Despite PVC being replaced by other plastics, now considered commodities, this plastic has shown resilience in industries related to construction, electrical, hardware, among others. This is mainly due to its low cost, versatility in formulation, and constant innovations to provide solutions that meet new international regulations. Among these new proposals, we can mention Calcium Zinc package for PVC pipes, which integrates, in a single product, the thermal stabilizer and lubricants necessary for the manufacturing of PVC pipes
Previously, Calcium Zinc, as a dual compound, lubricant, and thermal stabilizer, was a rather costly choice compared to the methyl tin thermal stabilizer. Nowadays, after experiencing the pandemic, coupled with the rise in the cost of tin due to its scarcity risk in Asian mines, the Calcium Zinc package for PVC pipes presents an intriguing alternative for the future.
In Chemical Additives from Mexico we offer these lubrication packages for PVC At an excellent price and with technical assistance to ensure continuous operation for long hours without machine stops and minimize waste. It's important to mention that the grades we offer are suitable for both the pipe extrusion process and the injection process for accessories.
4 main advantages of using a Calcium Zinc package for PVC pipes
- The first advantage we would like to mention is that manufacturers always seek ways to streamline their mixing operations to avoid errors, waste, and rework. With the conventional way of formulating PVC pipe, the manufacturer must add thermal stabilizers, external and internal lubricants, where any miscalculation can result in significant costs for the production process. With the Calcium Zinc package for PVC pipes, we reduce the number of ingredients to resin, fillers, pigments, and this itself, thus simplifying the mixing process.
For those manufacturers equipped with a closed and automated powder feeding system, this solution fits perfectly as we eliminate liquid products, such as tin thermal stabilizer, that can pose handling complications.
- The second advantage is the Calcium Zinc complex has been preferred by organizations such as the PPI (Plastic Pipe Institute) for being more consumer-friendly metals and presenting very low odor (compared to methyl tin). In fact, these metals in thermal stabilizers are gaining more ground, starting with the medical and food industries, and penetrating markets such as toys, footwear, and others. Furthermore, consumers have shown their interest in low-odor plastics, as the opposite generates some distrust, even though experts know there is no significant risk. This is reflected in trends, where the demand for the Calcium Zinc as an additive for PVC, has steadily increased in recent years.
- As mentioned earlier, the third advantage of the Calcium Zinc package for pipe, is the cost, as after the pandemic, many PVC additives became quite expensive, sparking interest among PVC pipe manufacturers to seek more viable alternatives. This, coupled with the recent advancements in Calcium Zinc, has made it possible to manufacture white pipes with a good finish and mechanical properties that align with the standard requirements. This Calcium Zinc package for PVC pipes allows passing fusion tests, chemical resistance, impact resistance, finishing, etc.
- Finally, for inventory and supply purposes, it is better to manage a smaller number of ingredients since if any is missing, it becomes impossible to continue production. The COVID-19 pandemic showed us how delicate the supply chain is, which is why having a simplified raw material planning has financial advantages and reduces the risk of shortages. Concentrating lubricants and thermal stabilizers into a single product also represents a reduction in logistic costs, where larger quantities of a single SKU can be brought in without the worry of excess inventory (reduction in the bill of materials).
How does the Calcium Zinc package work for PVC pipe?
Understanding the Calcium Zinc complex It can be somewhat complicated, as beyond neutralizing HCl like a conventional stabilizer, it relies on lubrication to reduce friction during extrusion, thus preventing discoloration of the pipe. Since these metals, primarily Zinc, don't form strong chemical bonds with chlorine, they break down in the short term with the high processing temperatures during extrusion. Hence, by reducing the shearing effect of friction, we can lower the melt temperature being plasticized within our equipment and thus delay heat degradation.
It's important to highlight that this package consists of a blend of stearates, synthetic waxes, calcite, boosters (zeolite), pigments, and antioxidants, which the Calcium Zinc package producer for PVC pipe has been specifically designed for a particular process and tube size. We can say it's a somewhat tailor-made material, so the mixture can withstand extreme friction conditions (as seen in a twin-screw extruder) at high temperatures.
Another important piece of information is that, even though this Calcium Zinc package for PVC pipes was designed for this product, its application can actually be extended to rigid PVC in a general sense. Of course, the peculiarities of each formula should be reviewed as there is no guarantee that all the necessary ingredients for each application are included here.
What are some disadvantages?
One disadvantage is that these packages (although they have been standardized to work with various clients using a single product) heavily depend on the equipment specifications, the pipe schedule being manufactured, and its final application, where the lubrication capacity must be adjusted. For the reader to better understand, we can conclude that the required lubrication level for a sanitary pipe is different from that of a larger schedule hydraulic pipe. Because of this, it sometimes happens that in Calcium Zinc packages for PVC pipes, the manufacturer may need to compensate by adding other lubricants, such as those offered by Chemical Additives from Mexico, in order to manufacture a smooth, white, and glossy pipe.
Nor should we lose sight of the main disadvantage of a Calcium Zinc package for PVC pipes is that the formulator loses the ability to adjust the formula because everything is already concentrated in a product where we do not know the exact composition. Additionally, over time and wear and tear on the equipment, the package typically needs an update or screw maintenance to ensure this product functions correctly as initially intended.
Now, if your aim is to avoid formulation or you lack the mixing equipment for this task, at Chemical Compounds, we offer PVC compounds. These compounds are tailored to your needs and machine specifications to produce a high-quality product. Feel free to contact one of our specialized technicians.