELMAN NatureShield is a new line of environmentally friendly, water-repellent additives for interior and exterior wood, stone, and concrete coatings. All are emulsions of natural oils and waxes that reportedly provide excellent water resistance and water beading when used in coatings, stains, and sealants.

with the temperature resistance of silicone sealants. Portions directly exposed to UV rays cure in seconds, while other areas cure by moisture in the air without adding heat. After curing, the product becomes an elastic rubber that can be used on electronic assemblies for bonding, potting, sealing or coating. Typical uses include conformal coatings and the sealing of connectors. The ability of this material to cure with both UV light and moisture mean that any portions in “shadow” will still cure. The resulting cured material reportedly remains elastomeric. Web: www.techsil.co.uk

TECHSIL SILICONES

The new RTV191 range consists of UV-curing, solvent-free silicones that combine the quick curing speed of UV adhesives

This company has expanded its performance masking tape offering with American® brand AM (Aqua Mask™), a tape designed to work in many demanding transportation masking applications. According to the company, the rubber-based adhesive provides secure adhesion to both painted and bare metals and plastics, yet removes cleanly without adhesive residue, paint “flaking” from backside, or surface staining. Applications also include multiple transportation-related paint applications such as marine and composites, bus, truck, RV, and automotive manufacturers. Web: www.intertapepolymer.com Adhesives & Sealants Industry

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WHAT’S NEW EQUIPMENT

HENKEL CORP. CURING SYSTEM

A new system has been designed to quantitatively assess the degree of cure of light-cure adhesives. The Loctite® AssureCure™ system includes new adhesive technology, fiber optic light sources, a light detector unit, and software that ties into users’ PC or PLC. Compared with alternative cure detection methods such as fluorescing and color changing adhesives or destructive and analytical testing, the AssureCure system reportedly provides the only reliable in-line method to confirm degree of cure. Phone: (888) 562-8483 Web: www.assurecure.com

METTLER TOLEDO WEIGHING TERMINALS

The IND131/IND331 is a new family of industrial process weighing terminals that provides maximum connectivity and small footprints. The models feature high-speed analog-to-digital circuitry and flexible connectivity, and are designed for easy integration into process control systems. The terminal reportedly features the speed to provide accurate on-time readings and connection options to transmit the data to a wide array of control systems. According to the company, the models are compact and easy to set up. The IND131/331 terminals have enclosure styles to match any process environment, and include IND131 DIN rail mount, IND131 J-box, IND331 panel mount, and IND331 Harsh/desk/wall mount. The OLED graphic display provides simple plain text menus and icon-driven operation. Web: www.mt.com

product and the base frame of the compact plant are stainless steel; alternately, the unit can be wear protected with urethane or ceramic for metal-contamination-free processing. Nearly all applications for ultra-fine grinding and classification can be solved with a basic plant module and the option to install three machine types for size reduction, including CGS fluidized bed jet mill; ConJet high-density bed jet mill; and CUM universal mill. The CFS and CFS/HD-S fine classifiers can be installed for the classification of powders. The plant is delivered completely assembled, including a fully automatic control system with a touch-screen user interface. Web: www.netzsch-grinding.com

A new website showcases the performance attributes and latest technological advancements in NEXAR polymers sulfonated polymer membrane technology. The polymers can reportedly improve the performance and efficiency of many products in myriad applications, including water management, industrial separation, and the enhancement of high-performance textiles and clothing. NEXAR polymers help designers develop water management systems that effectively remove contaminants from many natural water resources, as well as effluent water from industrial manufacturing plants, to make them suitable for use or reuse. Web: www.nexarpolymers.com

GLASS FIBER REINFORCEMENTS GUIDE

BULK MELTER

This company recently presented a chemical resistance guide for glass fibers at the international trade show for the National Association of Corrosion Engineers. The guide provides information to help end users, engineers and fabricators select glass fiber reinforcements for use in fiberglass-reinforced polymer (FRP) applications used in corrosive environments. The “Glass Fiber Reinforcement Chemical Resistance Guide” contains test results, examples of specifications and information about industry standards for glass fiber compositions used in FRP applications. The results were compiled from tests conducted in the laboratory and knowledge gained in the company’s field experience, and illustrate the effect of chemicals on different glass fibers. Web: www.owenscorning.com/composites/aboutAdvantex.asp

VersaDrum piston pump bulk melters can deliver consistent dispensing of sealants, mastics or adhesives to insulated glass production. Piston pumps provide constant pressure with variable flow, which can be used for intermittent dispensing applications. In addition, the “open” design of this highpressure melter supports high-viscosity materials and the large volume outputs required in the secondary sealing of insulated glass units. These melters reportedly offer quick, easy installation on linear extruders, as well as most other edge sealers. The VersaDrum melters support manual systems for fourth corner patch or handgun use. Phone: (800) 683-2314 Web: www.nordson.com

