Injection Stretch Blow Molding of NatureWorks PLA

Blow Molding of PLA

General PLA vs. PET Properties

Glass Transition Temperature (oF )

Process (Barrel) Temperatures (oF)

Thermal Conductivity (BTU/ ft-hr-oF)

Specific Heat (BTU/ lb oF)

Specific Gravity (g/cc)

NatureWorks PLA (7000D)

131-140

390-425

0.11

Below Tg: 0.29 Above Tg: 0.51

1.24

PET

158-176

510-575

0.11

Below Tg: 0.26 Above Tg: 0.48

1.32

Permeability Data

Resin
PLA PET

OTR
38-42 3-6.1

WVTR
18-22 1-2.8

N
9.5

CO
201 15-25

Note:

Units are ml mil/100 sq. in day for Oxygen and CO2; for water vapor transmission rate are in grams mil/100 sq. in day

Injection Molding of PLA Preforms

Trial Preparation

Review MSDS Review Nature Works ISBM Guide Ensure proper PPE is being used such as hand and eye protection Ensure processing equipment is in proper working order.

Prior to Injection Molding of NatureWorks PLA

PET and PLA are not compatible with each other. They process within significantly different temperature ranges.

This means that before running PLA on equipment normally used for PET, certain items MUST be done beforehand.

Prior to Injection Molding of NatureWorks PLA All PET needs to be removed from the drying and conveying equipment. This includes: Dryer Hoppers Vacuum Loaders Air Filters on Dryers and Vacuum Loaders Dryer Hoses Conveying Lines.

PET pellets or fines will show up in a PLA preform as un-melted white particles. PET contamination can be a difficult, and significant problem if the cleaning steps are not completed before running PLA.

Blow Molding of PLA Preforms

PET Contamination

Drying of NatureWorks PLA

NatureWorks PLA needs to be dry before processing. Failure to do so may result in significant molecular weight loss due to the combination of moisture and heat during processing. Significant reduction in molecular weight can result in preforms that provide an inconsistent blow molding process, and bottles with poor physical and mechanical properties. PLA must be dried using a desiccated drying system that is in good working order. Dryer should operate with a dew point of -40oF or lower.

Drying of NatureWorks PLA

Drying Temperature

Drying Half Time (t1/2)

40C 50C 60C 70C

4.3 hr 3.9 hr 3.3 hr 2.1 hr

Required drying time is dependent on the initial moisture level in the resin. Typically, NatureWorks 7000D is dried at 70C for at least 4-6 hrs before injection molding. It is best to make sure that the dryer being used does not have big temperature spikes during the regeneration process which can result in pellets blocking in the cone.

Drying of NatureWorks PLA

Drying Curve
3000

2500 Amorphous 40 C 2000 Moisture Level (ppm) Crystalline 50 C Crystalline 80 C Amorphous 50 C

1500

1000

500

0 0 1 2 3 4 Time (hrs) 5 6 7 8 9

Purging Injection Molder of PET

Since PET melt processes at higher temperatures than PLA, one should use an intermediate polymer such as a medium melt index PP (4-8 MFR), GPPS, or PETG (0.7 IV), to expel the PET from the system before adding PLA. PP is the recommended as being the best of the 3 resins for purging. A typical purging compound may also work as a substitute if PS or PP are not available. Purging times vary due to machine characteristics. Injection Molders with shooting pots can take longer to purge than conventional machines due to more areas available where resin can hang up.

Purging Injection Molder of PET

1. 2. 3. 4. 5. 6. 7. 8.

Introduce a medium melt flow PP (5 - 8 MFR) at normal PET operating temperatures. Purge 10-30 minutes as necessary. Let system empty as much as possible. Clean our hopper as much as possible. Change to normal PLA operating temperatures. Purge 10-30 minutes as necessary. Let system empty as much as possible. Alternatively, you can purge with a high flow PETG (similar to Eastman copolymer 6763), or GPPS. Then reduce temperatures to PLA conditions. Stop injection molder and completely clean all hoppers, elbow, slide gates, dryers, hopper loaders bins, hopper loader filters and material conveying lines of residual PET. Load PLA into material handling system. Transition to PLA and purge until melt is clear of any contamination. In order to get PET out of hot-runner, one might have to temporarily increase runner temperatures to 240C or 250C until all PET is expelled. Once this is complete you may decrease to normal PLA operating temperatures. At the completion of the run, purge all PLA from the extrusion system, by ramping up temperatures and adding PET back into system.

