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1. Alkatuff LLDPE Film Grades Additives Applications ine Heavy duty sacks agricultural films lamination and form fill and seal packaging where enhanced toughness and sealing characteristics are desired General purpose indusirial agricultural and heavy duty films and as a blend component to improve film handling in converting and packaging operations General purpose industrial agricultural and heavy duty films and as a blend component to improve film handling in converting and packaging operations High quality cast film for applications that require toughness high clarity and processability Notes VH Very High Slip H High Slip M Medium Slip Melt Index according to ASTM D1238 unless otherwise annotated Density according to ASTM D1505 unless otherwise annotated FOI Document 11 Jr Alkamax mLLDPE Film Grades Additives Applications Heavy duty bags industrial and agricultural films and 4 form fill and seal applications and ice bags where 0 918 outstanding toughness sealing and hot tack properties avery Viviv are desirable or for downgauging of existing film structures ML1810PN I5lejs bu Heavy duty bags industrial and form fill and seal applications and ice bags where outstanding toughness sealing hot tack properties and high slip are desirable or for downgauging of existing film struc
2. LL755 Applications requiring high ESCR chemical resistance iS and stiffness Incorporation of suitable UV stabilisation is 5 required for outdoor applications LL740UV High speed intricate applications requiring good ESCR chemical resistance toughness and UV protection i such as consumer goods and playground equipment Notes The levei of chemical resistance is a function of product design and environmental conditions Contact Qenos for further information Melt Index according to ASTM D1238 unless otherwise annotated Density according to ASTM D1505 unless otherwise annotated FOI Document 11 IZ Alkathene LDPE Film Grades Additives Melt Index oe A 9 10 min 190 C Density Applications 2 16kg om Heavy Duty Bags Carry Bags Cling Wrap Freezer Film XDS34 0 30 0 929 Heavy duty sacks pallet wrap and industrial applications requiring heavy gauge P film Additive free Heavy duty sacks pallet wrap and industrial applications requiring medium to LDF 433 we Y heavy gauge film with increased stiffness LDD201 0 929 General purpose medium to heavy gauge film for heavy duty bags and shrink 7 Nee film and for use as a blend component LDD203 0 929 General purpose medium to heavy gauge film for heavy duty bags and shrink PE film requiring antiblock and for use as a blend component LDD204 0 45 0 922 General purpose medium to heavy gauge film for heavy duty bags
3. Ram withdraws Figure 4 Injection Moulding Cycle Qenos Technical Guides INJECTION MOULDING 5 Figure 5 Pictorial Representation of the Injection Moulding Cycle As far as the polyethylene is concerned the output of any injection moulding machine depends predominantly on two factors e The time taken for the polyethylene to reach moulding temperature e The time taken for the polymer to be cooled sufficiently in order for the moulding to be removed A convenient method of assessing the effect of different types of polyethylene on output rate is to plot the number of mouldings which can be made in one hour against the cylinder temperature used Although the design of the mould and the type of machine affect output greatly for any given mould on a particular machine an output curve can be obtained by finding for each cylinder temperature the fastest possible cycle which gives mouldings acceptable in all respects except for that of surface gloss i e the minimum injection dwell time pressure and cooling time have been used A typical curve for a plunger machine is shown in Figure 6 It will be noticed that at first as the temperature increases the output also increases The reason for this is that at low temperatures a long cycle is necessary to melt the granules thoroughly but as the temperature increases the melting time becomes shorter and therefore the cycle is also shortened A point is soon reached ho
4. 2 Lig w a E F E D gt Y E 5 144 Temperature C Yield Stress Ys MPa Elongation at Break Er Ultimate Tensile Strength Ts MPa Figure 16 Yield Stress Ultimate Tensile Strength and Elongation at Break of HDPE as Functions of Temperature Long term Behaviour High density polyethylene is a viscoelastic material Like all thermoplastics it exhibits the property known as creep i e over a period of time it undergoes deformation even at room temperature and under relatively low stress After removal of stress a moulding more or less regains its original shape depending on the time under stress and the magnitude of the stress The recoverable deformation is known as elastic deformation whereas the permanent deformation is called plastic deformation it should be remembered that the mechanical properties of a plastic are dependent on the three important parameters of time temperature and stress In design calculations for moulded components the mechanical property values which in most cases are determined by long term tests must be divided by a safety factor Creep Behaviour Under Uniaxial Stress A distinction is made between creep and relaxation tests 14 Creep Test In the creep test the increase in deformation with time of a specimen held under a constant stress is measured and from this the creep modulus is calculated Measurement can be carried out in a flex
5. 24 Qenos Technical Guides FOI Document 18 SA AS ce a S INJECTION MOULDING 5 APPENDIX 2 INJECTION MOULDING TROUBLESHOOTING GUIDE Problem lesa Cause s Potential Solution s Action s Brittle mouldings Sharp corners notches Increase radii PE grade has insufficient impact strength Use lower flow and or lower density grade of PE Excessive orientation Increase melt temperature Inadequate thickness Increase thickness of moulding Burn marks Insufficient venting Increase venting co ite d Injection speed too high Reduce injection speed of flow path Melt temperature too high Reduce barrel and nozzle temperature settings Delamination Incompatible masterbatch Ensure PE based masterbatch is used Contaminant Check feed for contamination Material freezing prematurely Increase temperature settings Increase gate size Demoulding Poor design insufficient draft angles Increase draft angles incorporate slip additive difficulties Over packing Reduce injection speed and or second stage time pressure use higher flow PE grade Excessive second stage Reduce second stage pressure and or time Distortion Moulded in stress orientation Increase melt temperature Use increased melt flow index grade of PE Ribs too thick Employ more but thinner ribs to impart stiffness Variation in thickness Use ribs for varying thickness rather than solid walls Variation in mould cooling Increase cooling channels in difficult to cool ar
6. Enable the joint to be stabilised during the welding heating and cooling cycle Are stress free joints 2 Peeling Tools Rotational peeling tools must be capable of removing a continuous and uniform chip thickness from the outer oxidised surface over the required insertion depth when preparing the fusion zone Have uniform melt pressure within the joint Hand Scrapers are difficult to use and effective preparation is time consuming physically demanding and in most cases does not produce uniform scraping Therefore rotational scrapers or peeling tools are preferred when welding occurs at pipe ends see Figure 34 Figure 35a Re rounding and Alignment Clamp Assembly used for Wide Bore Pipe Figure 34 Rotational Peeling Tool Used to Prepare Pipe Ends 3 Re rounding and Alignment Clamps Re rounding and alignment clamps or other approved methods have to be used for restraining aligning and re rounding pipes during the fusion cycle see Figure 35a and b Figure 35b In field Laying of Multi Jointed Pipe Qenos Technical Guides 2r FOI Document 6 7 7 PIPE AND TUBING EXTRUSION 4 Pipe Cutters Pipe cutters are mounted instruments that are used for the accurate cutting of pipes to ensure uniform and perpendicular pipe end Such cutting devices should include the saw and saw guide see Figures 36a and b i Guillotine Pipe Cutter Figure 36a Examples of a Guillotine Moto
7. For the long term properties of a pipe material the position of the steep branch is crucial e g in practice the steeper branch in the pressure test is referred to as a knee It is determined by the resistance of the material to slow crack Each of the three curve stages is associated with three propagation This material property also referred to as different failure mechanisms In the flat stage of the brittle fracture resistance determines the service life of the pressure curves at 20 C and 80 C represented on pipeline In other words pipelines are designed to operate in Figure 25 only ductile fractures are observed Ductile a ductile failure regime The inflection point the transition type failure shows a visible deformation on the pipe in between the flat and steep branches can be observed if at the failure region Figure 24 shows a section of pipe that all only at high temperature and after very long endurance has failed in a ductile mode times This position denotes the transition from ductile to brittle type behaviour of pipe under pressure Pipe that has failed in a brittle mode doesn t show visible ductility in the failure region see Figure 26 Qenos Technical Guides 17 26 FOI Document 6 oy 7 PIPE AND TUBING EXTRUSION Figure 26 Pipe Failed in Brittle Mode Modern pipe grades such as PE 100 should not show brittle like pipe failures in hydrostatic tests even at 80 C
8. PIPE APPLICATION REQUIREMENTS The operating pressures for pipe systems could be as high as 2 5 MPa 25 bar for example in the transportation of water For gas applications the pressure is usually contained below 1 0 MPa 10 bar The ability of the pipe to withstand sustained pressure is important and dimensions and pressure ratings for pipe made from polyethylene are specified by relevant standards A very high resistance to cracking is required because of the wide range of environments and installation techniques that can be encountered in the field The pipe must have excellent weathering resistance because of extended outdoor exposure Drainage Rural applications such as management of water on farms etc Pipe materials have high strength and exceptionally high toughness At present PE 100 is the highest classification for polyethylene resins and compounds from which to make pressure pipe This means that in addition to retaining the generally acknowledged good properties Specifications for polyethylene resins to be used in pipes for the transportation of fluids under pressure are outlined in relevant standards ALKADYNE GRADE SELECTION FOR PIPE Table 1 Alkadyne Pipe Extrusion Grades Melt Index O 190 C 5kg Density g cm 0 961 10min HDF193B 0 3 Application High Density black PELOO Type resin certified to AS NZS 4131 for use in pressure pipes and fittings Excellent low sag properties and th
9. Stiffness The main factor determining the stiffness of a moulding is the density of the polyethylene Figure 14 shows how the stiffness as measured by the 100 sec tensile modulus increases rapidly with increasing density In the lower density range a change in density of as little as 0 007 g cm will double the stiffness Figure 14 also shows the effect of temperature on stiffness MFI has virtually no effect on stiffness Qenos Technical Guides INJECTION MOULDING 5 100 sec tensile modules at 0 2 strain Ib in x 10 Density g c c Figure 14 Variation of Stiffness and Density with Temperature Impact Properties One of the outstanding properties of low density polyethylene is its toughness when subjected to impact it will stretch and cold draw before it breaks rather than fail in a glass like manner On the other hand medium and high density polyethylenes can fail in a way that is unknown in low density polyethylenes This type of failure is known as brittle failure It is quite different from the tough failure of low density materials and is particularly noticeable in mouldings which have sharp notches or scratches on the surface The usual impact tests for plastic materials are difficult to apply to both brittle and tough types of polyethylene and therefore a specia test had to be devised For this an impact machine is used see Figure 15 in which small specimens 1 x 1 x 0 16 c
10. 11 ISO 13479 2009 Polyolefin pipes for the conveyance of fluids Determination of resistance to crack propagation Test method for slow crack growth on notched pipes notch test 12 ISO 13477 2008 Thermoplastic pipes for the conveyance of fluids Determination of resistance to rapid crack propagation RCP Small scale steady state test S4 test 13 ISO 4437 2007 Buried polyethylene PE pipes for the supply of gaseous fuels Metric series Specifications 14 ISO 4427 1 2007 Plastics piping systems Polyethylene PE pipes and fittings for water supply PMBWELD301B Butt Weld PE Pipelines Resource Manual Chisholm Institute 2010 15 Industry Guidelines Butt Fusion Jointing of PE Pipes and Fittings PIPA 2011 16 Industry Guidelines Butt Fusion Jointing of PE Pipes and Fittings for Pressure Applications PIPA 2011 17 Industry Guidelines Temperature Rerating of PE Pipes PIPA 2010 Issued January 2014 Qenos Technical Guides 43 FOI Document 6 enos A Blivestar Compeny Qenos Pty Lid ABN 62 054 196 771 Cnr Kororoit Creek Road amp Maidstone Street Altona Victoria 3018 Australia T 1800 063573 F 1800 638 981 qenos com Sete i FOI Document 7 Y UNCLASSIFIED ly From s47F Mgenos com Sent Thursday 4 September 2014 9 12 AM To TARCON Subject Objection Gazette no TC 14 33 TC 1425825 Attachments TC 1425825 objection Sep 14 signed pdf HD3690 CON item cost xlsx Polyethylene
11. C for installations where large unpredictable temperature variations occur up to a maximum of 80 C e g above ground installations such as irrigation systems Qenos Technical Guides FOI Document 6 2b PIPE AND TUBING EXTRUSION 7 Predictable Temperature Variations le ee Tal Ae For installations where predictable temperature variations where occur the average material temperature is determined Tm average pipe material temperature for the period from Item d or Item e as follows of time under consideration in C d Across the wall of the pipe the material temperature T average pipe material temperature for a proportion taken as the mean of the internal and external pipe of pipe life in C surface temperatures where a temperature differential exists between the fluid in the pipe and the external Eme ual Determining the MAOP Value The pressure and temperature condition where flow is stopped for prolonged periods should also be checked In this event fluid temperature and outside temperature may equalise L proportion of life spent at temperature Tn Once the temperature of the pipe wall has been determined using any one of the methods a b or c above the following tables can be used to determine the re rated MAOP for the PE pipe system e With respect to time the average temperature may be considered as the weighted average of temperatures for the proportion of time spent
12. Figure 5 Photos Illustrating some more Commonly Employed Mixing Sections Located at the Melt Delivery End of the Screw The typical screw length used in modern pipe extruders is generally around 30 L D e g screw length is described as a ratio of length divided by the screw diameter that is measured at the flight The newest generation high throughput pipe line extruders have even higher screw lengths of 40 L D For example a 90 mm well designed grooved feed extruder would operate at an output of close to 1 000 kg hr and some advanced extruders may achieve an output of 1 500 kg hr Qenos Technical Guides FOI Document 6 36 Table 3 shows expected specific screw output ranges expressed as kg hr rpm of pipe extruders versus screw diameter for high speed extruders with forced conveying feed sections Advanced extruders will have outputs close to the maximum of the designated output specification Table 3 LDPE and HDPE Specific Screw Output Data Versus Screw Diameter Screw diameter Specific output kg hr rpm mm a ROEE 45 0 4 0 6 0 5 0 8 60 0 9 1 2 1 2 1 7 75 18 24 2 5 3 0 90 020 4 0 5 0 120 6 0 8 0 8 0 11 150 10 13 12 16 The economics of a pipe production plant will depend on the following The range of pipe sizes e g diameter sizes e The length of pipe runs e g producing pipe of a set dimension e The available length of the cooling unit in the production building Bearing t
13. Information is based on POP 001 prepared by PIPA Polyolefin Industry Pipe Association as a guide to the electrofusion of polyethylene pipes and fittings complying with Australian New Zealand Standards AS NZS 4130 and AS NZS 412 These guidelines set out the principal requirements for equipment jointing procedures maintenance servicing and calibration of equipment records and training for jointing by socket electrofusion EF and saddle electrofusion The guidelines are also applicable to electrofusion fittings that are available in the size range DN16 to DN800 Development work is being undertaken for larger sized electrofusion fittings To consistently make satisfactory joints it is important to follow the jointing procedure with particular emphasis on pipe surface preparation avoidance of contamination and machine calibration as well as temperature control Pipes and fittings of different SDR can be joined together by the electrofusion process e g DN250 SDR11 pipe can be successfully electrofused using a DN250 SDR17 fitting Electrofusion fittings for pressure applications are usually 24 Single Low Single High Dual Low Pressure Pressure Pressure If e gt 20mm 200 to 245 200 to 230 225 to 240 0 17 0 02 O 52 2502 0 15 450 02 First indication of melt everywhere around pipe Approx Imm maximum 6mm Oto drag pressure O to drag pressure O to drag pressure 11 De 11 e 10e 60 0 5 0 1e 0 15e 1
