PET Processors UK

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PET Processors (UK)
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Company profile
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Company History
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Understanding SPP
The Solid Phase Polymerisation (SPP) technique is
widely applied in industrial manufacture of
certain polymers to achieve improved processing
and/or finished product features. Finished
products can include food/drink containers, wide
temperature range usage speciality films and
superior industrial fibres, monofilaments and
sheet. Solid Phase Polymerisation (SPP) is a
chemical process in which the polymer chain
length is increased by the controlled application
of heat in the absence of oxygen and water by
means of either a vacuum or by purging, with an
inert gas, to drive off the by-products of the
reaction. The reactivity is a function of polymer
type, applied temperature and pressure and the
diffusion of the by-products from the pellet
centre to the outer surface. SPP is an important
step frequently employed after melt
polymerisation for the purpose of improving the
mechanical and rheological properties of the
polymers. The batch process and systems employed
by PETUK enables extremely high accuracy of the
product measured molecular weight (IV) and
repeatability between batches.
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Services for...
Polymer Manufacturers
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Services for...
Polymer End Users

• Polymer end users can take advantage of the PETUK
  facilities to have
• Access to the processing benefits associated with
  batch SPP
• The SPP process can be modified to benefit
  finished product specifications
• Customer specified products to meet specific and
  commercially sensitive needs
• Customers to specify a rang of pre and post
  uprating treatments
• Enhancements in crystallinity or molecular weight
  to predetermined and repeatable values
• A focus and commitment to preserving the quality
  of the supplied polymer
• Additionally polymer end users with process and
  product development programmes can benefit from
• Access to polymer specialist and source of
  specialty grades
• Ability to carry small scale trials on polymers
  to meet customers needs
• Access to capacity from 1,000Kgm upwards
• Technical service

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Services for...
Increasing Polymer Efficiency

• Polymer end users can benefit from PETUK
  facilities as below
• The process generates low first pass
  efficiencies. Collected pre-consumer rework can
  be re-pelletised to achieve the original bulk
  density the upgrade then upgrade to the original
  polymer IV. Such polymer may be used to replace
  virgin material up to 100
• Processes that can be run with post consumer
  recycled polymers may have that material upgraded
  to specific IV's, or to higher IV's for blending
  with available low IV polymer
• Processes that create a level of unavoidable
  rework may have this re-pelletised and upgraded
  to a reusable IV
• Customers converting to semi-crystalline polymers
  on specific equipment may have the feed polymer
  customised to meet that machine's characteristics
  (e.g PET replacement of PVC)

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Process Flow
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Process Benefits

• Polymer uprating is the business core activity,
  market leaders in tolling with batch SSP
  technology.
• Over 20 years experience with a wide range of
  polymers.
• Batch technology lends itself to both product and
  process development.
• Quality control on each batch virtually
  eliminates batch to batch IV variation.
• Customer defined tailored IV product ability to
  influence secondary reaction and reduce oligomers
  content.
• Enhance polymer Crystallinity to specific levels.
  
• Customer defined feedstock and PETUK tailored if
  required.
• Capacity retained for Customer transients, market
  fluctuations and market development initiatives.
• Improving FPE of feedstock usage in manufacturing
  by utilising pre-consumer rework PCR at virgin
  specification (bulk density and IV).
• Use of PETUK in house analysis, measurement,
  audit and polymer solutions.
• Manufacturing process and Management systems to
  ISO 9002 and working towards ISO 9001/2000.
  Adherence to Customer specific internal audits.
• Product release on measured values with
  individual batch issue of Certificates of
  Conformance if required (standard is IV, colour
  and yield).
• Comprehensive range of pre-treatment and post
  off-line treatment including electrostatic
  de-dusting, masterbatch/additive blending.
• We offer absolute discretion in product
  development usually through preferred partnership
  arrangements.
• A genuine, customer focussed service built on
  integrity, service, quality and technical
  competence.

