Monofilaments for an innovative Technical Textile Ing. Barbara Fontana Sider Arc group: a bit of history… 1948 : Sider Arc was born 1959: Synthetic fiber extrusion 2003: ISO 9001:2000 certification 2005: PET 8 dtex monofilaments 2006: Monotex was born 2007 Oeko TEX standard 100 certification 2008 ISO 9001:2008 certification B.Fontana 2 Sider Arc group today 100 people Monotex Srl Sighisoara Romania 2 production plants 16 lines 3500 tonn /year production capacity Sider Arc Italia Srl Cornaredo Italy monofilament diameter range from 40 µm to 2500 µm B.Fontana 3 Sider Arc monofilaments – markets PPAP – IMDS technical support B.Fontana 4 Monofilaments Tradename Materia prima Principali settori di applicazione CRINLENE® PP Filtration fabrics and Open Mesh fabrics Medical application (USP class VI polymer) UV stabilized products Velcro – hook and loop CRINLENE® TH PP + STA additive (90% of the residual load at break after 2000h ageing in aìr @ 130°C) Filtration and open mesh fabrics ESTENE® PET Flame retardant PET (Trevira CS) Screen printing Filtration and open mesh fabrics Conveyor belts Architecture SIDLION® PA6 – PA66 – PA6.66 PA12 PA6.10 – PA6.12 Filtration and screen printing Tyre cords / Chefer fabrics / Lining fabrics Sewing threads E-SPACE® E-SPACE® Plus Polyester based resins 3D – spacer fabrics – automotive BIOLENE ® PLA Medical applications, filtration, 3D printers HDPE Geotextile PBT PBT Flame Retardant (UL-VO) PBT elastomeric Automotive Furniture Sun protection PPS – POM Resistance to chemicals, vs hydrolysis, abrasion, temperature 10 gennaio 2013 Monotex Srl 5 Crinlene® TH EVOLUTION B.Fontana Sider Arc S.p.A. 6 Sider Arc phylosophy is PARTNERSHIP in QUALITY MARKET KNOWLEDGE KNOW HOW CUSTOMIZATION EXPERIENCE IN SPINNING POLYMER KNOWLEDGE FLEXIBILITY STRONG COOPERATION WITH SUPPLIERS AND CUSTOMERS B.Fontana COMMITMENT TO QUALITY 7 Sider Arc old and new products for the technical textile market CRINLENE® TH – PLA BIOLENE CRINLENE® TH EVO GREEN HDPE ESTENE® SIDLION® E-SPACE® - E-SPACE® Plus PBT - PBT FR (UL-VO) PBT elastomeric PPS POM B.Fontana DEGRADABLE PP RECYCLED POLYESTER 8 Sider Arc starting with «bio» … 2009 PLA and MONOFILAMENTS bioassimilabile (hydrolytic degradation products can be assimilated by fungi / bacteria) coming from renewable resources thermoplastic biopolymer amendable by additives available on the market performances and costs in line with oil - derived materials B.Fontana 9 PLA polymer – chemistry D Lactide L lactide PLLA polymer 37% crystallinity High tensile modulus / low elongation Slow degradation Racemic mixture of Lactic acid L- and D- lactides Randomly distributed isomers PDLLA polymer Amorphous Law tensile strenght / high elongation Fast degradation B.Fontana 10 PLA degradation + + chemical hydrolysis – FIRST STEP + + + + PLA = Polylactide = lactic acid monomers chain H2 O First step: water attacks the chemical bonds in the amorphous phase and it reduces the polymer chains into small fragments molecular weight drops down B.Fontana 11 PLA degradation chemical hydrolysis – SECOND STEP Second step: enzymes / microorganisms metabolize these fragments polymer mass is lowering The decomposition by-products are incorporated into the cellular physiological processes and they’re finally excreted as CO2 B.Fontana and H2O 12 PLA polymer processing Density [g/cc] 1,24 • rheological: lower melt elasticity if compared to polyolefins Tg [°C] 60-65 • mechanical: a blend of those of PET and PS Tm [°C] 160-170 • hydrolytically biodegradable Reduction of: • molecular weight Drying -- 50 ppm moisture • melt viscosity Temperature control in the stretching phase • crystallization rate Shrinkage