14. JOINING PE PIPES Butt Fusion Jointing of PE Pipes and Fittings Relevant Standards Jointing Procedures Electrofusion Jointing of PE Pipes and Fittings SDR Pipe to Fitting Fusion Compatibility Electrofusion Socket Jointing OO NNN OO DD 0 PPR WO e O PPP PP PP BR oo KR SB SB ee o E co 0 I o 00h NR N O 0 N N RO N NM N NY N NY N O OIl bb W W y W Qenos Technical Guides 43 A FOI Document 6 a Equipment 1 Control Box 2 Peeling Tools 3 Re rounding and Alignment Clamps 4 Pipe Cutters 5 Weather Shelter Electrofusion Jointing Method Preparation of Pipe Ends Jointing Procedure Electrofusion Indicator Pins Maintenance Servicing and Calibration Records 1 Job Supervision 2 Equipment Servicing and Calibration 3 Training Electrofusion Saddle Jointing Equipment Preparation Jointing Procedure Top Load Electrofusion Branch Saddle Jointing Maintenance Servicing and Calibration Records 1 Job Supervision _ 2 Equipment Servicing and Calibration 3 Training Quality Assurance Management Responsibility 1 Customer Focus 2 Planning 3 Responsibility Authority and Communication Control of Documents 1 Purchasing 2 Fusion Jointing Control 4 Corrective Action 5 Preservation of Product 6 Control of Records T Competence Awareness and Training Qenos Technical Guides PIPE AND TUBING EXTRUSION 7 26 26 af 2T 2B 28 28 28 23 Sel 31 21 el 3d S
15. Not adequate water flows setting to the calibrator Melt temperature too low Too high melt temperature Excessive extruder screw speed Die too small for required throughput Die pin too hot Extruder Surging The saw blade is flexing The saw blade is lose Saw arm is entering pipe too quickly and with insufficient revolutions The saw arm is lose or bushes worn and is floating There is wear slack in Slip rings of the saw planetary components Uneven speed of haul off or cutting carriage Saw is not capable of cutting the pipe Uneven melt delivery from the die extruder surging Uneven take off speed Improper alignment of die and haul off units Die and pin not centred evenly Excessive sag of a polymer Moisture in resin Trapped air Potential Solution s Action s g Ensure minimum of 1 5 hrs drying of resin at 70 90 C Adjust water flows to calibrator Increase die and or extruder temperatures Adjust extruder and or die temperatures accordingly Lower extruder throughput Ensure adequate die size Check operation of pin cooling otherwise decrease throughput Check remedies for extruder surging Get thicker larger blades Check and fix Adjust as required Check and fix Check and fix Check uniformity of the speed of haul off and cutting carriage Check with OEM for saw specifications Check remedies for extruder surging Check haul off unit Check for alignment Even die gap Check remedies for
16. attachment should clearly identify the question to which it relates f Unless otherwise specified all information provided should be based on the situation as at the date of lodgement of the TCO application g Customs may require an objector to substantiate with documentary evidence information provided in relation to the objection h Further information on the Tariff Concession System is available in Part XVA of the Customs Act 1907 inthe foreword to the Schedule of Concessional Instruments inthe administrative guidelines in Volume 13 of the Australian Customs Service Manual in Australian Customs Notice No 98 19 on the internet at www customs gov au by e mailing information customs gov au or by phoning the Customs Information Centre on 1300 363 263 agree in submitting this form by electronic means including facsimile that for the purposes of Sub Section 14 3 of the Electronic Transactions Act this submission will be taken to have been lodged when itis first received by an officer of Customs or if by e mail when it is first accessed by an officer of Customs as specified in Sub Section 269F 4 of the Customs Act Position Held s47F s47F s47F Date j de 4 September 2014 NOTE SECTION 234 OF THE CUSTOMS ACT 1901 PROVIDES THAT IT IS AN OFFENCE TO MAKE A STATEMENT TO AN OFFICER THAT iS FALSE OR MISLEADING IN A MATERIAL PARTICULAR Full Name WHEN THIS FORM HAS BEEN COMPLETED LODGEJT WITH CUSTOMS BY posti
17. form This is the approved form for the purposes of those sections b A submission will be date stamped on the dayitis first received in Canberra by an officer of Customs The submission is taken to have been lodged on that day c For the submission to be taken into account it must be lodged with Customs no later than 50 days after the gazettal day for an application for a TCO noilater than 14 days after the gazettal day for an amended application for a TCO or where the Chief Executive Officer has invited a submission within the period specified in the invitation d Every question on the form must be answered e Where the form provides insufficient space to answer a question an answer may be provided in an attachment The attachment should clearly identify the question to which it relates Unless otherwise specified allinformation provided should be based on the situation as atthe date oflodgementof the TCO application g Customs may require an objector to substantiate with documentary evidence information provided in relation to the objection h Furtherinformation on the Tariff Concession System is available in Part XVA ofthe Customs Act 1907 inthe foreword to the Schedule of Concessional Instruments inthe administrative guidelines in Volume 13 of the Australian Customs Service Manual in Australian Customs Notice No 98 19 on the internet at www customs gov au by e mailing information customs gov au or by ph
18. gicm Heavy Duty Bags Shrink Carry Bags Antiblock Cling Wrap Heavy duty sacks palet wrap and industrial applications requiring heavy gauge film Additive free LDF433 0 925 Heavy duty sacks pallet wrap and industrial applications requiring medium to heavy gauge film with increased stiffness LDD201 0 922 General purpose medium to heavy gauge film for heavy duty bags and shrink film and for use as a blend component S lt S XDS34 0 922 General purpose medium to heavy gauge film for heavy duty bags and shrink LDD203 0 922 film requiring antiblock and for use as a blend component LDD204 0 45 0 992 Gerieral purpose medium to heavy gauge film for heavy duty bags and shrink pap film where a medium level of slip is required General purpose medium to heavy gauge film for heavy duty bags frozen food LDD205 0 45 and produce bags where a high level of slip is required or for use as a blend al ee y component Bundle shrink and other medium gauge film applications such as produce bags LDH210 0 922 carry bags and for blending into other film grades LDH245 0 929 General purpose medium gauge film for produce bags and carry bags frozen Bley food where a high level of slip is required or for use as a blend component XJF143 0 924 Additive free general purpose iow gauge film for overwrap and other y applications and for use as a blend component LDJ226 0 929 Bundle shrink low gauge shrink film and
19. which in extreme cases can result in thickness increases of approximately 30 When the mouldings were then subjected to an accelerated service test in an active environment the effects of too much packing constituted a very serious cracking hazard Mould Filling Time On some machines the injection speed can be varied virtually independently of the injection pressure by means of a flow control valve In long thin flow paths the polyethylene will cool rapidly and this section will contain a fairly high degree of strain In addition thin walled mouldings require higher pressures to fill the mould and therefore packing may occur before the extremities of the flow path have been reached The remedy is to use a higher melt temperature and as fast an injection speed as possible On the other hand for thick sectioned mouldings it is often an advantage to reduce the speed of injection so as to avoid jetting and turbulence which will lead to mouldings with a poor surface finish Summary The moulding conditions necessary to produce good mouldings with the best appearance and the lowest amount of frozen in strain are A melt temperature just high enough to give a glossy surface to the moulding e A mould temperature of about 30 50 C e The minimum injection pressure and dwell time Qenos Technical Guides normal injection dwell time normal pressure FOI Document 18 y excessive injection dwell time excessive
20. within the required one year testing time See Figure 27 Temperature C v o Eee O as n so CE Ol RRA de NE ae a e o Sl EA E ATA O te oe ey 4 e v co 7 a Time to failure Hrs Figure 27 Creep Rupture Curve for Qenos PE 100 Grade Alkadyne HDF193B Testing was According to ISO 9080 When a PE piping system is to operate at a continuous temperature higher than designated standard temperature of 20 C ISO 9080 analysis could be used to demonstrate capability of the pipe network in terms of extrapolated values for application stress and life time Actual service life time of the PE pipe network will depend on application conditions and ISO 9080 extrapolation should not be used to infer actual service life time of the PE network TEMPERATURE RE RATING OF PE PIPES The Maximum Allowable Operating Pressure MAOP of a polyethylene PE pipe system is influenced by the temperature of the pipe wall The nominal pressure rating PN assigned to an AS NZS 4130 PE pipe equates to performance at 20 C i e a PN16 pipe is capable of withstanding a MAOP of 160 m head or 1 6 MPa or 16 bar pressure when operating continuously at 20 C However as the temperature of the pipe wall increases the MAOP of the pipe is reduced progressively in other words the pipe system is re rated with increasing temperature The guidance provided in this document is based on typical P
21. 0 5 0 1e O 1e 4 O 1e 8 lt 10 0 4e 2 0 1e 8 lt 10 0 17 20 02 O52 T01 Q15 4002 e 3 0 43e 10541 See ISO 21307 0 025 0 002 Additional cooling time out of the machine and before rough handling or installation may be recommended but in most cases is not necessary recommended for use with PE pipes SDR17 or lower i e increased wall thickness Pipes of different PE materials PE 63 PE 80 and PE 100 can also be jointed successfully using electrofusion sockets provided that all components have adequate nominal pressure rating for the operating conditions and the PE materials comply with AS NZS 4131 Some manufacturers supply electrofusion fittings for thinner pipes down to SDR33 whereas others limit the use of some saddle type fittings to SDR11 or thicker These limitations are usually detailed on the fitting body or on the packaging If in doubt check with the supplier or manufacturer as unsatisfactory joints are likely to occur if the fitting pipe combination is incorrect It is recommended to refer to the supplier or manufacturer of the electrofusion fittings for the installation instructions as the method may be specific to the fitting geometry Accurate record keeping and manual or automatic electrofusion equipment that provides good control of jointing conditions are essential 1 EF fittings can be used with non pressure drainage pipes made to AS NZS 4401 and AS NZS 5065 Qenos Technical Guid
22. 6 IS A re a A A A AAA E AE E 7 PIPE AND TUBING EXTRUSION iv Inscribe an accurate witness mark or insertion depth NOTE Automatic contro boxes are available which onto the pipe and then insert the pipe ends into the obviate the need to enter the fusion time fitting so that they are in contact with the centre stop x If the control box is equipped with a barcode reader or and witness mark Itis critical that the pipe be fully barcode scanner scan the fusion data barcode into the inserted particularly for larger pipes or when there is machine to ensure a fully automated and controlled no centre stop Ensure an aligned pipe arrangement in data entry Barcode reading control boxes automatically order to avoid any stress during the jointing process adjust for variable temperature conditions For manual especially when using coiled pipes input of the heat fusion time into the control box v The pipe end s and the fitting must be correctly refer to the manufacturer s parameters supplied with aligned and free of any bending stress Use pipe the fitting clamps or other suitable means to secure the pipe s so they cannot move and ensure that the fitting is satisfactorily supported to prevent it sagging during the fusion procedure See Figure 38 Figure 39 Attachment of Control Box Leads to Pipe Fitting xi Press the start button on the control box and check that the heating cycle is proceeding as indicated by the display x
23. Appearance of Mouldings Frozen in Strain Mould Temperature Injection Variables Injection Pressure and Dwell Time Mould Filling Time Summary Eb Ls PR RPE FP RB eR A BWR RF PR PPeReE PR BR Pp 0 AA ZOO pd N NNNPRPRR Pp GOGO Qenos Technical Guides FOI Document 18 Ys INJECTION MOULDING 5 MOULDING FAULTS 21 MOULD RELEASE AGENTS 22 DECORATING POLYETHYLENE MOULDINGS 22 Decorating Untreated Polyethylene 22 Hot Stamping r Labelling 22 Embossing Pf Decorating Treated Polyethylene 22 6 Pre treatment ae f Flame Treatment Chemical Treatment 22 Tests for Pre treatment 23 Peel Test 23 Decorating Methods for Treated Surfaces 23 Silk screening 23 Vacuum Metallising 23 Tests for Finished Coatings 23 Scratch Test 23 Scotch Tape Test 23 APPENDIX 1 FROZEN IN STRAIN 24 APPENDIX 2 INJECTION MOULDING TROUBLESHOOTING GUIDE 25 O BIBLIOGRAPHY FURTHER READING 27 Qenos Technical Guides 3 INJECTION MOULDING 5 INTRODUCTION The purpose of this document is to provide an introduction to the processing of polyethylene by injection moulding The effects of Melt Flow Index MFI and density on moulding characteristics and on the properties of the finished moulding are discussed in the light of which recommendations are made as to the desirable values of these two factors for stressed and unstressed applications Mould design is considered with speci
24. Australia which are substitutable for the goods for which a TCO is being sought and the names and addresses of the manufacturers of those goods 6 PRODUCTION OF GOODS IN AUSTRALIA Goods other than unmanufactured raw products will be taken to have been produced in Australia if a the goods are wholly or partly manufactured in Australia and b not less than 1 4 of the factory or works costs of the goods is represented by the sum of i the value of Australian labour and ii the value of Australian materials and iti the factory overhead expenses incurred in Australia in respect of the goods Goods are to be taken to have been partly manufactured in Australia if at least one substantial process in the manufacture of the goods was carried out in Australia Without limiting the meaning of the expression substantial process in the manufacture of the goods any of the following operations or any combination of those operations DOES NOT constitute such a process a operations to preserve goods during transportation or storage b operations to improve the packing or labelling or marketable quality of goods c operations to prepare goods for shipment d simple assembly operations e operations to mix goods where the resulting product does not have different properties from those of the goods that have been mixed A Are the goods wholly or partly manufactured in Australia YES L NO B Does the total value of Australian l
25. CYLINDER TEMPERATURE C Figure 13 Effect of MFl and Temperature on Gloss Qenos Technical Guides FOI Document 18 Summary It can be concluded that a high MFI is the characteristic mainly responsible for ease of moulding and high output rates The higher the MFI the lower the cylinder temperature which can be used to obtain adequate mould filling and acceptable surface finish and consequently in most cases the higher the output will be For resins with a constant MFI the degree to which an increase in density leads to higher or lower outputs will depend mainly on the size of the moulding in relation to the size of the machine For adequate melting of the granules higher density polyethylenes require higher cylinder temperatures than do the lower density polyethylenes and melting is more likely to be a limiting factor Thus as far as processing is concerned the type of polyethylene chosen should have as high an MFI as possible However the choice of both MFI and density must also take into account the physical properties required in the finished moulding and this subject is discussed in the next section EFFECT OF MFI AND DENSITY ON THE PROPERTIES OF POLYETHYLENE MOULDINGS The physical properties of polyethylene which are of particular importance in injection moulded articles are e Stiffness Impact properties Resistance to environmental stress cracking Resistance to mechanical stress cracking
26. EUA AIDA AAA PROT PLB AREER PEER ATA AEH EPA OOO AURA CAME DIREAER EAHA EAAE AAA APIO AAA A TOP ER A HS BUR ABAOT EAE EEN PR PREP RAPER EAU E DS FOI Document 14 o 7 PRODUCTION OF GOODS IN THE ORDINARY COURSE OF BUSINESS Answer 7 1 or 7 2 7 1 SUBSTITUTABLE GOODS OTHER THAN MADE TO ORDER CAPITAL EQUIPMENT Substituiable goods other than made to order capital equipment are taken to be produced in Australia in the ordinary course of business if a they have been produced in Australia in the 2 years before the application was lodged or b they have been produced and are held in stock in Australia or c they are produced in Australia on an intermittent basis and have been so produced in the 5 years before the application was lodged and a producer in Australia is prepared to accept an order to supply such goods A Have the goods been produced in Australia in the last 2 years YES C NO B Have the goods been produced and are they held in stock in Australia YES LJ NO C if the goods are intermittently produced in Australia have they been so produced YES C NO in the last 5 years D Are you prepared to accept an order for the goods YES C NO 7 2 SUBSTITUTABLE GOODS BEING MADE TO ORDER CAPITAL EQUIPMENT Made to order capital equipment means a particular item of capital equipment that is made in Australia on a one off basis to meet a specific order rather than being the subject of regular or intermittent production and
27. FAA FEA FA CAPA FIA PA PAPER AAA A AIDA FEA PI PA E IAE MEDIA ee ee 1014010410100 k45 LOCAL MANUFACTURER DETAILS Name Qenos Business Address 471 513 Kororoit Creek Road Altona VIC 3018 Postal Address if the same as business address write as above Private Mail Bag 3 Altona VIC 3018 Australian Business Number A B N Reference 62 054 196 771 Company Contact Phone Number Facsimile Number E mail Address STF arr eros cor DETAILS OF THE SUBSTITUTABLE GOODS PRODUCED IN AUSTRALIA 1 Describe the locally produced substitutable goods the subject of the objection Substitutable goods are defined in the Customs Act 1901 as goods produced in Australia that arput or are capable of being put to a use that corresponds with a use including a design use to which the goods the subject of the application oof he TCO can be put High density polyethylene HDPE injection moulding resin A omes ee 2 State the use s to which the substitutable goods are put or are capable of being put Housewares thin walled containers and closures _ ol B444 JUN 2001 FOI Document 14 Attach technical illustrative descriptive material and or a sample to enable a full and accurate identification and understanding of the substitutable goods 4 Are you aware of any other local manufacturers producing substitutable goods YES NO Ifyes to question 4 please provide details of any goods produced in Austra
