|
Customer
Testimonials and Field Tests/Demonstrations
|
The case study
outlined below includes ONLY the brief summary of its individual
test background and result; please feel free to contact your local
dealer if you want
to know more about how TK Series can help your unique plastic
processing. |
| Case#
017: PVC tubes, fittings manufacturer achieves higher profit by
using high percentage of the recycled and/or scrapped PVC |
|
Customer: |
anonymous
|
| Product: |
PVC tubes, fittings, pipes
|
| Resin
Type: |
PVC, virgin/scrap/recycled
|
| Process: |
extrusion
|
|
Filler Type |
CaCO3 or TiO2 |
|
Customer concerns: |
1. significantly more surface
imperfection for PVC extruded parts when recycled or
scrapped/regrind resin being used.
2. looking for cost reduction in material costs, including both
resin and compounding additives, etc. |
| Tests
Brief: |
1. evaluate the quality performance
effect by using of TK-1
2. investigate the highest possible % scrapped PVC in place of the
virgin PVC
3. investigate the TK-1 effect on the dosage of expensive
compounding additives
|
| Tests
Result: |
1. Customer used 25% of scrap/recycle PVC in their production and
failed the quality requirements. After added with TK-1, the
recycled vs. virgin ratio can be raised to as high as 50% without
quality imperfections.
2. If using customer's in-house scrap/regrind PVC with TK-1;
customer finds they can even use up to 100% of the scrap/regrind
PVC and also require only minimal of the original compounding
additives. Refer below summary for the customer's cost analysis.
|
Formulation
|
Material
Cost/Kg
|
Virgin
PVC w/o TK
|
Scrap
PVC w/ TK
|
|
Dosage,
%
|
$$
|
Dosage,
%
|
$$
|
|
PVC
Resin (virgin)
|
32.730
|
100.000
|
3273.000
|
0.000
|
0.000
|
|
PVC
scrapped/regrind
|
11.440
|
0.000
|
0.000
|
100.000
|
1144.000
|
|
PW
762
|
244.570
|
1.500
|
366.855
|
0.640
|
156.525
|
|
TK-1
|
350.000
|
0.000
|
0.000
|
0.120
|
42.000
|
|
Thermo. 412
|
104.000
|
2.000
|
208.000
|
0.000
|
0.000
|
|
FMS
|
60.340
|
3.000
|
181.020
|
0.000
|
0.000
|
|
Z
298
|
90.370
|
1.000
|
90.370
|
0.000
|
0.000
|
|
B
4674
|
31.820
|
2.000
|
63.640
|
0.000
|
0.000
|
|
CaCO3
calpet
|
7.760
|
1.000
|
7.760
|
0.000
|
0.000
|
|
TiO2
|
73.440
|
0.200
|
14.688
|
0.000
|
0.000
|
|
Pig.
masterbatch
|
450.000
|
0.500
|
225.000
|
0.480
|
216.000
|
TOTAL
|
|
111.400
|
4445.605
|
101.240
|
1558.525
|
|
Unit Cost of Compound; $/kg
|
|
|
39.907
|
|
15.394
|
|
Cost Saving, $/kg
|
|
|
|
|
24.50
|
|
Cost Saving,
%
|
|
|
|
|
61
%
|
Summary:
1. Besides that we can use 100% PVC scrapped/regrind to substitute
the virgin PVC; by using TK-1, we can now significantly save the use
of composite additives (stabilizers, lubricants, processing aid,
pigments, etc.) which needed in the standard compounding PVC resin.
2. The overall material costs saving was up to amazing 61% per
this specific production test.
|
| Major
Benefits: |
1. Better dispensability and enhanced
processing. In general, the more recycled resin or the more filler
used, the lower extrusion rate for PVC production; TK additive
helps to increase the extrusion rate and therefore improve the
production throughput
2. Minimized
the use of PVC virgin resin material
3. Improved gloss and elimination of surface imperfections for parts
processed with either high filled compound or scrap/recycled
materials
|
Return
to Main Testimonial Page
|