RESOURCES BROOKFIELD

This company has developed a lab compact plant for ultra-fine grinding and classification of products of any hardness. It is designed for concept tests, as well as batches of up to 5 liters in one run. Parts in contact with the

POWDER FLOW VIDEO

www.adhesivesmag.com

POLYMERS WEBSITE

OWENS CORNING

COMPACT LABORATORY PLANT

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KRATON POLYMERS

NORDSON

NETZSCH-CONDUX

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“mass flow” and “core flow.” Typical problems that impede powder flow, such as arching and rathole formation, are reviewed. Reasons for the use of shear cell testing to characterize flow are compared to simpler methods like flow cups and angle of repose. Phone: (800) 628-8139 Web: www.brookfieldengineering.com/support/videos.asp

A new video answers basic questions about how to measure powders and examines the company’s powder flow tester (PFT). The video depicts basic flow behavior patterns known as

Have Product News to Share with the Industry? E-mail news releases to Teresa McPherson at [email protected].

May 2011

SERVICES MARKETPLACE P R I VAT E L A B E L I N G S E R V I C E S

D I S T R I B U T I O N S E RV I C E S Heigl Technologies ...................................................................................... 43

L A B O R AT O R Y & T E S T I N G S E R V I C E S Chemsultants International Network ............................................................ 44

M A N U FA C T U R I N G & P R O C E S S I N G S E R V I C E S

Incredible VOC Compliant Adhesives and Sealants From Ruscoe

Polymeric Systems, Inc. ............................................................................... 44 Resin Lab .................................................................................................... 44

P R I VAT E L A B E L I N G S E R V I C E S ChemLink.................................................................................................... 44 The Ruscoe Company .................................................................................. 43 This index is a feature maintained for the convenience of the advertiser. It is not part of the advertiser’s contract, and ASI assumes no responsibility for its accuracy.

W have consistently upgraded our formulas We t match customer requirements, while simulto t taneously meeting or exceeding governmental r regulations. We’re at the cutting edge of innovation and curW rently offer our customers a plethora of marketing r and a distribution options.

D I S T R I B U T I O N S E RV I C E S

Depending on volume, we can private label our D products or package p ackage a customer’s formula.

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Heigl Adhesives will provide distribution services tailored to your manufacturing needs. *Epoxies *Hot Melts *Cyanacrylates *Anaerobics *Urethanes *Silicones

The Ruscoe Company has been serving international industry indu with Pliobond adhesive and a host of other premium, p unparalleled adhesive and sealant p products since 1947.

C C compliant, Consider: VOC p ducts in your premium products c ame. company’s name. F additional For information, and a confidential ial review of your requirements,, oe. please E-Mail: Sales@Ruscoe. com or call Paul MIchalec, President, at 330.253.8148

*PUR Hotmelt *Methacrylates *Dispensing *Needles and Syringes *UV’s *Potting Compounds

Please call for a proposal today! p.800.401.1441 www.heigladhesive.com f.952.943.1255 [email protected]

Adhesives & Sealants Products Proven Professionally—Everyday

Promote Your Services to the Adhesives and Sealants Industry

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Be included in all 12 issues for one economical charge. Contact Peg Van Winkle at 614-760-4222 or [email protected] for more information regarding advertising in ASI 's Services Marketplace.

May 2011

Adhesives & Sealants Industry

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SERVICES MARKETPLACE M A N U FA C T U R I N G & P R O C E S S I N G S E R V I C E S

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Seeking Private Label Business • Seeking new Private Label/toll manufacturing for solvent-free adhesives, sealants/coatings. • Leader in North American polyether technology • Multiple packaging configurations • Standard and custom formulations • Excellent turnaround w/newly expanded capacities • Dedicated R&D facility [email protected] 800-826-1681 • www.chemlinkinc.com

CUSTOM REPRINTS

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If your company was mentioned in ASI, reprints of that article are a great sales tool!

Why Reprints? Distribute them at tradeshows. Mail them to your prospects. Use them in sales presentations.