28. Fan Gating Qenos Technical Guides FOI Document 18 7 For rectangular shapes the ideal gating arrangement is a fan gate see Figure 20 all along one edge so that flow takes place mainly along the major axis The moulding will still shrink to a greater extent in the direction of flow causing the major axis to be proportionately shorter than the minor axis when the moulding is cold but it will not distort To position a gate at the end of a rectangular article is relatively easy on small mouldings to be made on multi impression tools but it is not so easy on large single impression moulds Some machine manufacturers can arrange for off set injection points by altering the nozzle position from the usual central point and this is a very useful feature if large flat articles are to be made from high or low density polyethylene Choice of Polymer The likelihood of warping increases rapidly with increasing density of the polyethylene used high density polyethylene mouldings warp more than those of medium density which in turn warp more than those of low density polyethylene If flexibility in the moulding can be tolerated a polyethylene of low density e g 0 916 g cm will give the least distortion If the mouldings are not to be stressed and physical strength is not important e g sink trays and many box lids the best results are obtained from a low density polymer of high MFI 22 70 g 10 min according to the lack of str
29. OF MOULDINGS PER HOUR LIMITED BY N OF COOLING 120 150 170 230 20 860 2D CYLINDER TEMPERATURE C Figure 11 Variations of Surface Gloss of Mouldings with Cylinder Temperature Gloss is assessed both visually and by measuring the light reflected from the surface of mouldings made under standard conditions By the latter method gloss temperature curves can be plotted as shown in Figure 13 This not only shows the effect of cylinder temperature on gloss but also the very marked effect of MFI With a higher MFI high gloss mouldings can be produced at a lower cylinder temperature which allows for a faster output see Figure 13 UNITS OF GLOSS Figure 13 Effect of MFI and Temperature on Gloss 10 Qenos Technical Guides FOI Document 12 IIc Summary it can be concluded that a high MFI is the characteristic mainly responsible for ease of moulding and high output rates The higher the MFI the lower the cylinder temperature which can be used to obtain adequate mould filling and acceptable surface finish and consequently in most cases the higher the output will be For resins with a constant MFI the degree to which an increase in density leads to higher or lower outputs will depend mainly on the size of the moulding in relation to the size of the machine For adequate melting of the granules higher density polyethylenes require higher cylinder temperatures than do the lower densit
30. UD posadas EE AAA AEM a HEH T EERO MDE HEAD CaF aA RAP O RANE AFRESH a AAA SOP SHE PE PR RTE EES EO RALERE SH AARP APREUELET EST SAD ESTES SS REESE SPAS EF APH FIP LETHE REA PEE EG RHA Sea eth aS eH EA ad SE SEPR GE AOAFAAPHD ETHOS HASTE TISSR Aa ARS ee ad AAA dayana dao dada y FOI Document 8 7 PRODUCTION OF GOODS IN THE ORDINARY COURSE OF BUSINESS Answer 7 1 or 7 2 7 1 SUBSTITUTABLE GOODS OTHER THAN MADE TO ORDER CAPITAL EQUIPMENT Substitutable goods other than made to order capital equipment are taken to be produced in Australia in the ordinary course of business if aj they have been produced in Australia in the 2 years before the application was lodged or b they have been produced and are held in stock in Australia or c they are produced in Australia on an intermittent basis and have been so produced in the 5 years before the application was lodged and a producer in Australia is prepared to accept an order to supply such goods A Have the goods been produced in Australia in the last 2 years YES C NO B Have the goods been produced and are they held in stock in Australia YES NO e If the goods are intermittently produced in Australia have they been so produced YES NO in the last 5 years 1D Are you prepared to accept an order for the goods YES NO 7 2 SUBSTITUTABLE GOODS BEING MADE TO ORDER CAPITAL EQUIPMENT Made to order capital equipment means a particular item of capital equipment that is made i
31. above and use re rounding tools as appropriate vi Using an appropriate preparation tool remove the entire surface of the pipe over the full area marked If hand scrapping ensure long even scrapes starting outside the marked area to ensure craters do not occur in the fusion zone which can produce an excessive gap leading to a brittle weld Remove the swarf Metal files rasps emery paper etc are not suitable scraping tools and should not be used Qenos Technical Guides PIPE AND TUBING EXTRUSION 7 vil It is important in Australia that pipe and fittings are stored in the shade If left in the sun the pipe and fittings become very hot which may affect weld conditions particularly with thin pipe When jointing in high ambient temperature it is important that the pipe jointing area is shaded by an appropriate shelter Some fittings do not require adjustment to the heat cycle time for ambient temperatures in the range 10 C to 45 C whereas others require heat cycle time variations to compensate for ambient temperature variation within this range Jointing Procedure i Wipe the prepared surface only with the manufacturer s approved alcohol wipe to remove any dust residue and other contaminants For larger diameter pipes a multiple number of alcohol wipes shall be used NOTE Cleaning of the prepared surface is a critical step and one that has the potential to introduce contaminates if not done correctly remember this is t
32. all three welding procedures are outlined in Figure 33 and Table 10 which show e Procedures are similar in overall approach i e the seven steps of fusion Primary differences are in applied pressure and approach to cooling When properly performed all methods result in reliable joints r initial Bead Up Bead Roll Over nes 0 517 Mpa Q z o 3 i 9 i D Cooling Time 5 0 15 Mpa Heat Soak 0 025 Mpa Fid Time Fa Time to achieve j Interface Fusion Heater Plate removed Pressure Dual Pressure European Single Pressure USA Single High Pressure Figure 33 Schematic Diagram of the Various Stages of the Polymer Butt Welding Process 23 FOI Document 6 wl 7 PIPE AND TUBING EXTRUSION Table 10 Parameters Corresponding to the Three Butt Welding Processes Butt Welding Parameter Heater pipe temperature i l G Pi Bead up pressure MPa Ti Bead uptime Visual P2 Heat soak pressure MPa T2 Heat soak time Seconds Maximum bead size after T2 Mm T3 Maximum heater plate removal time Seconds T4 Maximum time to achieving welding Seconds pressure P3 Fusion jointing pressure Seconds T5 Cooling time Minutes T5a Fusion jointing time Seconds T5b Minimum cooling time in machine Minutes under reduced pressure P4 Cooling cycle reduced pressure MPa T6 Additional cooling time Minutes Electrofusion Jointing of PE Pipes and Fittings Note
33. also as a result of the moulding conditions and the design of the finished part see Conditions for Moulding Polyethylene section on pg 18 Once a polyethylene has been selected HDPE LLDPE LDPE for fabrication of the finished part internal stresses can be negated minimised through careful mould design and by controlling the processing conditions on the injection moulding machine Many mouldings however are also subjected in service to externally applied mechanica stresses which can cause cracking Examples of such mouldings are those containing metal inserts e g knobs and those used for interference applications e g snap on closures ferrules or feet for tubular furniture For such finished parts careful selection of the polymer is important Within the polyethylenes a balance is required between the MFI e g for ease of processing and the density e g which affects the level of shrinkage in order to minimise the level of internal stress Generally higher density polyethylenes wouid require a lower MFI and vice versa For example a polyethylene of MFI 20 g 10 min should generally not exceed a density of 0 918 g cm Although such rules of thumb are only 14 general recommendations other considerations of mould design and the generation of weld lines in the finished part are factors that need to be reviewed when assessing the strength of the moulding For articles not expected to be stressed in service cr
34. and Fittings Used in Construction of Gas and Water Distributions Systems ISO 21307 specifies three proven butt fusion jointing procedures for pipes and fittings with a wall thickness up to and including 70 mm taking into consideration The materials and components used The fusion jointing procedure and equipment e The quality assessment of the completed joint This standard also covers the weld procedure for activities such as surface preparation clamping alignment and cooling procedures Where ISO 21307 references other International Standards the equivalent Australian Standard is deemed to apply Where there is no equivalent Australian Standard then the International Standard applies see Table 9 Jointing Procedures Butt welding involves the heating of two pipe ends to fusion temperature and then subsequently joining the two ends by the application of force However a successful butt weld requires the correct combination and sequence of the welding parameters time temperature and pressure Various proven butt fusion methods with minor differences have been in use in different countries for many years ISO 21307 contains three distinct fusion methods described below for pipe and fittings with a wall thickness up to and including 70 mm It is essential that the parameters specified for a given method are followed Do not mix and match parameters from each method Single pressure low fusion jointing pressure Th
35. and Warping 13 FOI Document 18 5 INJECTION MOULDING Distortion of Polyethylene Mouldings Distortion or warping of polyethylene mouldings can be a problem on flat articles which do not have a solid rim or walls to keep the base firmly held in position The explanation of this warping is mainly due to polymer orientation and differential crystallisation across the moulding see Figure 19 Figure 19 Processing Conditions Causing Polymer Orientation which Leads to Warping When the mould is first filled a hot moulding will be made As the mould fills the long thread like polyethylene molecules would tend to be oriented in the direction of flow i e radially outwards but as the moulding cools a radial shrinkage will occur which is greater than the shrinkage at right angles to the radius Thus when the moulding is cold it will inevitably warp due to the difference in the stresses generated in the part All methods of preventing the distortion of flat articles without rims or walls depend in essence on reducing this difference Mould Design To reduce the warping in articles multiple pin gates must be used This system relies on reducing the length of each radial flow path and inter mingling the melt streams and is often adequate for low and medium density polyethylenes see Figure 20 16 Fan Gate Sprue Fan Gate Product Figure 20 Photos Illustrating Multiple Pin Gating and
36. and or moisture which can result in unsatisfactory joints Fittings should only be removed from their original packaging immediately before using for jointing Preparation i Ensure hands and tools are free from surface contaminants such as barrier hand cream sun screen detergent and surfactant used in horizontal directional drilling ii Expose the pipe onto which the tapping tee or saddle is to be assembled ensuring there is clear space around the pipe In a trench a minimum clearance of 150 mm is required all round Larger clearances may be needed for larger nominal sizes depending on the tool used ili Wipe the joint area where the saddle is to be fitted with alcohol wipes to remove traces of dirt mud and other contamination The joint area may be washed with clean water if necessary and dried with lint free material prior to scraping Ensure the joint surface is completely dry before proceeding Do not use detergent or surfactants to clean pipe surfaces NOTE Refer to fitting supplier for recommended alcohol wipes Personal cleaning wipes may contain lanolin and detergent and are not suitable for use in electrofusion iv Without removing the fitting from its packaging place it over the required position on the pipe Mark the pipe surface outlining the saddle base area plus about 20 mm with a suitable marker pen to allow for visual checking of the scraped area after jointing is complete v Check ovality as described
37. and shrink film where a medium level of slip is required General purpose medium to heavy gauge film for heavy duty bags frozen food LDD205 0 922 and produce bags where a high level of slip is required or for use as a blend component LDH240 0 0 929 Bundle shrink and other medium gauge film applications such as produce bags Pa Peale carry bags and for blending into other film grades LDH215 10 0 929 General purpose medium gauge film for produce bags and carry bags frozen v H el food where a high level of slip is required or for use as a blend component Additive free general purpose low gauge film for overwrap and other 2 applications and for use as a blend component Bundle shrink low gauge shrink film and general purpose applications where a LDJ226 E i aye i medium level of slip and antistatic are required LD0220MS 25 l Hig h quality low gauge film for lamination and overwrap applications where a medium level of slip is required High quality low gauge film primarily intended for bread bags and overwrap but LDJ225 25 hg E S also general purpose applications where a very high level of slip is required High quality very thin gauge and high clarity film primarily intended for food and XLF197 5 5 i i packaging wrap and for drycleaning film Additive free Notes Based on antistat additive VH Very High Slip H High Slip M Medium Slip S XJF143 0 921
38. are its Melt Flow Index MFI and density Moulding Machine Melt Flow index MFI MFI is a measure of melt viscosity at low Shear rates and is defined as the weight in grams of polyethylene extruded in 10 minutes from a Special plastometer under a given load at 190 C Thus a low MFI corresponds to a high melt viscosity Figure 3 shows how the MFI is related to the number average molecular weight of the polymer avergae motecular weight Figure 2 Finished Moulded Part including Sprue Injection Point MELT VISCOSITY Poisesr NUMBER AVERAGE MOLECULAR WEIGHT Injection Moulding is fundamentally simple easy to operate MELT FLOW INDEX and is capable of producing a very wide variety of industrial a y PR and domestic articles Of all thermoplastics polyethylene is one of the easiest to injection mould The resin flows easily into difficult cavities its viscosity changes smoothly as the melt temperature increases and it can be processed over a wide temperature range without decomposition Figure 3 Relation between MFI 8 10 min and Number Average Molecular Weight 6 Qenos Technical Guides FOI Document 18 y DENSITY Density is related to the crystallinity of the polyethylene and is measured in g cm Because polyethylene molecules are long and contain branches complete crystallisation cannot take place when polyethylene is cooled from the molten state
39. are mouldings of lower density The higher density materials however require higher cylinder temperatures to produce adequate melting of the granules particularly if the amount of material being handled is near the plasticising capacity of the machine and the use of such temperatures may slow down the output rate a pL 7 rr CONSTANT MELT FLOW INDEX iw 93 05 095 09 8 OUTPUT RATE E number of mouldings per hour g 3 8 e 0 0 DENSITY G C C Figure 7 Effect of Density on Output Rate for Polymers of the Same MFI To use injection moulding machines most efficiently the cylinder temperature should be chosen so that the output is at its peak There are however two factors which frequently prevent this being done namely the necessity to fill the mould and the desire to obtain mouldings with a good surface finish These factors are discussed below MOULD FILLING In practice there are some moulds for which it is not possible to draw an output curve over the whole range of cylinder temperatures because the mould cannot be filled at the lower temperatures Therefore the moulding temperature which has to be used is the lowest temperature at which the mould can be filled and this may restrict the output In order to attain as close to the maximum theoretical output good mould filling properties are obviously desirable in a polyethylene The spiral flow test was devised to as
40. at a Glance 6th Edition pdf Book 5 injection Moulding pdf Categories objections Dear National Manager Tariff Branch Please find attached Qenos objection to Gazette no TC 14 33 TC 1425825 and supporting material Qenos Pty Ltd as a E A qenos com W www genos com Oenos 1 UNCLASSIFIED FOI Document 8 WA 1 e If this form was completed by a business with fewer than 20 employees o please provide an estimate of the time taken to complete this form TIME Hours Minutes SUBMISSION OBJECTING TO THE MAKING OF A TARIFF CONCESSION ORDER TCO THIS FORM MUST BE COMPLETED BY A LOCAL MANUFACTURER WHO WISHES TO OBJECT TO THE GRANTING OF A TCO THE INFORMATION PROVIDED ON THIS PAGE WILL BE FORWARDED TO THEAPPLICANT FOR THE TCO THE FORM SHOULD BE READ CAREFULLY BEFORE BEING COMPLETED DETAILS OF THE TCO APPLICATION TO WHICH THIS SUBMISSION REFERS GAZETTE NO TC 14 33 DATE 27 August 2014 Gazetted description of goods TC Reference Number RESINS unpigmented polypropylene heterophasic copolymer PES PFU PUMPS PREP ER EE PN PE PSE PE LAA PRE ee ee ee hes proplyene based with comonomer ethylene in pelletised form TRAGA FAP DA PRA A IDA A IIA AAA A ST ENE IN ALLE BS Geen PSP Pe he ae dd ee oe ee i i a AAA AL LAR NATA ee ee AA ee ee PP ee ee eee eae eee Ee PSE DEE ad ER RG eee e er AI BP Pd Pe eee rr A ee ia Bd Pe id AU A AAA AA IA A A he ee PPP PPP ee es ee ee ee eee ee ee Senne
