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Innovation for Sustainability
Innovation for Sustainability
Indorama Ventures – A Leader in Polyester
Beverages
Food
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Care
Pharma
Apparel
Medical
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Textiles
Geotextile
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Dedicated to Polyester World Wide
Global Polyester Fiber and PET Producer
− 4 million tons PET per year - 17% global capacity share
− High-Value-Added PET for specialty applications
− Commodity and high-value-added polyester fibers
− Innovation for Sustainability in products and business
Backward Integrated to grow Polyester
− PTA and EG feedstock integration
− 7.3 million tons total capacity in 55 facilities, 19 countries, 4 continents
− 6.2 million tons production including PTA/MEG/PET
Key Figures: 2014
− Revenue: $7.5 billion - 6% Growth
− EBITDA: $600 million - 30% Growth
− Employees: >14,000
Note: “LTM” is last twelve months
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Global Manufacturing Presence 2013
Integrated PTA/Polyesters
Co-located PET/Fiber
Standalone
1. Under expansion from 200ktpa to 390ktpa. Expected to come online in 2012 2. 50:50 JV between IVL and PCH Holding SRL 3. Under construction and expected to come online in Q4 2011 4. 75:25 JV between IVL and Sinterama 5. Polyester fiber capacity to be expanded by 300kT by 2013
Workington, UK
• PET: 155kT
Asheboro, USA
• PET: 225kT
Spartanburg, USA
• PET & Polymers 400kT
• Polyester fibers: 70kT
Decatur, USA
• PET: 432kT
• Virtual PTA integration with BP
Ottana, Italy2
• PTA: 192kT
• PET: 150kT
Rotterdam,
Netherlands1
• PTA: 350kT
• PET: 200kT
Bobingen & Guben,
Germany4
• Polyester fibers: 120kT
Klaipeda, Lithuania
• PET: 198kT
• PET: 180kT
• Preforms: 965m, bottles:
405m, closures: 1,575m
Lopburi, Thailand
Nakhon Pathom,
Thailand
• Polyester fibers: 101kT
Map Ta Phut,
Thailand
• PTA: 540kT
• PET: 108kT
• Polyester fibers: 144kT
Kaiping, China
• PET& Film Grade Chips:
276kT
• Textile grade: 130kT
Rayong,
Thailand
• PTA: 700kT
Tangerang &
Karawang, Indonesia5
• PET: 86kT
• Polyester fibers: 110kT
Port Harcourt,
Nigeria3
• PET: 75kT
Queretaro, Mexico
• PET: 480kT
• Polyester fibers: 55kT
Wloclawek, Poland
• PET: 140kT
• PTA co-location with PKN
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Water
Polyclear® Splash PET 3301
Preformance ® PET N2R
OxyClear® Barrier PET
OxyClear® Shield PET
Liquor / Custom
Polyclear® Crystal PET 3302
Preformance® PET 1708CC
Hot-Fill
Polyclear® Preserve PET 2201
Preformance® PET 1708HS
CSD
Polyclear® Refresh PET 1101
Preformance ® PET ES11
Up to 25% PCR Content
FuTuRe-PET® Resin
Packaging Resins - North America
for extrusion-blow-molding
containers with handles
that can be recycled with PET
Reinventing Extrusion Blow Molding
EBM PET
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Resins for Extrusion Blow Molding
Larger containers and containers with handles can require extrusion
blow mold processing
• Higher melt strength required for continuous polymer melt extrusion
Typical applications
• Food and beverage containers
• Household cosmetics and consumer products
• Automotive and industrial packaging
• Containers requiring excellent clarity and gloss
Typical materials used today
• HDPE: Widely used - Easy to extrude – Colored/opaque containers
• PETG: Crystal-clear – More difficult to process – Recycling challenge
• PVC: Fair clarity – Good melt strength but difficult to extrude
• PP/EvOH/PP: Opaque - Oxygen barrier – Can use regrind
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EBM PET Potential in North America
Polyclear® EBM PET can address and potentially improve
sustainability of about 1 billion pounds of EBM material:
HDPE: 825 million pounds - Out of 4.5 billion pounds EBM total
PP/EvOH/PP: 100 million pounds - Hot fill requires higher heat deflection
PETG: 50 million pounds - Orange Juice/Water – in progress
PVC: 25 million pounds - Various
Products in EBM Containers that could be converted to EBM PET containers Estimates [MM lbs.]
Liquid Food Bottles (incl. milk) 400
Household Industrial Chemicals 375
Pharmaceuticals/ Cosmetics 85
Motor Oil Bottles 15
Other 125
Total 1,000
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The EBM PET Revolution …
… for crystal-clear containers with and w/o handles
that can be recycled with PET
A revolutionary PET resin for extrusion-blow molding
1. High melt strength for extrusion blow molding process
Can be processed on existing equipment with minor modifications
2. Containers can carry the resin code “PETE 1”
It is a semi-crystalline PET with high melt point
3. Can be recycled with standard PET
Obtained APR critical guidance recognition
4. Oxygen permeation similar to PET
Higher barrier compared to existing EBM resins
5. Ideal for containers with handles
Glass-like clarity and high gloss
for extrusion-blow-molded
containers with handles
that can be recycled with PET
PETE 1 & APR Critical Guidance Recognition
EBM PET
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A Semi-Crystalline PET = “PETE 1”
Semi-crystalline polymer
with high melt point
Material can be dried at
PET conditions
Melt temperature similar
to standard PET with an
IV of approx. 1.0 dl/g
Polyclear® EBM PET 5505 is a PET with physical properties very
similar to regular PET and can carry the “PETE 1” resin code
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APR Recognition for PET Recycling
+
APR, the Association of Postconsumer
Plastic Recyclers, is pleased to recognize
Indorama® Ventures’ Polyclear® EBM PET
5505, as meeting or exceeding the APR
PET Critical Guidance Document
protocol.