Preform Production

Normal PLA injection molding conditions

Feed throat Feed Section Compression Section Metering Section Hot Runner Nozzle Tips Mold Screw Speed Back Pressure Mold Shrinkage

70 (20) 355 (180) 410 (210) 415 (213) 420 (216) 425 (218) 77 (25) 50-100 rpm 150-200 psi 0.004 in/in +/- 0.001

(Please note that these are recommended starting parameters and may need to be optimized)

Injection Molding of NatureWorks PLA

When injection molding PLA for the first time it is usually best to increase the cooling time by 20-25% over normal PET conditions in order to find the parameters needed to make a quality part first. Once these conditions are found, then start decreasing the cooling time in increments of 5 seconds until the minimum cooling time is reached. Since the glass transition of PLA is lower than PET, a slightly longer cooling time might be required in order for the parts to set up properly. This usually effects the overall cycle time of around 3-6 seconds depending on the tooling, equipment, mold temperature, and melt temperature being used.

Injection Molding of NatureWorks PLA

Moldflow Plastics Labs has done an analysis on injection molding of NatureWorks PLA 7000D. A report (.pdf) is available on the Moldflow database or by request from NatureWorks LLC. This report details some specifics about NatureWorks PLA for injection molding such as shrinkage, viscosity, and thermal properties.

Blow Molding of PLA

Blow Molding of PLA Preforms NatureWorks PLA can be reheat blow molded using conventional equipment typically utilized for PET. PLA typically is blow molded using lower processing temperatures than PET. Preform temperatures are usually 85-95C going into the blow mold. PLA is more temperature sensitive than PET. Smaller temperature changes can result in changes to material distribution within the bottle. PLA stretch rod speeds are slightly faster than what is typically used for PET, but are also specific to a particular preform, bottle, and process equipment. An adequate oven length will also be required in order to get the inner wall of the preform hot enough for stretching. The use of a reheat additive might also be desired.

Blow Molding of PLA Preforms

When Blow Molding PLA preforms for the first time, one of the most common problems is making a bottle that it too heavy in the base region. This can result in a loss to drop impact strength due to less orientation of the plastic in this region of the bottle. It can also result in the deformation and the popping out of the base pushup due to the material still being to hot after leaving the blow mold. It is best to adjust oven temperatures, and preblow timing in order to get the best material distribution possible. A bottle design that has ribs in the base to help spread material out is also beneficial.

Blow Molding of PLA Preforms

Deformation of Base Pushup

Preform Design Usually, using PLA in a preform initially designed for PET will work. It is likely, however, that you will need to change some aspects of the blowing process. If desired, changes to the design can be made specifically for PLA. Typical Stretch Ratios Include: Axial: 2.8-3.2 Radial: 3-4 It has also been found that PLA works well in preforms with shorter, uniform, and less abrupt transitions that are found in some preforms used with PET.

General Information

On the web, go to natureworksllc.com for more information about NatureWorks, and NatureWorks PLA. On the website you can find tech datasheets, latest news, and other applications where NatureWorks PLA is being used. Corporate Customer Service: USA/Canada Europe Japan 1-877-423-7659 +31-(0)35-699-1344 81-33-285-0824

General Information NatureWorks LLC has been working in the area of technical development with Plastic Technologies Inc. (PTI) as well as Husky Injection Molding Systems. Both of these companies have been providing consultation for NatureWorks customers with specific issues, such as preform and tooling design, as well as the injection molding and blow molding processes. PTI 1440 Timberwolf Dr. Holland, OH 43528 (419) 867-5400 Husky Injection Molding Systems 530 Queen Street South Bolton, Ontario Canada LE7 5S5 (905) 951-5000

Thank You
www.natureworkspla.com