41. at each temperature under operational pressures it is calculated with the equation Table 5 nominates the corresponding MAOP for a given temperature for PE 80B material Table 6 provides the same information for PE 100 material Table 5 Maximum Allowable Operating Pressure PE 80 Min Life Design yr Factor PN 4 PN10 PN12 5 A 100 1 0 32 40 64 80 102 128 160 200 25 1 0 32 40 64 80 102 128 160 200 30 1 2 7 33 53 67 85 107 133 167 35 1 3 25 31 49 62 78 98 123 154 40 13 25 31 49 62 78 99 123 154 45 1 4 28 29 46 57 73 91 114 143 50 36 1 6 20 25 40 50 63 80 100 125 55 24 1 7 19 24 38 47 60 75 94 118 60 12 1 8 18 22 36 44 56 71 89 111 80 1 2 4 13 17 37 33 42 53 67 83 Table 6 Maximum Allowable Operating Pressure PE 100 Min Life Design yr Factor PN 6 3 SDR41 SDR26 SDR21 SDR17 SDR13 6 SDR11 SDR9 SDR7 4 20 100 1 0 40 64 80 100 127 160 200 250 25 100 1 4 36 58 73 91 115 145 182 297 30 100 1 1 36 58 73 91 115 145 182 227 35 50 12 33 53 67 83 106 133 167 208 40 50 19 33 53 67 83 106 133 167 208 45 35 1 3 31 49 62 77 99 123 154 192 50 22 1 4 29 46 57 71 91 114 143 179 55 15 1 4 29 46 57 71 91 114 143 179 60 7 1 5 27 43 53 67 85 107 133 167 80 1 2 0 20 32 40 50 63 80 100 125 Note the minimum life periods may be considered to be the minimum potential service lives and represent the maximum extrapolated periods permitted by the ISO 9080 extrapolation rules given the available test data Qenos Technical Guides 19 FOI D
42. cause of the break e g inadequate fuel in the generator or power supply failure etc NOTE Do not attempt a second fusion cycle until the entire fitting has cooled to less than 45 C Some manufacturers recommend replacement of the fitting rather than a second fusion cycle Refer to the fitting manufacturer for details xiv The completed joint should be left in the clamps for cooling The time needed will be specified on the fitting or by its data carrier or in the display of the automatic control box xiv When the joint has cooled remove it from the clamps and inspect Electrofusion Indicator Pins The fusion indicator protrusion following the completion of the fusion process indicates that fusion pressure has developed but does not guarantee the quality of the joint The height of the extended pin is dependent upon the fitting in use component tolerances and the pipe material The pins are used as a pointer to whether a more detailed inspection of the joint is required so in the event that the pin does not rise the supervisor or operator must investigate the following to determine if the joint is satisfactory Dimensional check and compliance of the pipe spigot OD and ovality e The fitting socket internal diameter by measurement or batch traceability e In the case where the pipe and socket are concentric the maximum gap between the two should not exceed 1 of the nominal diameter If the socket and spigot are
43. cylinder temperature should be raised until mouldings with a uniform glossy finish are obtained If the surface finish is acceptable but mouldings are tending to stick in the mould the melt temperature is probably too high and the cylinder temperature should be reduced until the trouble is eliminated These procedures are effective for all grades of Alkathene LDPE but it should be remembered that with materials of MFI below 0 5 g 10 min the cycle time may have to be rather long to allow the melt to reach the required temperature Frozen in Strain Melt viscosity and hence melt temperature is the most important factor determining frozen in strain As highlighted in Appendix 1 the presence of frozen in strain is associated with orientation of the polyethylene molecules as they are injected into the mould cavity At high temperatures the viscosity of the polyethylene is low and the mould is filled rapidly only the layer of material immediately adjacent to the mould surface has frozen before the mould is filled so that during cooling the maximum relaxation of orientation can take place Qenos Technical Guides INJECTION MOULDING 5 At low moulding temperatures the melt viscosity is higher the mould fills relatively slowly and the polyethylene freezes quickly so that relatively little relaxation of the polymer orientation can occur It has been shown quite conclusively not only by laboratory tests but also by extensive s
44. density polyethylenes poorer processability poorer mould filling and in general higher processing temperatures will be required It can also be seen that with polyethylenes of lower density a much wider choice of MFI is possible without sacrificing toughness The dependence of brittle failure on density is also complicated by the fact that the density of any polyethylene is affected by its rate of cooling from the molten state This effect is illustrated opposite in Table 1 Values for densities quoted in the literature usually refer to specimens prepared in a standard way involving slow cooling In injection moulding however the polyethylene is cooled rapidly and the molecular chains have no time in which to pack into their equilibrium positions and consequently the density is reduced to below the equilibrium value Subsequently over time the density increases towards its equilibrium value a process which is very slow but which is accelerated at elevated temperatures Provided that a polyethylene is chosen with a density and MFI such that the polyethylene when cooled at the slowest rate found in injection moulding lies in the tough region in Figure 16 no detrimental change to the mouldings impact strength will arise But if a polyethylene in the brittle region is chosen for example a material with a MFI of 20 g 10 min and a density greater than 0 927 g cm mouldings produced under conditions of rapid cooling wil
45. each at 90 to the pipe circumference and with a defined geometry Vee angle 60 notch depth 20 of wall thickness See Figures 28 and 29 for details Slow Crack Growth Notched Pipe test A Four notches equi spaced around the pipe circumference The ligament thickness is 0 78 to 0 82 gf times minimum specified wall 77 Position of minimum C wall thickness Section AA se Pipe end caps Figure 28 lllustration of Notched Pipe Test 20 This pipe is then pressure creep tested under the following conditions e PE 100 80 C 4 6 MPa Hoop Stress endurance time gt 500 hrs e The PE 100 materials pass this test without any problem Figure 29 Pipes Notched and Assembled to be Tested for Slow Crack Growth Property as per ISO 13479 Pipes made from Qenos Pipe Grade Alkadyne HDF193B RESISTANCE TO RAPID CRACK PROPAGATION RCP OF PE PIPES By rapid crack propagation we mean the following phenomenon if a gas pipe during operation is damaged by an external force e g by construction machinery or by a stress induced crack e g in a defective weld then under the action of internal pressure and hence of the potential energy stored in the gas the crack can spread over an extended length at almost the speed of sound see Figure 30 in the case of PE 100 the range of applications is widened to include higher operating pressures therefore pipe designers must be giv
46. eee ee ee ee ee eed ee ee ee bee de ed a ee ae ee eel GEE DEPP PR PP a a LOCAL MANUFACTURER DETAILS Name Qenos Business Address 471 513 Kororoit Creek Road Altona VIC 3018 Postal Address if the same as business address write as above Private Mail Bag 3 Altona VIC 3018 Australian Business Number A B N 62 054 196 771 Company Contact Phone Number Facsimije Number E mail Address S47F S47F A O genos com DETAILS OF THE SUBSTITUTABLE GOODS PRODUCED IN AUSTRALIA 1 Describe the locally produced substitutable goods the subject of the objection Substitutable goods are defined in the Customs Act 1901 as goods produced in Australia that are pul or are capable of being put to a use that corresponds with a use including a design use to which the goods the subject of the application or of the TCO can be put High density polyethylene HDPE injection Moulding resin nres Reference 2 State the use s to which the substitutable goods are put or are capable of being put Housewares thin walled containers and closures B444 JUN 2001 FOI Document 8 Lo Attach technical illustrative descriptive material and or a sample to enable a full and accurate identification and understanding of the substitutable goods 4 Are you aware of any other focal manufacturers producing substitutable goods YES NO If yes to question 4 please provide details of any goods produced in
47. for use as a blend component General purpose medium to heavy gauge film for heavy duty bags and shrink LDD203 film requiring antiblock and for use as a blend component General purpose medium to heavy gauge film for heavy duty bags and shrink film where a medium level of slip is required LDD204 General purpose medium to heavy gauge film for heavy duty bags frozen food and produce bags where a high level of slip is required or for use as a blend component Bundle shrink and other medium gauge film applications such as produce bags LDH210 carry bags and for blending into other film grades General purpose medium gauge film for produce bags and carry bags frozen food where a high level of slip is required or for use as a blend component Additive free general purpose low gauge film for overwrap and other applications and for use as a blend component Bundle shrink low gauge shrink film and general purpose applications where a LDJ226 medium level of slip and antistatic are required High quality low gauge film for lamination and overwrap applications where a LD0220MS medium level of slip is required High quality low gauge film primarily intended for bread bags and overwrap but also general purpose applications where a very high level of slip is required High quality very thin gauge and high clarity film primarily intended for food and packaging wrap and for drycleaning film Additive free Notes Based on
48. if large flat articles are to be made from high or low density polyethylene Choice of Polymer The likelinood of warping increases rapidly with increasing density of the polyethylene used high density polyethylene mouldings warp more than those of medium density which in turn warp more than those of low density polyethylene If flexibility in the moulding can be tolerated a polyethylene of low density e g 0 916 g cm will give the least distortion If the mouldings are not to be stressed and physical strength is not important e g sink trays and many box lids the best results are obtained from a low density polymer of high MFI 22 70 g 10 min according to the lack of strength which can be tolerated Moulding Conditions Obviously the ideal moulding conditions would be those which give no orientation in the moulding and thus no warping In practice such conditions can never be achieved It has been found that long injection dwell times and high pressures because they reduce the overall level of shrinkage can often reduce warpage but these conditions give rise to packing stresses and may cause the mouldings to split across the sprue The best compromise in moulding conditions has been found to consist of a very high melt temperature i e 50 C higher than that normally used for a given polyethylene and a very cold mould i e as cold as can be achieved INJECTION MOULDING 5 Weld Lines Weld lines can occur in any pl
49. it breaks rather than fail in a glass like manner On the other hand medium and high density polyethylenes can fail in a way that is unknown in low density polyethylenes This type of failure is known as brittle failure It is quite different from the tough failure of low density materials and is particularly noticeable in mouldings which have sharp notches or scratches on the surface The usual impact tests for plastic materials are difficult to apply to both brittle and tough types of polyethylene and therefore a special test had to be devised For this an impact machine is used See Figure 15 in which small specimens 1 x 1 x 0 16 cm are notched to a depth of 0 020 cm and subjected to a blow from a pendulum The energy lost by the pendulum in striking the specimens is termed the impact energy although much of this energy is expended in bending the specimen as the pendulum swings past it Polyethylene specimens are rarely broken by the first blow and therefore after a short rest period they are given a second blow The energy absorbed by this second blow expressed as a percentage of the energy absorbed by the first blow is termed the fracture resistance This quantity is found to be a useful measure of the amount of damage caused by the first blow Qenos Technical Guides 14 FOI Document 12 INT AAA A A A ee ee A 5 INJECTION MOULDING Impact energy and fracture resistance depend on both MFI and density as
50. measure of the degree of orientation can be obtained by cutting specimens from a moulding and measuring the percentage retraction which takes place in the direction of flow when the specimens are heated A large retraction indicates a high level of frozen in strain 24 if a highly strained surface comes into contact with an active environment such as synthetic detergents or fat a small crack may develop which is likely to propagate rapidly especially at elevated temperatures Depending on the particular type of polyethylene either cracks may develop throughout the whole section or failure may be restricted to surface peeling Figure 25 A Section from a Polyethylene Moulding Showing the Layered Structure Qenos Technical Guides an q FOI Document 12 D7 er A AA INJECTION MOULDING 5 APPENDIX 2 INJECTION MOULDING TROUBLESHOOTING GUIDE Problem Issue Cause s Brittle mouldings Sharp corners notches PE grade has insufficient impact strength Excessive orientation Inadequate thickness Potential Solution s Action s Increase radii Use lower flow and or lower density grade of PE Increase melt temperature Increase thickness of moulding Burn marks Insufficient venting Carbonised no niata at end Injection speed too high of flow path Melt temperature too high Increase venting Reduce injection speed Reduce barrel and nozzle temperature settings Delamination In
51. of negligence directly or indirectly suffered or incurred as a result of or related to anyone using or relying on any of the information except to the extent Qenos is unable to exclude such liability under any relevant legislation Freedom from patent rights must not be assumed Qenos Technical Guides FOI Document 12 Z 5 INJECTION MOULDING INTRODUCTION Injection moulding is one of the most widely used processes for converting thermoplastic raw materials into finished products Fundamentally a solid polymer is plasticated into a molten mass via thermal and frictional heating and once a suitable volume of melt has been produced the polymer is injected into the mould to form the finished part see Figures 1 and 2 Pins Plastic Figure 1 Schematic Representation of an Injection Moulding Machine Ejector Cavity Nozzle Cylinder However this very ease of processing often leads to the use of moulding conditions which are not the most suitable for producing the finished part Also because almost all of the many different types of polyethylene can be moulded on standard equipment the polyethylene type that is most suitable for a particular application is not always chosen EFFECT OF TYPE OF POLYETHYLENE ON PROCESSING AND PROPERTIES OF MOULDINGS To obtain polyethylene mouldings which will withstand Plastic long and arduous service two important questions must Granules be answered A a Which type of
52. of Different MFI as defined by fracture resistance contours at 40 and to Environment Stress Cracking 20 with MFI and Density ee A A A a r FA TAL A AA In practice it is important that high MFI polymers even Environmental Stress Cracking of low density should not be used for applications in which they will be severely stressed when in contact with active environments For such applications a polyethylene of low MFI is essential and the higher the density of the polyethylene the lower the MFI must be Environmental stress cracking is the name given to a phenomenon by which polyethylene under high stresses may crack in contact with certain active environments such as detergents fats and silicone fluids Atypical application for which a polyethylene of low MFI is preferred in order to reduce the hazards of environmental stress cracking is that of closures used in contact with liquid detergents soap solutions and certain cosmetics The resistance of polyethylene to environmental stress cracking decreases rapidly as the MFI is increased Figure 17 indicates how test specimens of polyethylenes of different MFl and of constant density behave when subjected to a severe stress in the presence of an active It is important however not to exaggerate the seriousness environment Comparison of polyethylenes of constant of environmental stress cracking It has been found that MFI but of different densities is more complicated because the majori
53. of processing conditions on the structure and surface microhardness of injection moulded polyethylene Issued January 2014 Qenos Technical Guides IF FOI Document 18 A Biest Company Qenos Pty Ltd ABN 62 054 196 771 Cnr Kororoit Creek Road amp Maidstone Street Altona Victoria 3018 Australia T 1800063 5 3 F 1800683581 qenos com trace
54. of processing often leads to the use of moulding conditions which are not the most suitable for producing the finished part Also because almost all of the many different types of polyethylene can be moulded on standard equipment the polyethylene type that is most suitable for a particular application is not always chosen Injection moulding is one of the most widely used processes for converting thermoplastic raw materials into finished products Fundamentally a solid polymer is plasticated into a molten mass via thermal and frictional heating and once a suitable volume of melt has been produced the polymer is injected into the mould to form the finished part see Figures 1 and 2 EFFECT OF TYPE OF POLYETHYLENE ON PROCESSING AND PROPERTIES OF MOULDINGS To obtain polyethylene mouldings which will withstand Cavity Plastic long and arduous service two important questions must 3 _ Granules be answered B Nozzle Cylinder dl e a Which type of polyethylene should be used b What are the correct moulding conditions To do this it is necessary to know how the different types of polyethylene used for injection moulding differ from each other first in the way in which they are processed and Mould second in the physical properties of the moulded article Plastic Classification of Polyethylenes ma The most important variables which characterise a PU es ponte Representation of an Injection polyethylene
