ORS3-1346
Development of a PFAS-Free Polymer Processing Additive for Polyolefin Film Extrusion
When and Where
Nov 30, -0001
12:00am - 12:00am
Presenter(s)
YONGWOO LEE (3M)
Co-Author(s)
Abstract
Polymer Processing Additives (PPAs) have been widely used in polyolefin film extrusion to eliminate melt fracture, reduce die build-up, lower extrusion pressure, and improve process stability. With increasing regulatory requirements and market demand for PFAS-free solutions, the development of alternative processing technologies has accelerated.
In this study, the performance of a newly developed PFAS-free Polymer Processing Additive (PPA), 3M HX-9551, was evaluated in blown film extrusion applications. The additive was investigated under various resin architectures, processing conditions, and additive packages, including anti-blocking (AB) and slip agents.
Performance was assessed based on melt fracture elimination, die build-up reduction, pressure reduction, and film optical properties. Experimental results demonstrated rapid melt fracture elimination across multiple LLDPE and mLLDPE grades under shear rates ranging from 220 to 500 s⁻¹ and melt temperatures up to 250°C. The PFAS-free PPA demonstrated performance comparable to or exceeding that of commercial fluoropolymer-based PPAs in terms of melt fracture removal and process stabilization. In addition, the additive maintained effectiveness in formulations containing AB and slip packages, which are known to influence PPA performance.
Long-term extrusion studies further showed significant suppression of die build-up and stable operation during increased output-rate conditions without reappearance of melt fracture. Pressure reduction performance was also observed, indicating reduced flow resistance and improved extrusion efficiency. Evaluation of film properties showed maintained or improved haze, clarity, and gloss compared with benchmark commercial PPA systems.
These results demonstrate that PFAS-free PPA technology can provide robust processing performance while meeting emerging sustainability and regulatory expectations. The developed additive offers a promising solution for polyolefin film manufacturers seeking to transition away from fluorinated processing aids without compromising extrusion productivity or film quality.
In this study, the performance of a newly developed PFAS-free Polymer Processing Additive (PPA), 3M HX-9551, was evaluated in blown film extrusion applications. The additive was investigated under various resin architectures, processing conditions, and additive packages, including anti-blocking (AB) and slip agents.
Performance was assessed based on melt fracture elimination, die build-up reduction, pressure reduction, and film optical properties. Experimental results demonstrated rapid melt fracture elimination across multiple LLDPE and mLLDPE grades under shear rates ranging from 220 to 500 s⁻¹ and melt temperatures up to 250°C. The PFAS-free PPA demonstrated performance comparable to or exceeding that of commercial fluoropolymer-based PPAs in terms of melt fracture removal and process stabilization. In addition, the additive maintained effectiveness in formulations containing AB and slip packages, which are known to influence PPA performance.
Long-term extrusion studies further showed significant suppression of die build-up and stable operation during increased output-rate conditions without reappearance of melt fracture. Pressure reduction performance was also observed, indicating reduced flow resistance and improved extrusion efficiency. Evaluation of film properties showed maintained or improved haze, clarity, and gloss compared with benchmark commercial PPA systems.
These results demonstrate that PFAS-free PPA technology can provide robust processing performance while meeting emerging sustainability and regulatory expectations. The developed additive offers a promising solution for polyolefin film manufacturers seeking to transition away from fluorinated processing aids without compromising extrusion productivity or film quality.