control (fixing) B.Fontana 13 PLA Biolene monofilament – tensile test 100µm diameter B.Fontana 14 Biolene Ingeo TM : monofilaments mechanical performances B.Fontana 15 Biolene : applications in the medical market • implant absorption • radiotransparency • no toxicity • gradual strain transfer to healing tissue • reduction of rejection of the foreign body • material metabolized inside the human body • it can be sterilized • suitable for gradual drug release B.Fontana 16 Other PLA monofilament applications Food filtration liquid filtration 3D printers Home textiles, matresses, spacer fabrics B.Fontana 17 Sider Arc: green HDPE monofilaments – the idea behind GREEN CHEMICALS Manufactured from renewable raw materials (more than 90% biobased content) Waste minimizing Eco-processes Sugarcane ethanol SUSTAINABLE PRODUCTS Lowest impact on the environment Same performances of the oil derived materials B.Fontana 18 Sider Arc: green HDPE monofilaments – processing Dimensional stability Tenacity – tensile strenght Different stretching process Spinning and stretching optimization in comparison with the standard HDPE. R&D research with the suppliers to get the right green chips for monofilament extrusion B.Fontana 19 Sider Arc: green HDPE monofilaments – results 2.500,00 Virgin HDPE chips 2.000,00 1.500,00 1.000,00 Green HDPE chips 500,00 0,00 B.Fontana 20 Sider Arc: green HDPE monofilaments – applications Shading and protecting nets (protection of pipes from corrosion – coated nets) Ropes Clothes labelling B.Fontana 21 Sider Arc recycled polyester – concept Environmental impact reduction Mechanical recycling of PET bottles & packaging Clean recycling – no chemicals involved B.Fontana Second life polymer New PET monofilaments 22 Sider Arc recycled polyester – trials and results Virgin PET chips 100,00 80,00 60,00 40,00 20,00 0,00 Recycled PET chips Material pre-treatment for the extrusion process New spinpack filtration systems New stretching process: highest mechanical performances without overstretching B.Fontana 23 Sider Arc recycled polyester – applications Clothes and protective garments Spacer fabrics B.Fontana 24 Sider Arc degradable PP – the idea behind oxidation Shorter chains – easily degradable structures oxidation/bio degradation CO2 + H2O + biomass B.Fontana 25 Sider Arc degradable PP – activities New extrusion process Additives selection – compatibility Spinfinish definition Testing of the yarn / fabric to check the degradation behaviour under different conditions ( oxygen, light, environment) B.Fontana 26 Sider Arc degradable PP – results 20,00 20,00 18,00 18,00 16,00 16,00 14,00 14,00 12,00 12,00 10,00 10,00 New oxo-degradable PP monofilament 0,22mm 8,00 6,00 8,00 6,00 4,00 4,00 2,00 2,00 0,00 0,00 B.Fontana Crinlene® PP monofilament 0,22mm 27 Sider Arc degradable PP – applications Fabric disposing Compostable fabrics Geotextiles B.Fontana 28 Sider Arc - certificates B.Fontana 29 Sider Arc green line Starting from tradition B.Fontana With the highest quality and the best performances for new technical textile sustainable monofilaments And trying to think green 30 Thank you for your attention Ing. Barbara Fontana Monofilament Technical Manager Via G. Galilei 45 20010 Cornaredo (MI) - ITALY Tel.: + 39 02 9393 04 1 Fax: + 39 02 9393 04 79 E-mail: [email protected] www.siderarc.com The information provided in this document are given in good faith and are based on Sider Arc’s current knowledge. Such information can only be deemed as indicative, Sider Arc can not be held responsible for any claims arising from the information contained in this document. B.Fontana 31
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