55. pressure note thickening a before test b After accelerated cracking test Effect of Injection Pressure and Dwell Time on Poly ath ne Mouldings cuy ene WIOULQINES Faults in polyethylene mouldings may be divided into two classes those that are obvious from visual inspection and those arising from the presence of frozen in strain these can be detected only by testing Appendix 2 lists the obvious faults that can occur with their possible causes and remedies Faults arising from frozen in strain have already been dealt with earlier In using Appendix 2 it should be noted that because the machine variables are interdependent a remedy that involves the adjustment of any one machine variable may Qenos Technical Guides also necessitate adjustment of the others Alteration of the melt temperature should be gradual insteps of 10 C and a full cylinder of material should be injected before the results of any 10 C step are assessed Alteration of the cycle time which affects the length of time the materia is in the cylinder and hence the melt temperature should also be carried out gradually Enough time should be allowed between successive adjustments to ensure that steady conditions at any one setting are obtained before the effect of that setting on the quality of the mouldings is determined 2a FOI Document 18 Je 5 INJECTION MOULDING MOULD RELEASE AGENTS If
56. range 30 50 C have been found to offer the best compromise between the effects of frozen in strain and notch sensitivity Figure 23 shows the variation of retraction with mould temperature for a constant cylinder temperature 19 FOI Document 12 Ja 5 INJECTION MOULDING RETRACTION MOULD TEMPERATURE C Figure 23 Variation of Retraction with Mould Temperature Cylinder Temperature is Constant Because of the importance of correct mould temperature and the growing tendency to reduce cycle times it is essential as already remarked that in the initial designing of the mould provisions should be made for efficient cooling unfortunately this is a feature which is all too often overlooked with consequent difficulties in subsequent operation Injection Variables The injection variables will be considered under two headings injection pressure and dwell time and mould filling time Injection Pressure and Dwell Time To produce good mouldings both quickly and economically the injection pressure should be kept to a minimum and the dwell time made as short as possible Increasing the packing of an additional volume of polyethylene into the mould during the dwell time to compensate for the shrinkage of the polyethylene due to crystallisation is also important The degree of packing should be kept to a minimum because the excess polyethylene is forced into the mould cavity when the melt ha
57. should establish and maintain appropriate procedures for handling and storage of pipe fittings and fusion jointing equipment on site NOTE Damaged packaging can permit ingress of dirt and moisture which can adversely affect joint integrity 6 Control of Records The installer should establish and maintain procedures for collection indexing filing and storage of quality records for a minimum period of 6 years from the date of installation Qenos Technical Guides FOI Document 6 7 Competence Awareness and Training The installer should e Determine the necessary competence for personnel performing fusion jointing Provide training or take other actions to satisfy these guidelines e Evaluate the effectiveness of the actions taken e Ensure that personnel are aware of the relevance and importance of their activities and how they contribute to the achievement of effective fusion jointing and e Maintain appropriate records of education training skills and experience Qenos Technical Guides PIPE AND TUBING EXTRUSION 7 39 FOI eal e Y PIPE AND TUBING EXTRUSION APPENDIX 1 RECORD SHEETS Record sheets should be maintained for all equipment required for all fusion jointing operations The sheet should be headed SERVICING AND CALIBRATION RECORD SHEET Followed by ELECTROFUSION SOCKET EQUIPMENT OR ELECTROFUSION SADDLE EQUIPMENT Then the appropriate sub title from
58. stored inthe shade If left in the sun pipe and fittings become very hot which may affect weld conditions particularly with thin pipe When jointing in high ambient temperature it is important that the pipe jointing area is shaded by an appropriate shelter Some fittings do not require adjustment to the heat cycle time for ambient temperatures in the range 10 C to 45 C whereas others require heat cycle time variation to compensate for ambient temperature within this range ENSURE THE PREPARED SURFACES ARE COMPLETELY DRY BEFORE PROCEEDING DO NOT TOUCH THE PREPARED PIPE SURFACE Clean Wipe Figure 37 Illustration of Pipe End Preparation Prior to Welding Qenos Technical Guides gt PIPE AND TUBING EXTRUSION 7 Jointing Procedure Wipe the prepared pipe surface only with a recommended alcohol wipe to remove any dust residue and other contaminants For larger diameter pipes use a multiple number of alcohol wipes NOTE Cleaning of the prepared surface is a critical step and one that has the potential to introduce contaminates if not done correctly remember this is the surface that is about to be welded and the presence of contaminates can readily result in a poorly welded joint To avoid contamination ONLY wipe the peeled fusion zone area Do not under any circumstances use methylated spirits acetone methyl ethyl ketone MEK or other solvents to clean the fusion area Rags are not recomme
59. strain is the hazard to be avoided and a polyethylene of higher MFI is preferred Provided that these few simple principles are followed articles giving a long and satisfactory service life can be moulded from polyethylene without difficulty SOME ASPECTS OF DESIGNING MOULDS FOR POLYETHYLENE A detailed examination of mould design is outside the scope of this booklet There are however three problems affecting mould design which although not peculiar to low density polyethylene occur frequently with this material and which can conveniently be discussed here These are e Shrinkage e Distortion e Weld lines Shrinkage of Polyethylene Mouldings The influence of moulding conditions and the shape of mouldings is so great that it is almost impossible to predict the exact shrinkage of polyethylene mouldings it is recommended therefore that trials under controlled moulding conditions should be carried out before the mould is hardened and polished The mould may then be adjusted accordingly To allow for any after shrinkage the dimensions of mouldings should not be checked until at least 24 hours after removingthe mouldings from the mould 14 Qenos Technical Guides FOI Document 12 It Measurements must be checked in all important dimensions because mould shrinkage varies with the direction of flow and checking only one dimension and applying proportional corrections to the others may lead to major inacc
60. suppliers may consider smaller capacity generators acceptable for small diameter fittings The nominal output of the generator should be 240V 15 15 between no load and full load It should be noted that electrofusion control boxes may generate considerable heat Refer to the supplier of the controller for details Control boxes should include safety devices to prevent voltages greater than 42V AC for a 40V system being present at the control box output The safety device should operate in less than 0 5 sec ii Pipe surface preparation tool Scraper or peeler has to be capable of removing the oxidised surface of the pipe over the full area of the saddle base The tool should remove a surface layer of between 0 2 mm and 0 4 mm Hand scrapers can be difficult to use in trench conditions and effective preparation by hand may be time consuming and physically demanding Therefore rotational scrapers or peeling tools are preferred Re rounding clamps or other approved methods of re rounding pipes should be used particularly if pipe out of roundness exceeds 1 5 Qenos Technical Guides FOI Document 6 YA iv A pipe clamp of suitable dimensions for making the service or branch connection is needed v Pipe cutters should include a saw and saw guide vi Suitable shelter should be used to provide adequate protection for pipe fittings and equipment against adverse weather conditions and contamination of the jointing surfaces by dust
61. than the shrinkage at right angles to the radius Thus when the moulding is cold it will inevitably warp due to the difference in the stresses generated in the part All methods of preventing the distortion of flat articles without rims or walls depend in essence on reducing this difference Sprue Mould Design To reduce the warping in articles multiple pin gates must Parting Line Fan Gate be used This system relies on reducing the length of each radial flow path and inter mingling the melt streams and is often adequate for low and medium density polyethylenes see Figure 20 Product Figure 20 Photos Illustrating Multiple Pin Gating and Fan Gating 16 Qenos Technical Guides FOI Document 12 lo For rectangular shapes the deal gating arrangement is a fan gate see Figure 20 all along one edge so that flow takes place mainly along the major axis The moulding will still shrink to a greater extent in the direction of flow causing the major axis to be proportionately shorter than the minor axis when the moulding is cold but it will not distort To position a gate at the end of a rectangular article is relatively easy on smal mouldings to be made on multi impression tools but it is not so easy on large single impression moulds Some machine manufacturers can arrange for off set injection points by altering the nozzle position from the usual central point and this is a very useful feature
62. that is not produced in quantities indicative of a production run Capital equioment means goods which if imported would be goods to which Chapters 84 85 86 87 89 or 90 of Schedule 3 to the Customs Tariff Act 1995 would apply Goods that are made to order capital equipment are taken to be produced in Australia in the ordinary course of business if a a producer in Australia i has made goods requiring the same labour skills technology and design expertise as the substitutable goods in the 2 years before the application and ii could produce the goods with existing facilities and b the producer in Australia is prepared to accept an order to supply the substitutable goods E Have goods requiring the same labour skills technology and design expertise as the goods the subject of the application been made in Australia in the last 2 years CJ YES NO If yes describe the goods made during this period SSCS CAS PoE AEE AA AI AAA AAA PUSH UEF HFS OA EASE EASESR ERS AR CRERSEESTATESE SAS THAME EOF OADEPAAAPESSPERES Ra Ga EEEF RSS PEEL EP ERS H EEF ER EL EHE EPSPS rra rosa rara nou rr dr rr AAA aa dara rra EE ESS APACE TER AF NEHER ERE FOR SE EAE EF ERPS EEA ETE SOUT Usas Ar ardor SD EET AAGEAASEAOTRATR ED PHA TASE EP OOEEE PEP EAP ASE AES EAASEREAEAESATASEPASEPASR SFOS PSHE EP SAP SDE PRP PREP ESEFEE AA ASSET TEED rr AAA AEDS CERT CEE rro SORE PARAR PALA ASHE PEF APTA SE EP SEE PHASE ASS AU FESO STOTT AAA SESE E SST ET TESTED SSSR TEST FES TE C
63. the correct moulding conditions have been chosen polyethylene mouldings are unlikely to stick in the mould If they do and the fault cannot be corrected by adjusting the moulding conditions mould lubricants such as stearates or fatty amides may be used Silicone oils and greases may cause environmental stress cracking in polyethylene mouldings and therefore before they are used as mould release agents they should be tested with the moulding to see if they are suitable If any doubt exists as to their suitability they should not be used DECORATING POLYETHYLENE MOULDINGS There are several ways in which polyethylene mouldings can be decorated These fall into two classes those applied directly to the polyethylene surface and those which require some form of pre treatment of the surface The following sections briefly deal with the various methods of pre treatment decoration and also with tests for the effectiveness of these processes Decorating Untreated Polyethylene The following methods are commonly used Hot stamping Labelling Embossing Hot Stamping Basically this method consists of pressing on to the polyethylene a tape which is coated with pigment Heat and pressure are applied via a male die and the pigment is released from the tape and fused into the polyethylene Stamping should preferably be carried out while the moulding is still warm after being ejected from the die Because it is recessed the coating obtaine
64. used A typical curve for a plunger machine is shown in Figure 6 It will be noticed that at first as the temperature increases the output also increases The reason for this is that at low temperatures a long cycle is necessary to melt the granules thoroughly but as the temperature increases the melting time becomes shorter and therefore the cycle is also shortened A point is soon reached however when the time taken to melt the granules is no longer the limiting factor The greater parameter of importance is then the time taken for the mouldings to cool to a temperature at which they can be extracted easily from the mould Beyond this point as the melt temperature increases the cycle time has to be extended and the output consequently falls Qenos Technical Guides FOI Document 12 7 5 INJECTION MOULDING T ali TT Se POF COO it a A OUTPUT RATE Number of mouldings pre hour ae fak pw Laid CYLINDER TEMPERATURE C Figure 6 Variation in Output Rate of Mouldings with Cylinder Temperature Figure 7 shows the effect of density on output rate for polyethylenes of the same MFI It indicates that the higher the density the higher the output rate on the cooling side of the curve at any given cylinder temperature The reason for this is that mouldings of higher density can be extracted from the mould at higher temperatures because they are more rigid at these temperatures than
65. 05 unless otherwise annotated FOI Document 5 aa Alkamax mLLDPE Film Grades Additives Applications Heavy duty bags industrial and agricultural films and form fill and seal applications and ice bags where 1 0 0 918 outstanding toughness sealing and hot tack properties are desirable or for downgauging of existing film structures ML1810PN Heavy duty bags industrial and form fill and seal applications and ice bags where outstanding toughness sealing hot tack properties and high slip are desirable or for downgauging of existing film structures ML1810PS Heavy duty bags lamination industrial and form fill and seal applications where outstanding stiffness toughness optical and sealing properties are desirable or for downgauging of existing film structures ML2610PN Stretch cling films with addition of appropriate cling additive and other film applications where outstanding toughness optical and sealing properties are desirable or for downgauging of existing film structures ML1710SC 1 0 0 917 Notes VH Very High Slip H High Slip M Medium Slip Alkatane HDPE Film Grades Applicalicns Melt Index P r Grade 9 10 min Dens iy Applications 190 C 2 16kg igicm Purpose aoned Barner Filt Carry bags and liners where high impact toughness and stiffness are desirable and as a
66. 20 g 10 min the suggested starting temperature is 260 C When the cylinder temperature has been set the injection pressure and cycle time should be adjusted to the minimum values consistent with the production of full mouldings and moulding should then be carried out for long enough usually 15 30 minutes to enable conditions to settle down The mouldings should then be inspected and tested Testing should be conducted after conditioning for 24 hours preferably in a constant temperature environment Appearance of Mouldings lf the surface of the mouldings is dull or patchy or contains matt rings or chevron marks See Figure 12 this is an indication that the melt temperature is too low and the cylinder temperature should be raised until mouldings with a uniform glossy finish are obtained If the surface finish is acceptable but mouldings are tending to stick in the mould the melt temperature is probably too high and the cylinder temperature should be reduced until the trouble is eliminated These procedures are effective for all grades of Alkathene LDPE but it should be remembered that with materials of MFI below 0 5 g 10 min the cycle time may have to be rather long to allow the melt to reach the required temperature Frozen in Strain Melt viscosity and hence melt temperature is the most important factor determining frozen in strain As highlighted in Appendix 1 the presence of frozen in strain is assoc
67. 269F 4 of the Customs Act Position Held S47F S47F a s47F Date j Bl September 2014 NOTE SECTION 234 OF THE CUSTOMS ACT 1901 PROVIDES THAT IT IS AN OFFENCE TO MAKE A STATEMENT TO AN OFFICER THAT IS FALSE OR MISLEADING IN A MATERIAL PARTICULAR WHEN THIS FORM HAS BEEN COMPLETED LODGE IT WITH CUSTOMS BY posting it by prepaid post to the National Manager TariffBranch Australian Customs Service Customs House 5 Constitution Avenue CANBERRA ACT 2601 or e delivering it to the ACT Regional Office located at Customs House Canberra or sending it by facsimile to 02 6275 6376 or e mailing it to tarcon customs gov au E Polyethylene ata Glance Alkadyne PE100 Pipe Extrusion Grades High Density black PE100 type resin certified to AS NZS 4131 for use in pressure pipes and fittings Excellent low sag properties and throughput suitable for the majority of PE100 pipe dimensions High Density black PE100 type resin certified to AS NZS 4131 for use In pressure pipes and fittings Exceptional HDF145B 961 f Me l low sag properties and throughput suitable for the most challenging pipe dimensions HDF193N 03 0 95011 High Density natural resin for extrusion into a full range of non standard pipe products and as a base for PE100 type striping arid jacket compounds Notes ASTM D1505 D2839 HDFAS3E 0 961 Alkadyne PE Pipe Extrusion Grades MOOB04 i 0 952 Medium Density black P
