Learn what goes into polyvinyl chloride (PVC) and the PVC sheet extrusion process.

1. IAPD e-Training Webinar
Sponsored By:

2. PVC 101: Overview
I.
II.
Why PVC?
Polyvinyl Chloride: The Basics of
Raw Materials & Compounding
A.
B.
C.
What material goes into PVC
PVC versus Other Polymers/Plastics
Environmental/Toxicity of PVC
III. Sheet Extrusion Made Practical &
Simple
IV. Market Applications

3. Why Use PVC in Manufacturing Products?
PVC’s Key Features
Benefits for Manufacturers
Inherent Flame
Resistance
PVC is inherently flame resistant
• Thicker material is more resistant
Faster Part Approval
•
Material meets agency flame ratings which reduces part testing
Chemical Resistance
Resists discoloration or stress cracking from cleaners, foods, oils, detergents,
insecticides and many chemicals
UV Resistance
Enhanced Image
•
Parts look newer longer because they resist discoloration due to UV
exposure
Cost Performance
Reduced Manufacturing Costs By:
• Rigid vinyl can replace higher cost engineered materials like FR ABS,
PC+ABS and PC
• Flexible PVC can replace higher cost thermoplastic elastomers and rubber
• Flexible PVC is the most versatile and cost effective plastic on the market
Improve Manufacturing Efficiency
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Lower Scrap Rates
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100% recyclable

4. PVC Usage
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Commercial Markets
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Strip Doors
Clean Rooms
Computer and Electrical
Equipment Enclosures
Sound Block
Automotive
Tank Lining
Geomembranes
Many Others
Other Markets
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Laminated Products
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Banners
Tents
Awnings
Wallcovering and Wallboards
Swimming Pool Liners
Tapes and Labels
Advertising (signs)
Many Others

5. Polyvinyl Chloride
The Basics of Raw Materials
• PVC Resin
– The Building Block
– Product of salt and oil/natural gas
– Two primary manufacturing methods:
• suspension method
• dispersion method
– Accounts for approximately 50% of
content for flexible sheet

6. Polyvinyl Chloride
The Basics of Raw Materials
• Plasticizer
– Additive that gives flexibility and pliability
– Types Include Phthalates, Adipates and
Phosphates
– Accounts for 30-40% of flexible sheet

7. Polyvinyl Chloride
The Basics of Raw Materials
• The Remaining 10-20%
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Fillers
Stabilizers
Process Aids
Fungicides
Flame-Retardants
UV Inhibitors
Anti-Stat

8. Polyvinyl Chloride
The Basics of Raw Materials
• Pricing in the PVC Sheeting
Market is Driven by Two Primary
Items:
– Oil and/or natural gas pricing
• As oil prices increase, prices for other
polymers based on 90-100% hydrocarbon
increase at a higher rate than PVC, which
is 43% hydrocarbon-based
– Seasonality factors such as the
construction industry

9. Making Polymers
Process for Making Most Polymers
Additives
Hydrocarbons
(Oil, Nat Gas)
Intermediate
Chemicals
Polymer
Compound
Polymer
Process for Making PVC
Additives
Hydrocarbons
(Oil, Nat Gas)
PVC
Compound
Intermediate
Chemicals
Salt Water
PVC

10. Polyvinyl Chloride
Global Demand (2010 figures)
Vinyl is the second largest polymer
manufactured globally.
• World Polymer Demand:
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PVC Resin Demand:
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75 billion lbs.
18% of total global demand
USA & Canada PVC Demand:
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419 billion lbs.
9.5 billion lbs.
China expected to be 44% of
global demand by 2020

11. PVC is Used in a Variety of Plastic Processing
Blow
Molding
Sheet
Extrusion
Calendering
Profile
Extrusion
Injection
Molding

12. Polyvinyl Chloride
Eco-Friendly
• Advancements in Eco-Friendly Raw
Materials
– Bio-based plasticizers
• Plant based
• Smaller carbon footprint
• Renewable resource
– Lead additives phasing out in North America
and Europe
• Less VOCs than PE, PP or ABS
• Vinyl chloride and chlorine gases not
released if PVC degrades
• Can be safely recycled, land-filled and
incinerated
• Processed at lower temperatures than
competing polymers, i.e.; requires less
energy

13. Polyvinyl Chloride
Safe, Non-Toxic Polymer
PVC Has Been Safely
Used for Over 50 Years
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Vinyl chloride monomer (VCM) exposure well
below levels that pose a threat
FDA approved for food packaging
FDA & USP approved for medical use
CPSC allows vinyl use in children’s toys
NSF International approved for potable water
piping
UL, CSA, CFSM and NFPA approved for fire
safety
PVC has not been legislatively banned by
any country or state/province

14. Phthalates and Children's Toys
Consumer Product Safety Improvement Act:
Phthalates Provision for Toys
CPSIA Restrictions Apply to Specified Phthalates:
• Permanent Restrictions (on use in children’s toys & articles
with concentrations >0.1%)
– DEHP
– DBP
– BBP
• Temporary Restrictions (see Appendix)
– DINP
– DIDP
– DnOP
(See Appendix)

15. Polyvinyl Chloride
The Basics of Compounding
• Compounding basics
– Mix raw materials
• Intensive vs. ribbon
– Transfer to compounding line
• Single screw, twin screw, continuous or kneader
– Pelletizer
• Air-cut, underwater or strand
– Package and ship pellets