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Range of Materials
PET poly ethylene terephthalate PEN poly
ethylene napthalate PBT poly butylene
terephthalate PBTE poly butylene terephthalate
elastomers PTT poly trimethylene terephthalate
PPS poly phenylene sulphide PA polyamides 6,
66 and derivatives CXG Customer experimental
grades (customer specific) LCP liquid crystal
polymers
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Typical Applications

• Medical sterile containers
• High Profile appealing cosmetic containers
• Rigid wide temperature range food containers
• High impact strength car components
• Thick film for electric motor rotor insulation
• Long shelf life Beer Bottles
• High Tenacity Strapping Tape monofilaments
• Fibre optic cabling
• Pachenco Gaming cards (Japan)
• Semi flexible membranes

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IV Uprating Range
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Quality...
ISO 9002

• The company has established a quality policy for
  its operations, which aims to ensure that the
  customer requirements are met and that there is
  a commitment to continually improve the
  effectiveness of the quality management system.
  This is achieved by clear policies for all
  aspects of the business. These are documented in
  the Quality Manual and understood and practised
  by all staff.
• A documented Quality Management System applies
  and follows the principles laid down in ISO
  9001/2000.
• This endorses the commitment the company has to
  meet, or exceed, the expectation by customers for
  quality products and services.
• Measurement of policy success will be by
• Attainment of no batches produced with IV's
  outside the target value 0.02 (or specifically
  higher figure contracted by the customer).
• No customer's giving rise to complain about
  processing.
• The "Quality Policy" is to be reviewed for the
  continuing suitability.
• Quality Objectives are established and reviewed
  on a continuous basis.

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Quality...
IV Methodology

• IV is measured as a function of polymer Molecular
  Weight.
• PETUK determine IV by measuring melt viscosity,
  NOT by solution viscometry.
• Laboratory equipment is calibrated and complies
  with PETUK ISO certification and, as required,
  EQE standards. ISO standards are achieved by
  using specified equipment, prescribed operating
  variables, prescribed methodology and audit
  against known polymer standards.
• As the term IV is loosely applied within the
  Industry PETUK will always measure Customer
  supplied samples of both feedstock and required
  product to establish a correlation with our
  measurements and to determine precise Customer
  requirements.
• PETUK measurements are made to an accuracy of 3
  decimal places.
• PETUK products are used as a benchmark for
  polymer manufacturers.

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Quality...
Statistical Process Control
SPC is an important tool in maintaining the high
quality standards within PETUK. The attached
graphs of real data (Customer specific data
withheld) indicates the high degree of batch to
batch stability over protracted periods, the
conformance to product and commercial
specification and with a Cpk value at over 1.3
the process is in control. Such a graph is quite
typical.
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Quality...
Laboratory

• PETUK operations incorporate a dedicated
  laboratory to facilitate internal processing and
  external polymer testing.
• The following techniques are available
• Differential Scanning Calorimetry (DSC) for
  polymer characterisation and Crystallinity
  measurement.
• Intrinsic Viscosity (IV) of polymer to ISO
  certified process.
• Polymer colour by calibrated tri-stimulous.
• Moisture by calibrated IR loss of weight.
• Microscopy
• Dust measurement
• Turbo Vacuum generators to 10 Torr to certify
  the applied process vacuum

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Pricing Factors

• Factors influencing the SPP Uprating of Polymers.
  
• Polymer morphology
• Polymer catalyst system
• Incoming feedstock molecular weight (measured as
  Intrinsic Viscosity IV).
• Target product IV. (Note All reference to IV
  measurements will require correlation of Customer
  and PETUK values)
• Feedstock moisture content.
• Pellet size, shape, cut and consistency.
• Polymer thermal history (for continuously
  produced polymer and recycle).
• Level of co-polymerisation or additive content.
• Additionally PETUK applied processing profile,
  which is based on the above will take cognisance
  of the following
• Batch size, dependent also on bulk density.
• Polymer heat transfer characteristics.
• Pellet quality and levels of dust.
• Special processing profiles to maintain/change
  Customer specific polymer characteristics.
• Adjustments arising through our own DSC analysis.