68. C Density Applications 2 16kg giem GF7740F2 0 950 Extrusion applications including stretched tape monofilament tarpaulins and over pouches for medicinal products Notes ASTM D1505 D2839 Alkatuff LLDPE Rotational Moulding Grades Meit Index E Grade 9 10 min 190 C Density Applications 2 16kg ren Applications requiring excellent ESCR chemical resistance stiffness toughness and UV protection such as LL711UV 0 938 i water and chemical tanks septic systems and kayaks 0 935 Applications requiring high ESCR chemical resistance toughness stiffness and high leve UV stabiliser such as leisure craft playground equipment and agncultural tanks 0 935 Applications requiring high ESCR chemical resistance toughness and siess Incorporation of suitable UV l stabilisation is required for outdoor applications High speed intricate applications requiring good ESCR chemical resistance toughness and UV protection LL710UV 0 930 such as consumer goods and da equipment Notes The level of chemical resistance is a function of product a and environmental conditions Contact Qenos for further information Melt Index according to ASTM D1238 unless otherwise annotated Density according to ASTM D1505 unless otherwise annotated FOI Document 5 Eo Alkathene LDPE Film Grades Additives Applications Melt Index re SE 9 10 min 190 c Density Applications 2 16kg
69. D1505 unless otherwise annotated 7 Document 11 Cnr Korc Front Cover o c r CO E t gt t e lo E ct UN s B SCO e g r Q E 14 Nu a nradiuc a ro gt C J Qenos Pty Ltd ADNI 7 f i Cc sa t Pa 1 lt gt i t pe i E rurale AUSTRALLAN MADE 50 9001 Ws aa 3 e oi q 35 e ye E T f e y it J e A H E N i J 4 Jenos A Bluestar Company INJECTION MOULDING TECHNICAL GUIDE Alkathene Alkatuff Alkatane FOI Document 12 27 Front Cover Qenos produces injection moulded products for applications including caps pails crates sealant cartridges mobile garbage bins produce bins housewares and lids A full range of Alkatane HDPE Alkathene LDPE and Alkatuff LLDPE grades are available across the Melt Index and density spectrum In addition Qenos distributes a number of speciality polymers suitable for injection moulding Qenos Alkathene Alkatuff and Alkatane are trade marks of Qenos Pty Ltd INJECTION MOULDING a FOI Document 12 Wa 5 INJECTION MOULDING TABLE OF CONTENTS INTRODUCTION EFFECT OF TYPE OF POLYETHYLENE ON PROCESSING AND PROPERTIES OF MOULDINGS Classification of Polyethylenes MFI DENSITY Effect of MFI and Density on Moulding Characteristics MOULD FILLING Surface Finish Summary EFFECT OF MFI AND DENSITY ON THE PROPERTIES OF POLYETHYLENE MOULDINGS stiffne
70. E compounds used in Australia and New Zealand to manufacture AS NZS 4130 PE pipe and listed in PIPA Guideline POPOO4 Polyethylene Pipe Compounds Note These guidelines apply to pipe used for the conveyance of water Where other incompressible fluids are being considered the designer must assess the effect of the fluid on the PE pipe system at the operating temperature For example internal fluids such as aggressive condensates when absorbed may have the effect of reducing the material strength upon which design stress is based The rerating factors in this guideline are expressed in terms of metre head of water and are not for use with compressed air or gas applications The following information details how to determine the temperature of the pipe wall and then using Table 5 and 6 determine the de rated MAOP value for the system These recommendations are not to be taken as detailed specifications Determining the Temperature of the Pipe Wall The pressure rating of PE pressure pipe systems is based on the temperature of the pipe wall which may be determined from either a An assumption of a constant pipe wall temperature typical for continuous service at a set temperature e g cold water Service or b The determination of an average service temperature where temperature variations are likely to occur in a predictable pattern refer below e g in cavity walls or roof spaces or c The maximum Service temperature less 10
71. E80B type resin certified to AS NZS 4131 for use in pressure pipes and fittings Medium Density natural resin for extrusion into a full range of non standard pipe products and as a base for PE80 type striping and jacket compounds GM7655 a 0 954 High Density natural high molecular weight resin for extrusion into a full range of non standard pipe products MDF 169 0 943 Medium Density natural high molecular weight resin for extrusion into a full range of non standard pipe products LLO228 TO 0 9231 Linear Low Density resin for use in pipe extrusion applications MD0992 0 0 942 Notes ASTM D1505 D2839 D1238 190 C 2 16kg Alkadyne PE Wire and Cable Grades MDI592 0 942 Designed for extrusion into a full range of wire and cable products where natural Medium Density resins are required Designed as ganera purpose jacketing compound for buried wires and cables where abrasion and cut through r 1 MD0898 1 0 953 resistance is required Notes ASTM D1505 D2839 Alkatane HDPE Tape and Monofilament Grades Melt Index at Ker 9 10 min 190 C Applications 2 16kg GF7740F2 0 950 Extrusion applications including stretched tape monofilament tarpaulins and over pouches for medicinal products Notes ASTM D1505 D2839 Alkatuff LLDPE Rotational Moulding Grades Meit Index fui Py igo min 190 C Best Applications 2 16kg grea Applications requiring excellent ESCR chemical resistance st
72. FOI Document 1 Go From A C 20S co Sent riday 24 October 2014 9 29 AM To TARCON Cc a Subject enos objection to TC 1425824 Attachments HDF193B CON item cost xlsx Qenos invoices HDF193B CON 2014 pdf TC 1425824 objection Oct 14 signed pdf Polyethylene at a Glance 6th Edition pdf Book 7 Pipe and Tubing Extrusion_web pdf Dear National Manager Tariff Branch Please find attached Qenos objection to Gazette no TC 14 33 TC 1425824 and supporting material Qenos Pty Ltd as E cenos com W www genos com Oenos FOI Document 2 S1 0 if this form was completed by a business with fewer than 20 employees 9 please provide an estimate of the time taken to complete this form Tine Hours Minutes SUBMISSION OBJECTING TO THE MAKING OF A TARIFF CONCESSION ORDER TCO THIS FORM MUST BE COMPLETED BY A LOCAL MANUFACTURER WHO WISHES TO OBJECT TO THE GRANTING OF A TCO THE INFORMATION PROVIDED ON THIS PAGE WILL BE FORWARDED TO THE APPLICANT FOR THE TCO THE FORM SHOULD BE READ CAREFULLY BEFORE BEING COMPLETED DETAILS OF THE TCO APPLICATION TO WHICH THIS SUBMISSION REFERS GAZETTE NO TC 14 33 DATE 23 October 2014 Gazetted description of goods LOCAL MANUFACTURER DETAILS Name Qenos Business Address 417 513 Kororoit Creek Road Altona VIC 3018 Postal Address if the same as business address write as above Private Mail Bag 3 Altona VIC 3018 Australian Business Number A B
73. L 32 32 33 33 36 af S af at a af 38 38 38 38 38 38 38 38 38 38 39 FOI Document 6 Lp 7 PIPE AND TUBING EXTRUSION APPENDIX 1 RECORD SHEETS 40 APPENDIX 2 PIPE EXTRUSION TROUBLESHOOTING GUIDE 41 BIBLIOGRAPHY FURTHER READING 43 4 Qenos Technical Guides o gt AS oe k ro gt a a w i o Ta O a Ed ll ES NE a Din PIPE AND TUBING EXTRUSION INTRODUCTION Alkadyne polyethylene grades are used for the extrusion of pipe The application areas in which Alkadyne pipe resin is typically used include e Mining for conveyance of corrosive and abrasive slurries and tailings Water management projects such as large scale irrigation for agriculture Residential water distribution e Civil work such as Sewers e Residential and industrial gas distribution Gas and water management in Coal Seam Gas extraction Management of industrial fluids Drainage Rural applications such as management of water on farms etc Disclaimer All information contained in this publication and any further information advice recommendation or assistance given by Qenos either orally or in writing in relation to the contents of this publication is given in good faith and is believed by Qenos to be as accurate and up to date as possible The information is offered solely for your information and is not all inclusive The user should conduct its own in
74. N MOULDING TECHNICAL GUIDE Alkathene Alkatuff Alkatane FOI Document 18 1S Front Cover Qenos produces injection moulded products for applications including caps pails crates sealant cartridges mobile garbage bins produce bins housewares and lids A full range of Alkatane HDPE Alkathene LDPE and Alkatuff LLDPE grades are available across the Melt Index and density Spectrum In addition Qenos distributes a number of speciality polymers suitable for injection moulding Qenos Alkathene Alkatuff and Alkatane are trade marks of Qenos Pty Ltd FOI Document 18 INJECTION VIOULDING 9 Ory i F e FOI Document 18 OL 5 INJECTION MOULDING TABLE OF CONTENTS INTRODUCTION EFFECT OF TYPE OF POLYETHYLENE ON PROCESSING AND PROPERTIES OF MOULDINGS Classification of Polyethylenes MFI DENSITY Effect of MFI and Density on Moulding Characteristics MOULD FILLING Surface Finish Summary EFFECT OF MFI AND DENSITY ON THE PROPERTIES OF POLYETHYLENE MOULDINGS Stiffness Impact Properties Environmental Stress Cracking Mechanical Stress Cracking Summary SOME ASPECTS OF DESIGNING MOULDS FOR POLYETHYLENE shrinkage of Polyethylene Mouldings Distortion of Polyethylene Mouldings Mould Design Choice of Polymer Moulding Conditions Weld Lines Flow Weld Lines CONDITIONS FOR MOULDING POLYETHYLENE Cylinder and Melt Temperatures
75. N Reference 62 054 196 771 Company Contact Phone Number Facsimile Number E mail Address SU qenos com DETAILS OF THE SUBSTITUTABLE GOODS PRODUCED IN AUSTRALIA 1 Describe the locally produced substitutable goods the subject of the objection Subsiitufable goods are defined in the Customs Act 1901 as goods produced in Australia that are put or are capable of being put to a use that corresponds with a use including a design use to which the goods the subject of the application or of the TCO can be put 2 State the use s to which the substitutable goods are put or are capable of being put Pipes and fittings A FOI Document 2 Attach technical illustrative descriptive material and or a sample to enable a full and accurate identification and understanding of the substitutable goods 4 Are you aware of any other local manufacturers producing substitutable goods E YES NO if yes to question 4 please provide details of any goods produced in Australia which are substitutable for the goods for which a TCO is being sought and the names and addresses of the manufacturers of those goods 6 PRODUCTION OF GOODS IN AUSTRALIA Goods other than unmanufactured raw products will be taken to have been produced in Australia if 2 the goods are wholly or partly manufactured in Australia and b notless than 1 4 of the factory or works costs of the goods is represented by the sum of 1 the value of Au
76. PS antioxidants and titanium dioxide For the full Qenos range please refer to the Qenos website Customer Service or your Account Manager Melt Index according to ASTM D1238 unless otherwise annotated Density according to ASTM D1505 unless otherwise annotated FOI Document 5 L Alkathene LDPE Extrusion Coating Grades Melt Index kl AA Grade g 10 min 190 C Density Applications 2 16kg giem Applications including milkboard and fabric extrusion coating where very good drawdown low moisture vapour cl i E transmission rates and excellent hot tack are desirable Additive free Liquids packaging and other sensitive food packaging laminates where excellent heat seal low extractables good WNC199 8 0 0 918 i ze melt strength and low odour and taint are desirable Additive free LDN248 76 0 922 Liquids packaging and other sensitive food packaging laminates where low extractables and low odour and taint are desirable Additive free LD1217 19 0 918 Liquids packaging and other sensitive food packaging laminates where high line speed low neck in low extractables and low odour and taint are desirable Additive free Alkathene LDPE Injection Moulding Grades Melt Index va 3 Grade 9 10 min 190 C Density Applications 2 16kg tgier XDS34 0 3 0 922 Small part injection moulded caps and closures Additive free m A E A ee ee WJG117 17 0 918 Thick section mouldings caps and closures industri
77. PSP AL TAP AFH EHH SERREAS EASES ES EASES THSE SEP ASE ABR AAAS PASHAAT IATA AA rd dra rra der AA dsd rr rro ro F Can the goods be produced with existing facilities yes no G Are you prepared to accept an order for the goods C YES NO What was the first date on which you were prepared to accept an order 11 1980 Are the goods still in production YES NO If the answer is no when did production cease lf production has ceased and goods are held in stock please estimate the date by which stock is expected to be sold based on past sales information and attrition rate of the local goods Pi FOI Document 14 17 9 Provide any additional information in support of your objection Cost analysis based on the bill of materials provided for Qenos grade HD3690 packaged in 20 tonne NOTES a Section 269K and 269M ofthe Customs Act 1901 require that a submission opposing the making ofa TCO bein writing bein an approved form contain such information as the form requires and be signedinthe manner indicated in the form This is the approved form for the purposes of those sections b A submission will be date stamped on the day itis first received in Canberra by an officer of Customs The submission is taken to have been lodged on that day c For the submission to be taken into account it must be lodged with Customs nolater than 50 days after the gazettal day for an application for a TCO e no later th
78. Polyethylene at a Glance 6th Edition pdf Book 5 injection Moulding pdf Qenos invoices HD3690 CON 2014 pdf TC 1425826 objection Sep 14 signed pdf Dear National Manager Tariff Branch Please find attached Qenos objection to Gazette no TC 14 33 TC 1425826 and supporting material Qenos Pty Ltd as E genos com W www genos com Oenos 1 UNCLASSIFIED FOI Document 14 122 SE If this form was Competed by a business with fewer than 20 employees o 2 please provide an esimate of the time taken to complete this form TME Hours Minutes SUBMISSION OBJECTING TO THE MAKING OF A TARIFF CONCESSION ORDER TCO THIS FORM MUST BE COMPLETED BY A LOCAL MANUFACTURER WHO WISHES TOOBJECT TO THE GRANTING OF ATCO THE INFORMATION PROVIDED ON THIS PAGE WILL BE FORWARDED TOTHE APPLICANT FOR THE TCO THE FORM SHOULD BE READ CAREFULLY BEFORE BEING COMPLETED DETAILS OF THE TCO APPLICATION TO WHICH THIS SUBMISSION REFERS GAZETTE NO TC 14 33 DATE 27 August2014 Gazetted description of goods TC Reference Number TC BES CALA LEA PARA A LA A Ai eR PE SEE PP PPE Pee A IIA PP Pe Pe PR Te Pee ee bE he bee bee eed ped ee ee E A PE AS LS ee es es AA AA ALFA eh ee ee Stated use For the manufacture of this walled containers for food packaging oom fae Didier AAA PH E AAA LE E E ie ee PAE IFA FIFA RAIL IA Pe a eo LAIA AAA AA AAA eee using high speed injection moulding LEAR CEA PAPA AP E a E PATA PIPE PAPI TIFF Be Me FAP AA IEA
79. Technical Guides re and Dwell Time on Poly Mouldings etmyiene also necessitate adjustment of the others Alteration of the melt temperature should be gradual in steps of 10 C and a full cylinder of material should be injected before the results of any 10 C step are assessed Alteration of the cycle time which affects the length of time the material is in the cylinder and hence the melt temperature should also be carried out gradually Enough time should be allowed between successive adjustments to ensure that steady conditions at any one setting are obtained before the effect of that setting on the quality of the mouldings is determined 2i FOI Document 12 loy 5 INJECTION MOULDING MOULD RELEASE AGENTS if the correct moulding conditions have been chosen polyethylene mouldings are unlikely to stick in the mould if they do and the fault cannot be corrected by adjusting the moulding conditions mould lubricants such as stearates or fatty amides may be used Silicone oils and greases may cause environmental stress cracking in polyethylene mouldings and therefore before they are used as mould release agents they should be tested with the moulding to see if they are suitable If any doubt exists as to their suitability they should not be used DECORATING POLYETHYLENE MOULDINGS There are several ways in which polyethylene mouldings can be decorated These fall into two classes those applied directly to the polyethylen
80. a full range of non standard pipe products 0 923 Linear Low Density resin for use in pipe extrusion applications Notes ASTM D1505 D2839 D1238 190 C 2 16kg Medium Density black PE80B type resin certified to AS NZS 4131 for use in pressure pipes and fittings MD0592 MDF 169 LL0228 MD0592 0 9421 Designed for extrusion into a full range of wire and cable products where natural Medium Density resins are required Designed as general purpose jacketing compound for buried wires and cables where abrasion and cut through MD0898 1 0 9531 i resistance is required Notes ASTM D1505 D2839 Alkatane HDPE Tape and Monofilament Grades Melt Index P E 9 10 min 190 C Density Applications 2 16kg gic GF7740F2 0 950 Extrusion applications including stretched tape monofilament tarpaulins and over pouches for medicinal products Notes ASTM D1505 D2839 Alkatuff LLDPE Rotational Moulding Grades Melt index aul E Grade 9 10 min 190 C penal Applications 2 16kg A Applications requiring excellent ESCR chemical resistance stiffness toughness and UV protection such as LL711UV 3 0 998 water and chemical tanks septic systems and kayaks 1 LL7OSUV 0 935 applications requiring high ESCR chemical resistance toughness stiffness and high level UV stabiliser such as leisure craft playground equipment and agricultural tanks
81. a greatly magnified picture of a section cut through an injection moulding which shows clearly the different layers that are formed In service the oriented chains will tend to revert to their normal coiled configuration and this tendency is reflected in a reduction in the dimensions of a specimen parallel to the direction of flow and an increase in the dimensions at right angles to the flow If these dimensional changes are resisted by the shape of the moulding mechanical forces arise which can produce internal stresses large enough to cause cracking in the presence of an active environment At elevated temperatures the tendency for the oriented molecules to revert to their normal configuration is increased and some measure of the degree of orientation can be obtained by cutting specimens from a moulding and measuring the percentage retraction which takes place in the direction of flow when the specimens are heated A large retraction indicates a high level of frozen in strain If a highly strained surface comes into contact with an active environment such as synthetic detergents or fat a small crack may develop which is likely to propagate rapidly especially at elevated temperatures Depending on the particular type of polyethylene either cracks may develop throughout the whole section or failure may be restricted to surface peeling Figure 25 A Section from a Polyethylene Moulding Showing the Layered Structure