Call Peg at 614-760-4222 or email: [email protected] 44

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May 2011

CLASSIFIEDS

New & Used Equipent

FOR SALE

P O S I T I O N S AVA I L A B L E ViscoTec America offers Sales Position

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Account Managers Privately held, regional specialty chemical distributor has two openings for experienced Account Managers, selling to customers in the Paint & Coatings, Sealants & Adhesives, Plastics and Graphic Arts Industries. These positions will be responsible for developing new business in their geographic territories, as well as maintaining existing accounts. 3-5 years asi0411class-Viscotec.indd 1 3/2/11 11:33 AM sales experience is required. Some overnight travel will be necessary. Positions available in Central Ohio and Minnesota. Salary and benefits commensurate with experience. Send resumes to 6075 B Glick Rd., Powell, OH 43065

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Product Manager WANTED TO PURCHASE: held, packaging supplier has an opening for an Used Dispersers & Mixers Maroon1.inddPrivately 1 3/15/11 experienced Product Manager, selling plastic pails, steel pails, paint cans and related items to customers in the Paint & Coatings, Sealants & Adhesives, Graphic Arts and Food Industries. Responsibilities of this position will include product management, sales management and 5/21/09 9:38:43 AMdirect selling. Salary with large bonus potential bases on P&L performance. 5+ years experience required. Send resumes to 6075 B Glick Rd., Powell, OH 43065

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Specializing in adhesives/sealants industry. Seeking passionate, high-impact professionals for nationwide positions. Send your resume in confidence to: Spencer M. Hermann

for West Coast Area (CA, OR, WA, AZ) Thorough sales experience and knowledge of pumping and dosing technologies is a must. We offer above average pay and benefits. Direct resume to: [email protected] www.viscotec-america.com

A leader in the grinding and dispersion industries

• • • • • •

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Volume 18, Issue January 2011 •

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Adhesives & Sealants Industry

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45

ASK

AD INDEX

DR.DAVE

QUESTION: We have been hearing a lot about modified silicone (MS) sealants recently. How are they different from conventional sealants? ANSWER: MS sealants are 100%-solid systems with no solvents, and they have actually been available for many years. MS sealants dominate the market in Japan, where they were invented in the late 1970s. They have been described as a kind of hybrid sealant with some similarities (but also a lot of differences) to silicones or polyurethanes. The original versions of these sealants use a polyether backbone polymer with silyl end groups, which give them similar properties to a polyurethane, but they cure using the same mechanism as silicones (by the reaction of atmospheric moisture with the silyl end groups). These sealants were classified by the Japan Sealant Industry Association as These sealants modified silicone sealants, really should be and this term seems to have become accepted worldwide. It called silaneis an unfortunate description, however, because the term modified polyether silicone should be used for polymers with exclusively or silyl-terminated a silicon-oxygen-silicon backbone. These sealants polyethers. really should be called silanemodified polyether or silylterminated polyethers. Similar U.S.-developed technologies have an actual polyurethane polymer backbone with silyl end groups, and have been correctly called silane-terminated polyurethanes. The formulated sealants offer many of the benefits of polyurethanes, particularly in construction applications, with good adhesion to many surfaces and excellent paintability. They are non-staining to surfaces and, unlike polyurethanes, do not contain isocyanates, which are hazardous irritants and can cause undesirable sealant foaming. They will never compete with silicones where high temperature resistance is required and apparently do not have sufficient UV and weathering resistance to be used in window glazing applications, an area where silicones have an outstanding track record. These sealants have achieved good market penetration in Europe and are making good progress in the U.S., although the dominance and market acceptance of silicones and polyurethanes is somewhat of a barrier.

Adhesives & Sealants

www.adhesivesmag.com/fbfan

3

American Ultraviolet Co.

www.americanultraviolet.com

30

Applied Test Systems, Inc.

www.atspa.com

10

Brookfield Engineering

www.belusa.com

20

Chemquest Int’l Network

www.chemquest.com

22

Clear Seas Research

www.clearseasresearch.com

Conn & Co.

www.connblade.com

27

F.L.D. Enterprises

[email protected]

38

Green Manufacturing Expo

www.GreenMfgExpo.com

34

Imass, Inc.

www.imass.com

10

Intertape Polymers Group

www.itape.com

9

Loparex Inc.

www.loparex.com

11

Merlin Packaging Technologies Inc.

www.merlinpackaging.com

12

& Applications Systems

www.semcopackaging.com

7

SEMI

www.semi.org/events

Univar USA Inc.

[email protected]

Wacker Chemie AG

www.wacker.com/e-business

IBC

Semco Packaging

BC

4

Dr. Dave Dunn is a former vice president and director of Loctite Corp. and has spent many years troubleshooting adhesive and sealant problems in the adhesives, sealants, specialty rubbers, and plastics fields. Questions for publication should be directed to him at 242 Trails End, Aurora, OH 44202; (330) 562-2930;

IFC

FAX (330) 247-1690; email [email protected]; or visit www.fldenterprises.com. Any views or opinions expressed in this column are those of the author and do not represent those of Adhesives & Sealants Industry, its staff, Editorial Advisory Board or BNP Media.

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This index is a feature maintained for the convenience of the advertiser. It is not part of the advertiser’s contract, and ASI assumes no responsibility for its accuracy.

May 2011

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