In addition, Indorama has successfully
completed the testing protocol for bottle to
bottle, to sheet, to strapping, and to fiber
recycling at PTI and is expecting the APR
recognition at the October review meeting
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Tropicana orange juice in 89 and 118 oz. containers with handles Replaced white HDPE jugs to allow for clear transparent container
Container show good clarity and drop performance
Market roll out in 2013 was a great success
Containers have APR Critical guidance recognition and can be fully
recycled within the PET PCR stream
Converting remaining containers with handles for orange juice o Replace white HDPE jugs to allow for clear transparent container
o Replace PETG to allow for recycling with PET PCR
Expanding applications require additional functionalities • Improved drop performance
• Higher Heat deflection for hot fill applications
Market Success
5507 is a slightly modified 5505 with higher IV
Significantly better drop performance, clarity and gloss
Improved and easier processing on shuttle machines
Similar in APR Critical Guidance Testing
Expanding PET Extrusion Blow Molding
EBM PET 5507
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Improved Initial Drop with Reduced Aging
Bruceton Drop Heights
24
30
36
42
48
54
60
66
72
1-Day 7-Day 14-Day 21-Day 28-Day 60-Day
5505 5507PolyClear® EBM PET
Significant better initial drop on larger filled bottles maintained over shelf life 25% higher initial drop and 40% after 60 days due to lack of aging
We request APR to review the critical
guidance data developed by PFE and
issue a recognition letter
APR Critical Guidance Recognition
EBM PET 5507
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The IV drop of Polyclear® EBM PET 5507 blends in extruded pellets is
within the requirements of the critical guidance of APR
Pellet IV after Second Heat Cycle
0.680
0.700
0.720
0.740
0.760
0.780
0.800
0.820
0.840
100% PET Control 25% EBM PETin PET Control
50% EBM PETin PETControl
IV of Extruded Pellets in dl/g
0.000
0.010
0.020
0.030
0.040
0.050
0.060
0.070
100% PETControl
25% EBM PETIn PET Control
50% EBM PETin PET Control
IV Drop -Extruded Pellets [dl/g]
Extruded pellet IV’s of Polyclear®
EBM PET 5507 blends with PET are
higher than pellet IV’s of standard PET after 2 heat cycles
IV drops of the extruded pellets were
within the specification requirement
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• EBM PET blends and PET control show melting temperatures in the
required range of 235 – 255° C
• Final IV’s of EBM PET blends are within the required IV range of the
PET control with difference of less than 0.04 dl/g after 8 hours
• Final IV’s of EBM PET blends are within the required IV range of the
PET control with difference of less than 0.075 dl/g after 15 hours
Solid-State Polymerization
Polyclear® EBM PET 5507 did not require solid stating with standard
PET in the post consumer recycling (PCR) stream due to the high
starting IV
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Polyclear® EBM PET 5507 meets the specifications for yellowness and haze in extruded plaques after three heat cycles
• EBM PET blends showed less than 1 unit shift (b*) and meet the specification
• EBM PET blends showed less haze than the PET control
• All plaques shows L* transmission of ~89 to 90 well above the specified 82
Color & Haze after 3rd Melt History
0
0.5
1
1.5
2
2.5
3
3.5
100% PETControl
25% EBM PETIn PET Control
50% EBM PETin PET Control
Yellowness [b*] Plaques
0.00
1.00
2.00
3.00
4.00
5.00
6.00
7.00
100% PETControl
25% EBM PETIn PET Control
50% EBM PETin PET Control
Haze [%] Plaques
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Polyclear® EBM PET 5507 meets the specifications…
• Plastics Forming Enterprise LLC has provided services to evaluate the
recyclability for Indorama 5507 EBM PET Bottles. The Evaluation was
processed according to the APR PET Bottle Critical Guidance Document.
• The Indorama 5507 EBM flake was successful when processed through the
PET recycle stream simulation.
• PFE did not observe any fuming, odd odor generation, sticking or residue
build up during extrusion/pelletizing and injection molding.
• PFE determined the intrinsic viscosity, melting point, color and percent
haze are within the recommended guidelines of the test protocol.
In Summary
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Disclaimer
NOTICE:
This presentation contains selected information about a specific Auriga
Polymer Inc. product, or group of products, and particular uses of the
same. This presentation does not contain a complete statement of, and does
not constitute a representation, warranty or guaranty with regard to, a product's
characteristics, uses, suitability, safety, efficacy, hazards or health
effects. Purchasers and users of the product are responsible for determining
that the product is suitable for the intended use and that its workers and the
general public are advised of any risks resulting from such use. Nothing
contained in this presentation shall be construed to modify any of the
commercial terms pursuant to which the product was or is sold by Auriga
Polymers Inc. including, but not limited to, terms and conditions addressing
each party's respective rights and obligations with regard to warranties,
remedies and indemnification.
www.indoramaventures.com