82. able Additive free Liquids packaging and other sensitive food packaging laminates where excellent heat seal low extractables good WNC199 8 0 0 918 a melt strength and low odour and taint are desirable Additive free LDN248 76 0 922 Liquids packaging and other sensitive food packaging laminates where low extractables and low odour and taint are desirable Additive free Liquids packaging and other sensitive food packaging laminates where high line speed low neck in low iai i 0 918 extractables and low odour and taint are desirable Additive free Alkathene LDPE Injection Moulding Grades Melt Index E T gli0ming irc Density Applications 2 16kg tom 0 922 Smail part injection moulded caps and closures Additive free Thick section mouldings caps and closures industrial containers where a high level of toughness is desirable ascii ll 0 918 Additive free XJF143 i 25 0 921 Injection moulded caps and closures and thick walled sections Additive free LDN248 7 6 0 922 Injection moulded caps and closures Additive free High flow resin for reseal lids housewares and toys where excellent gloss low warpage and flow to toughness ratio are desirable Additive free LD6622 70 0 922 High flow resin for lids and other thin wall injection moulding applications Additive free Aikatuff LLDPE Injection Moulding Grades Injection moulding and compounding applications such as housew
83. abour Australian materiais and factory overhead expenses incurred in Australia represent at least 25 of the factory or works costs YES I NO Specify each of the following costs per unit for the substitutable goods Ausiralian labour Australian materials Australian factory overhead expenses Imported content TOTAL Specify the date or period to which the costs relate 12 months ending 31 Aug 2014 Attach a copy of the working papers that were used to prepare the above costing information Those working papers should be supported by at least two extracts from the accounting records of the business C Is at least one substantia process in the manufacture of the goods carried out in Australia YES C NO If yes please specify at least one major process involved Conversion of Ethane gas supplied from Bass Strait into ethylene using a steam cracking process and then PRADA SS RH APT EDT FIS FE KARE EPH HES AH IRALA TIA AA SED ESR SHOOT AICA UA AAA ADA IIA ICAIC AICA AAA Arda das RA ACA RARA UA ERED AAA AAA Aras yr an A a osas asas POP e OTTO ATT MAOH THETA EAP AOR HHS AE TVAD AA Ayers EES EPS EAD ET DAS ra IIA PR AVIAT HASSE ARF TREK OTHVO COREE TAL EHA ETH T SFT IETS TEESE PETE EHH RHEE EE EAD ETRE ARTE RATERS REE AIDA AA AA AAA so Ad ass sra Par eed sewed eR A AEH HAASE DETTE F HR STO ROR ETTHAVEOSFTED OT ESTER T rs EEE REM UEE REA He EAE E SERRA SEEKER AAA AA EOE AHA a Aaa FA AHEM EASA AAP O Ke DORE RSA HESS EEE HAREM OBR ORAAAE HAE
84. acking caused by frozen in strain is the hazard to be avoided A polyethylene of higher MFI is preferable because it is easier to mould such a polyethylene to give a low level of frozen in strain Summary In general polyethylenes of high MFI and low density are most commonly used for injection moulding because they give the highest outputs have the best mould filing properties and give the glossiest mouldings For applications in which mouldings are likely to be stressed in service polyethylenes of low MFI must be used If increased stiffness is required polyethylenes of higher density are necessary but these must have a lower MFI to prevent them from becoming brittle and to improve resistance to environmental and mechanical stress cracking For non stressed applications frozen in strain is the hazard to be avoided and a polyethylene of higher MFI is preferred Provided that these few simple principles are followed articles giving a long and satisfactory service life can be moulded from polyethylene without difficulty SOME ASPECTS OF DESIGNING MOULDS FOR POLYETHYLENE A detailed examination of mould design is outside the scope of this booklet There are however three problems affecting mould design which although not peculiar to low density polyethylene occur frequently with this material and which can conveniently be discussed here These are e Shrinkage e Distortion e Weld lines Shrinkage of Polyeth
85. al containers where a high level of toughness is desirable i l Additive free XJF 143 2 5 0 921 Injection moulded caps and closures and thick walled sections Additive free LDN248 7 6 0 922 Injection moulded caps and closures Additive free High flow resin for reseal lids housewares and toys where excellent gloss low warpage and flow to toughness ratio are desirable Additive free High flow resin for lids and other thin wall injection moulding applications Additive free Alkatane HDPE Injection Moulding Grades Melt Index vat a Grade 9 10 min 190 C Ble Applications 2 16kg gica Stackable crates for transport storage and bottles and industrial mouldings where very good mechanical properties are desirable HD0390 4 0 955 Mouldings requiring long term weatherability including mobile garbage bins crates and industrial mouldings where HD0397UV d 0 955 gt very good mechanical properties are desirable HD0490 AS 0 955 eer io for transport storage and bottles and industrial mouldings where very good mechanical properties Mouldings requiring long term weatherability including mobile garbage bins crates and industrial mouldings where HD0499UV 4 5 0 355 very good mechanical properties are desirable x industrial pails crates closures and sealant cartridges where a good balance between flow and impact resistance is HD0790 0 956 Hecate ble Industrial pails crat
86. al reference to questions of shrinkage and distortion and examples are given to illustrate these points The moulding process itself is discussed in some detail guidance being given on all the operations which have to be carried out Moulding faults causes and remedies are also summarised Disclaimer All information contained in this publication and any further information advice recommendation or assistance given by Qenos either orally or in writing in relation to the contents of this publication is given in good faith and is believed by Qenos to be as accurate and up to date as possible The information is offered solely for your information and is not all inclusive The user should conduct its own investigations and satisfy itself as to whether the information is relevant to the user s requirements The user should not rely upon the information in any way The information shall not be construed as representations of any outcome Qenos expressly disclaims liability for any loss damage or injury including any loss arising out of negligence directly or indirectly suffered or incurred as a result of or related to anyone using or relying on any of the information except to the extent Qenos is unable to exclude such liability under any relevant legislation Freedom from patent rights must not be assumed Qenos Technical Guides FOI Document 18 PS HA AAA AA a a A A 5 INJECTION MOULDING INTRODUCTION However this very ease
87. als in pipe form by extrapolation sets out rules for the determination of the long term hydrostatic strength of polyethylene pipes 15 lt _M ES e oz 7 PIPE AND TUBING EXTRUSION The hydrostatic tests that are carried out on pipe sections under internal pressure take into account the effect of the 4 hir i multi axial strain occurring in practice The pipes are filled yA Peng ae with water and suspended in a temperature controlled dl lie environment such as a water bath see Figure 22 Wc ii i Figure 20 The First Creep Rupture Test Started In 1956 In HOECHST today known As Lyondell Basell Laboratory Frankfurt The same test rig and original pipes are still in operation today see Figure 21 On 18th October 2006 two pipe specimens on this historical test stand finally confirmed the predicted service of 50 years Figure 22 Extensive Hydrostatic Pipe Testing at Qenos Technical Centre Figure 21 The First Creep Rupture Test Started in 1956 in HOECHST today known as Lyondell Basell Laboratory Frankfurt is still on test 16 Qenos Technical Guides FOI Document 6 AAA AAA re A A A A E A PIPE AND TUBING EXTRUSION 7 Pipe pressure Curve and Service Life Extrapolation The results of these tests are plotted on a log log scale Test stress is plotted against endurance time After sufficie
88. an 14 days after the gazettal day for an amended application for a TCO or e where the Chief Executive Officer has invited a submission within the period specified in the invitation d Every question on the form must be answered e Where the form provides insufficient space to answer a question an answer may be provided in an attachment The attachment should clearly identify the question to which it relates f Unless otherwise specified all information provided shouldbe based on the situation as at the date oflodgement ofthe TCO application gq Customs may require an objector to substantiate with documentary evidence information provided in relation to the objection h Further information on the Tariff Concession Systemis availablein Part XVA of the Customs Act 1901 intheforeword to the Schedule of Concessional Instruments inthe administrative guidelines in Volume 13 of the Australian Customs Service Manual in Australian Customs Notice No 98 19 on the internet at www customs gov au by e mailing information customs gov au or by phoning the Customs Information Centre on 1300 363 263 agree in submitting this form by electronic means including facsimile that for the purposes of Sub Section 14 3 of the Electronic Transactions Act this submission will be taken to have been lodged when itis first received by an officer of Customs or if by e mail when it is first accessed by an officer of Customs as specified in Sub Section
89. and amorphous regions occur between the crystallites The smaller the number of branches the more crystalline the polyethylene will be and the higher its density Although MFI and density are the most important variables which characterise a polyethylene it must be emphasised that all polyethylenes with the same MFI and density are not necessarily identical Each polyethylene producer has specific manufacturing processes and by varying reactor conditions it is possible while maintaining a constant MFI and density to alter various features of the polymer such as the molecular weight distribution and the degree of long and short chain branching that cause changes in the processing behaviour and the physical properties of the polymer Effect of MFI and Density on Moulding Characteristics The injection moulding process is shown diagrammatically in Figures 4 and 5 For any given machine and mould the MFI and density of the polyethylene will considerably affect the injection dwell and cooling times in the cycle The injection time is not significantly affected and the mould opening extraction and mould closing times are not affected by the MFI or density of the polymer A A A O A A lt m oaoa Mould closin rd Moulding Ram begins to extracted move forward H injection time Mould opening Polythene _ under pressure Cooling Injection time dwell time
90. antistat additive VH Very High Slip H High Slip M Medium Slip Alkatuff LLDPE Film Grades Additives Applications Heavy duty sacks agricultural films lamination and form fill and seal LL438 0 8 packaging where enhanced toughness and sealing characteristics are desired General purpose industrial agricultural and heavy duty films and as a LL501 1 0 blend component to improve film handling in converting and packaging operations General purpose industrial agricultural and heavy duty films and as a LL601 1 0 blend component to improve film handling in converting and packaging operations Notes VH Very High Slip H High Slip M Medium Slip Melt Index according to ASTM D1238 unless otherwise annotated Density according to ASTM D1505 unless otherwise annotated Alkamax mLLDPE Film Grades Additives ML1810PN ML1810PS ML2610PN ML1710SC Applications Heavy duty bags industrial and agricultural films and form fill and seal applications and ice bags where outstanding toughness sealing and hot tack properties are desirable or for downgauging of existing film structures Heavy duty bags industrial and form fill and seal applications and ice bags where outstanding toughness sealing hot tack properties and high slip are desirable or for downgauging of existing film structures Heavy duty bags lamination industrial and form fill and seal applicatio
91. ares and lids Alkatane HDPE Injection Moulding Grades Melt Index a eo 9 10 min 190 C Density Applications 2 16kg ger Stackable crates for transpori storage and bottles and industrial mouldings where very good mechanical properties are desirable Mouldings requiring long term weatherability including mobile garbage bins crates and industrial mouldings where HD0397UV very good mechanical properties are desirable HD0490 Stackable crates for transport storage and bottles and industrial mouldings where very good mechanical properties are desirable Mouldings requiring long term weatherability including mobile garbage bins crates and industrial mouldings where HDO499UV very good mechanical properties are desirable HD0790 industrial pails crates closures and sealant cartridges where a good balance between flow and impact resistance is desirable Industrial pails crates closures and sealant cartridges where a good balance between flow and impact resistance is HD1090 desirable Mouldings requiring long term weatherability including industrial pails crates and tote boxes where a good balance HD1099UV between flow and impact resistance is desirable HD2090 2l Housewares thin walled containers and closures where excellent mould flow and flexibility is required HD3690 Melt index according to ASTM D1238 unless otherwise annotated Density according to ASTM
92. astic moulding when the melt stream is divided as it flows round some obstruction or can arise through non uniform filling of the mould caused by for example eccentricity of cores see Figure 21 Figure 21 Mouldings Illustrating the Formation of Weld Lines When Two Melt Fronts Meet Weld lines are particularly troublesome in polyethylene mouldings which are stressed in service because failures are likely to occur some considerable time after the part has been installed With many plastics weld lines are immediately obvious as a physical weakness in the moulding which is detectable by brittleness on impact or flexing With polyethylene the fault may not appear so serious and it may only be when stress is applied over a period of time in service particularly in contact with an active environment that failure will occur Weld lines can be minimised by the use of high melt and mould temperatures and also by utilisation of high injection pressures Although care must be taken not to create greater difficulties by introducing packing around the sprue A better solution however is to avoid weld line formation wherever possible by suitable positioning of the gate On many bottle closures for example a centre pin gate can be used instead of a side gate The mould may cost more with centre gates but with bottle caps in particular which are stressed in an outwards direction the advantages of mouldings free from w
93. ative to the die Sizing device calibrator in adequate or out MT Pipe tear Pipe sag of shape Pipe is too warm when it reaches the haul off unit Wrong vacuum setting in vacuum tanks Haul off too fast Pipe too hot at the entrance to calibrator Pipe dragging in cooling tanks Melt temperature too high Die gap not adjusted to accommodate sag for the pipe wall thickness No enough cooling capability in line Qenos Technical Guides Check the calibrator for concentricity Ensure it is 3 5 larger than the final pipe diameter Ensure sufficient downstream cooling length before pipe gets to the haul off unit Decrease throughput Ensure proper vacuum setting in vacuum tanks Check and adjust the speed of haul off Check for water flows on calibrator and adjust to avoid hot spots Ensure adequate calibrator size Check and eliminate drag spots Adjust extruder temperature setting and throughput to lower melt temperature Adjust die gap wider at the top and narrower at the bottom of the die Resin s inherent resistance to sag is not adequate Use low sag resin Ensure adequate water temperature in cooling baths and enough cooling length 41 FOI i 3 7 PIPE AND TUBING EXTRUSION Problem Issue Rough surface inside or outside Thermal degradation of pipe failed OIT Uneven pipe cut Uneven wall thickness Voids in pipe Disclaimer Cause s Moisture in resin
94. blend component into 1 Pu vale ad LDPE and LLDPE films for heavy duty applications lt K lt HDF895 0 80 0 960 Moisture barrier and blend component into LDPE and LLDPE films to enhance stiffness Blend component in core i layer for high clarity coextruded films 3 z EM Notes ASTM D1505 D2839 Alkatane HDPE Blow Moulding Grades Melt Index Grade 9 10 min 190 C 2 16kg Density glcm Applications D0840 0 9530 Large part blow mouldings especially blow moulded self supported drums and tanks 25 220 litres Exceptional ESCR HD1155 i 0 953 Large part blow mouldings including 25 litre to 220 litre tanks and drums Exceptional ESCR GM7655 0 9541 Blow moulded containers including household and industrial chemical HIC Suitable for larger part mouldings i Exceptional ESCR GF7660 0 9590 Household and industrial chemical HIC containers including detergent and pharmaceutica bottles l Excellent ESCR GE4760 i 0 964 Blow moulded water dairy and fruit juice bottles HD5148 0 962 High speed dairy packaging applications and other thin walled bottles such as milk cream fruit juice and cordial Notes ASTM D1505 D2839 Qenos imported polymers and additives Complementing our Australian manufactured Polyethylene grades Qenos acts as a local distributor for a wide range of imported polymers and additives including rubbers elastomers adhesives plastomers EVA BOPP Film E