16. Sheet Extrusion Process

17. Sheet Extrusion Process: Equipment Basics

18. Sheet Extrusion Made
Practical & Simple
• Compounded raw materials are moved
to the manufacturing area, typically in
boxes, gaylords or via silo
• Compound is then drawn into a system
of hoppers and dryers (image on left)
• Compound then proceeds through to a
single or twin screw extruder (image on
right)

19. Sheet Extrusion Made
Practical & Simple
• Material is conveyed through the
screw and into a sheet die
– Compound is re-melted and mixed by
both shear heat and pressure through
this process
• Typical types of dies:
– Coat hanger die (image)
– Pipe die
– Plate die

20. Sheet Extrusion Made
Practical & Simple
• After exiting the die, the PVC is
then forced through a series of
chrome rolls
• The thickness of the material is
set at this point in the process
• Typical types of rolls:
– High polish
– Frosted
– Embossed

21. Sheet Extrusion Made
Practical & Simple
• The formed sheet then goes
through a cooling process, that
can include:
– Water bath (image on top)
– Chilled rolls (not pictured)
• Light boxes can be installed for
visual quality control (image on
bottom)

22. Sheet Extrusion Made
Practical & Simple
• Knives or slitting equipment such
as crush cutters are set to slit
wide sheet into specific roll widths
(pictured)
– 4”, 6”, 8” etc.
• Excess PVC is then recycled,
reground and put back into the
process

23. Sheet Extrusion Made
Practical & Simple
• PVC sheet then is pulled into a
wind-up where it is wound onto
cores
• Typical types of wind-ups found in
the plastics processing industry:
– Surface winders
– Turret winders

24. Market Applications
Strip Doors
Data Centers

25. Market Applications
Tank Lining
Enclosures

26. Summary
PVC 101:
I.
Compounding
A.
II.
Raw materials are mixed and extruded
as pellets
Extruding
A.
Pellets go through a series of hoppers
and dryers
Pellets go through a single or twin screw
extruder
Hot material winds through a three roll
calender stack. Embossed at this point
Sheet is cooled and wound onto cores
B.
C.
D.
III.
PVC Markets
A.
Commercial Markets
I.
B.
Strip Doors, Clean Rooms, Computer &
Electrical Enclosures, Automotive,
Geomembranes, etc.
Many Other Markets

27. Questions?
• Resources, Additional Questions & Information
– TMI, LLC
• www.tmi-pvc.com | 1.800.888.9750
– American Chemistry Council
• www.americanchemistry.com
– The Vinyl Institute
• www.vinylinfo.org
– Vinyl Council of Canada
• www.plastics.ca
– European Council of Vinyl Manufacturers
• www.pvc.org

28. Appendix
Phthalates and Children's Toys
Consumer Product Safety Improvement Act: Phthalates Provision for Toys
In August 2008, President Bush signed into law the Consumer Product Safety
Improvement Act (CPSIA), (H.R. 4040). The CPSIA overhauled the Consumer Product
Safety Act, and responded, in part, to public concerns about imported toys containing
lead. Among the CPSIA’s provisions are restrictions on six phthalates in toys and
children’s products. These restrictions became effective February 10, 2009.
The phthalates restrictions of the CPSIA apply to specified phthalates in particular
products:
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DEHP, DBP and BBP: There were permanent restrictions, effective February 10, 2009, on
the sale of children’s toys and child care articles with concentrations of more than 0.1
percent of di-(2-ethylhexyl) phthalate (DEHP), dibutyl phthalate (DBP) or benzyl butyl
phthalate (BBP).
DINP, DIDP and DnOP: CPSIA placed temporary (interim) restrictions, effective February
10, 2009, on the sale of children’s toys that can be placed in a child’s mouth, and on child
care articles that contain more than 0.1 percent of diisononyl phthalate (DINP), diisodecyl
phthalate (DIDP) or di-n-octyl phthalate (DnOP). Toys that can be put in the mouth are
defined to include toys or parts smaller than five centimeters in one dimension. Toys that
cannot be put in the mouth, but can be licked, are not included.
For the three interim-restriction phthalates (and for other phthalates and plasticizers), the
Consumer Product Safety Commission (CPSC) must convene a scientific study
conducted by a Chronic Hazard Advisory Panel (CHAP). After the CHAP is completed,
CPSC must decide whether to lift the interim restriction or make it permanent.

29. Appendix
Phthalates and Children's Toys, What You Need to Know
The CPSIA sets specific standards on the presence of certain phthalates in toys and child
care articles. However, unlike lead, where prior to the passage of CPSIA there had been
numerous, highly publicized recalls of children’s products by CPSC, there had been no
equivalent activity by the CPSC with regard to phthalates. It is also important to note that:
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Of the six phthalates restricted by the CPSIA, DINP had been typically used in toys in
recent years; this phthalate has not been permanently restricted by CPSIA. Instead, it has
been referred for further study. DINP was found safe in a previous review by CPSC.
A CHAP convened in 2001 to review the safety of DINP concluded that, “For the majority of
children, the exposure to DINP from DINP-containing toys would be expected to pose a
minimal to nonexistent risk of injury.”
The CHAP also added there might be a risk to children who mouth DINP-plasticized toys
for 75 minutes a day or more, day after day for an extended period of time; however,
mouthing experiments showed that children kept toys in their mouths for less than two
minutes a day.
CPSC has never expressed immediate concerns about phthalates used in toys and child
care articles, therefore, consumers should not be alarmed or concerned that some
children’s products may still contain phthalates.
The industry voluntarily removed DEHP and DINP from teethers, rattles and pacifiers and,
as a result, these products are made from plastics that are not expected to contain
phthalates. The CPSIA simply put this voluntary agreement into law.