95. compatible masterbatch Contaminant Material freezing prematurely Ensure PE based masterbatch is used Check feed for contamination Increase temperature settings Increase gate size Demoulding Poor design insufficient draft angles Increase draft angles incorporate slip additive difficulties Over packing Reduce injection speed and or second stage time pressure use higher flow PE grade Excessive second stage Reduce second stage pressure and or time Distortion Moulded in stress orientation Increase melt temperature Use increased melt flow index grade of PE Ribs too thick Employ more but thinner ribs to impart stiffness Variation in thickness Use ribs for varying thickness rather than solid walls Variation in mould cooling Increase cooling channels in difficult to cool areas Sink marks Increase second stage pressure and or time Gate freezing off too quickly Increase gate size Flashing Inadequate clamp force Increase clamp force Move mould to a higher clamp force machine Excessive vent size Reduce venting PE melt flow index too high Change to a low flow grade of PE Excessive injection speed Reduce injection speed Matt or streaky Gate inappropriately positioned resulting in snake Position gate so that the material is forced to change surface like jetting direction immediately upon entering the mould Melt disturbance resulting Matt Gloss pattern Increase melt temperature Reduce injection speed Moisture Dry the polyeth
96. considerably affect the injection dwell and cooling times in the cycle The injection time is not significantly affected and the mould opening extraction and mould closing times are not affected by the MFI or density of the polymer Mould closing Ram begins to _ move forward F Moulding extracted _ Mould Injection time opening Polythene under pressure injection Cooling dwell time time Figure 4 Injection Moulding Cycle INJECTION MOULDING 5 Figure 5 Pictorial Representation of the Injection Moulding Cycle As far as the polyethylene is concerned the output of any injection moulding machine depends predominantly on two factors e The time taken for the polyethylene to reach moulding temperature e The time taken for the polymer to be cooled sufficiently in order for the moulding to be removed A convenient method of assessing the effect of different types of polyethylene on output rate is to plot the number of mouldings which can be made in one hour against the cylinder temperature used Although the design of the mould and the type of machine affect output greatly for any given mould on a particular machine an output curve can be obtained by finding for each cylinder temperature the fastest possible cycle which gives mouldings acceptable in all respects except for that of surface gloss i e the minimum injection dwell time pressure and cooling time have been
97. ction moulding machines most efficiently the cylinder temperature should be chosen so that the output is at its peak There are however two factors which frequently prevent this being done namely the necessity to fill the mould and the desire to obtain mouldings with a good surface finish These factors are discussed below MOULD FILLING In practice there are some moulds for which it is not possible to draw an output curve over the whole range of cylinder temperatures because the mould cannot be filled at the lower temperatures Therefore the moulding temperature which has to be used is the lowest temperature at which the mould can be filled and this may restrict the output In order to attain as close to the maximum theoretical output good mould filling properties are obviously desirable in a polyethylene The spiral flow test was devised to assess the mould filling properties of materials It involves the measurement of the length of spiral obtained when moulding under standard conditions using the special mould shown in Figure 8 in order to compare different types of polyethylene the cylinder temperature mould temperature cycle time injection speed and pressure are all held constant and under these conditions the length of spiral obtained gives a good comparative evaluation of the mould filling properties of the polyethylenes being used Figure 8 Spiral Flow Mould Figure 9 shows that the main factor which influe
98. ctional heating of the material as it passes through the gate Qenos Technical Guides FOI Document 12 of if material is injected rapidly through a small gate the heat generated may be sufficient to raise the melt temperature above that of the cylinder From these examples it is clear that it is not possible to predict the exact cylinder temperature that must be used to obtain a given melt temperature but that it is necessary to choose a suitable cylinder temperature as a starting point and then to make adjustments based on visual inspection of the mouldings and on considerations of frozen in strain For grades with MFI above 20 g 10 min the suggested starting temperature is 210 C and for grades with MFI below 20 g 10 min the suggested starting temperature is 260 C When the cylinder temperature has been set the injection pressure and cycle time should be adjusted to the minimum values consistent with the production of full mouldings and moulding should then be carried out for long enough usually 15 30 minutes to enable conditions to settle down The mouldings should then be inspected and tested Testing should be conducted after conditioning for 24 hours preferably in a constant temperature environment Appearance of Mouldings If the surface of the mouldings is dull or patchy or contains matt rings or chevron marks see Figure 12 this is an indication that the melt temperature is too low and the
99. d by hot stamping has a good degree of scratch resistance Other advantages of this process are the absence of solvents and negating the need for drying facilities Labelling Labelling is an inexpensive way of achieving a very wide range of effects The choice of adhesive will depend on whether the label is required to be permanently fixed or easily removed Embossing A relief pattern on mouldings is easily achieved by cutting the pattern in the mould Conversely a relief pattern on the mould produces a corresponding recessed pattern in the moulding The embossed design can subsequently be decorated by printing or by painting A wide range of textures and finishes can be obtained by this method Decorating Treated Polyethylene Pre treatment Because polyethylene is non polar and cannot be dissolved in any known solvent at room temperature it is not possible to directly apply conventional inks paints and lacquers There are however several ways in which polyethylene can be made polar These are e Chlorination e Chemical oxidation e Flaming Electronic methods Of these chlorination is of little commercial importance and electronic methods are usually restricted to thin films Flaming is a versatile process which can handle any surfaces which do not contain deep or intricately shaped recesses Chemical methods are not used so frequently but they are the most satisfactory for parts of complex design Flame Treatment F
100. d tanks 25 220 litres Exceptional ESCR 0 9531 Large part blow mouldings including 25 litre to 220 litre tanks and drums Exceptional ESCR 0 954 Blow moulded containers including household and industrial chemical HIC Suitable for larger part mouldings i Exceptional ESCR Household and industrial chemical HIC containers including detergent and pharmaceutical bottles Excellent ESCR Blow moulded water dairy and fruit juice bottles High speed dairy packaging applications and other thin walled bottles such as milk cream fruit juice and cordial Qenos imported polymers and additives Complementing our Australian manufactured Polyethylene grades Qenos acts as a local distributor for a wide range of imported polymers and additives including rubbers elastomers adhesives plastomers EVA BOPP Film EPS antioxidants and titanium dioxide For the full Qenos range please refer to the Qenos website Customer Service or your Account Manager Melt Index according to ASTM D1238 unless otherwise annotated Density according to ASTM D1505 unless otherwise annotated FOI Document 11 Pdo Alkathene LDPE Extrusion Coating Grades Melt Index va had Grade 9 10 min 190 C Density Applications 2 16kg igicm Applications including milkboard and fabric extrusion coating where very good drawdown low moisture vapour XLC177 45 0 923 owe ZA transmission rates and excellent hot tack are desir
101. e melt will cool and the greater will be the tendency for frozen in strain to develop Therefore to reduce frozen in strain a warm mould is recommended and for the minimum amount of strain a heated mould as hot as possible would be required However the use of a very hot mould would slow down the cooling rate and thus not only prolong the moulding cycle but also substantially increase the density of the moulding This is particularly true for mouldings that contain thick sections As explained in the Impact Properties section pg 11 certain polyethylenes can under these conditions be brought from the tough region into the brittle region see Figure 16 In practice mould temperatures in the range 30 50 C have been found to offer the best compromise between the effects of frozen in strain and notch sensitivity Figure 23 shows the variation of retraction with mould temperature for a constant cylinder temperature 19 FOI Document 18 5 INJECTION MOULDING RETRACTION MOULD TEMPERATURE C Figure 23 Variation of Retraction with Mould Temperature Cylinder Temperature is Constant Because of the importance of correct mould temperature and the growing tendency to reduce cycle times it is essential as already remarked that in the initial designing of the mould provisions should be made for efficient cooling unfortunately this is a feature which is all too often overlooked with con
102. e remedy is to use a higher melt temperature and as fast an injection speed as possible On the other hand for thick sectioned mouldings it is often an advantage to reduce the speed of injection so as to avoid jetting and turbulence which will lead to mouldings with a poor surface finish Summary The moulding conditions necessary to produce good mouldings with the best appearance and the lowest amount of frozen in strain are A melt temperature just high enough to give a glossy surface to the moulding e A mould temperature of about 30 50 C e The minimum injection pressure and dwell time Qenos Technical Guides normal injection dwell time normal pressure FOI Document 12 C6 i 1010 JING 5 excessive injection dwell time excessive pressure note thickening a before test b After accelerated cracking test Effect of Injection Pressu Faults in polyethylene mouldings may be divided into two classes those that are obvious from visual inspection and those arising from the presence of frozen in strain these can be detected only by testing Appendix 2 lists the obvious faults that can occur with their possible causes and remedies Faults arising from frozen in strain have already been dealt with earlier In using Appendix 2 it should be noted that because the machine variables are interdependent a remedy that involves the adjustment of any one machine variable may Qenos
103. e surface and those which require some form of pre treatment of the surface The following sections briefly deal with the various methods of pre treatment decoration and also with tests for the effectiveness of these processes Decorating Untreated Polyethylene The following methods are commonly used Hot stamping e Labelling Embossing Hot Stamping Basically this method consists of pressing on to the polyethylene a tape which is coated with pigment Heat and pressure are applied via a male die and the pigment is released from the tape and fused into the polyethylene Stamping should preferably be carried out while the moulding is still warm after being ejected from the die Because it is recessed the coating obtained by hot stamping has a good degree of scratch resistance Other advantages of this process are the absence of solvents and negating the need for drying facilities Labelling Labelling is an inexpensive way of achieving a very wide range of effects The choice of adhesive will depend on whether the label is required to be permanently fixed or easily removed 22 Embossing A relief pattern on mouldings is easily achieved by cutting the pattern in the mould Conversely a relief pattern on the mould produces a corresponding recessed pattern in the moulding The embossed design can subsequently be decorated by printing or by painting A wide range of textures and finishes can be obtained by this method D
104. e using a top load tool and tightening clamp device to ensure a positive contact is made between the pipe and saddle The joint gap should not exceed 0 5 mm see Figure 49 Qenos Technical Guides FOI Document 6 Figure 49 Illustration of Top load Tool Attached to Both the Saddle and Pipe v Connect the terminals and apply the fusion voltage following the method outlined above in Jointing Procedure vi The completed joint should be left in the clamps for cooling The time needed will be specified on the fitting label or by its data carrier or in the display of the automatic control box Maintenance servicing and calibration All equipment should be well maintained and keptina clean condition at all times The equipment should be serviced and calibrated regularly The frequency at which this is carried out will be different for individual items of equipment and will also depend on usage but should be at least once every 12 months Guidance should be sought from the equipment manufacturer and a scheme of calibration and servicing should be implemented Particular attention should be given to the control box the generator and the scraping or peeling tools The sharpness of the cutter head of tools should be checked at least on a monthly base Qenos Technical Guides PIPE AND TUBING EXTRUSION 7 Records 1 Job Supervision Electronic or written records of appropriate fusion pr
105. ea on to the article Qenos Technical Guides INJECTION MOULDING 5 Screen printing has the great advantage of low capital cost particularly when the operation is done manually Fully automatic units are available The main disadvantage of silk screening is that no more than one colour can be applied at one pass If additional colours need to be applied then the moulding must be dried before the next colour is applied Vacuum Metallising In vacuum metallising a thin continuous layer of metal is deposited onto a prepared surface by vaporising the meta under high vacuum and condensing it on the surface In practice a lacquer is applied to the pre treated polyethylene as a base coat This serves to smooth out any imperfections and also acts as a key for the metallic film The metallic film usually of aluminium is deposited and a top coat of protective lacquer is applied Low density polyethylene articles are successfully finished in this way Although the flexibility of the material is a disadvantage Tests for Finished Coatings Two simple but effective tests are the Scratch test and the Scotch Tape test Scratch fest A good idea of the adhesion of a coating can be obtained by scratching it with a finger nail or a knife to see if it flakes Scotch Tape Test In this test a length of pressure sensitive tape such as Scotch Tape supplied by 3M is stuck on to the polyethylene moulding and then pulled off slowly at first and
106. eas Sink marks Increase second stage pressure and or time Gate freezing off too quickly Increase gate size Flashing Inadequate clamp force Increase clamp force Move mould to a higher clamp force machine Excessive vent size Reduce venting PE melt flow index too high Change to a low flow grade of PE Excessive injection speed Reduce injection speed Matt or streaky Gate inappropriately positioned resulting in snake Position gate so that the material is forced to change surface like jetting direction immediately upon entering the mould Melt disturbance resulting Matt Gloss pattern Increase melt temperature Reduce injection speed Moisture Dry the polyethylene or masterbatch Incompatible masterbatch Change masterbatch to one with a PE base Poor colour Back pressure too low Increase back pressure homogenisation Masterbatch not compatible Ensure PE based masterbatch is used Barrel size too small insufficient shots in barrel Move to a larger machine Masterbatch add rate too low Use masterbatch with lower pigment concentration at higher add rate Temperature too low Increase temperature settings Qenos Technical Guides 25 FOI Document 18 oy 9 INJECTION MOULDING Problem Issue Cause s Potential Solution s Action s Short shots incompletely filled mouldings Weak weld lines Disclaimer PE melt flow index too low Melt temperature too low Inadequate vent size Inadequate thickness Insufficient injection speed Insuf
107. eccentric the gap should not exceed 2 e That there is no disruption to the input power supply from the fusion box with no control box error messages e That the heat fusion parameters are correct The pipe to fitting alignment is correct with no visible plastic extruded out from the fitting Qenos Technical Guides PIPE AND TUBING EXTRUSION 7 Maintenance Servicing and Calibration All equipment should be well maintained and kept in a clean condition at all times The equipment should be serviced and calibrated regularly The frequency at which this is carried out will be different for individual items of equipment and will also depend on usage but should be at least once every 12 months Guidance should be sought from the equipment manufacturer and a scheme of calibration and servicing should be implemented Particular attention should be given to the control box the generator and the scraping or peeling tools The sharpness of the cutter head of the tools should be checked at least on a monthly base Records 1 Job Supervision Eiectronic or written records of appropriate fusion procedure for each joint should be kept as required 2 Equipment Servicing and Calibration Electronic or written records of appropriate servicing and calibration should be kept The minimum information to be recorded is given in Appendix 1 3 Training Instructions should be provided by Registered Training Organisations RTO s that a
108. echanica properties are desirable HD0490 Stackable crates for transport storage and bottles and industrial mouldings where very good mechanical properties i are desirable Mouldings requiring long term weatherability including mobile garbage bins crates and industria mouldings where HD0499UV i very good mechanical properties are desirable Industrial pails crates closures and sealant cartridges where a good balance between flow and impact resistance s desirable industrial pails crates closures and sealant cartridges where a good balance between flow and impact resistance is HD1090 desirable Mouldings requiring long term weatherability including industrial pails crates and tote boxes where a good balance HD1099UV l between flow and impact resistance is desirable Housewares thin walled containers and closures where excellent mould flow and flexibility is required Housewares thin walled mouldings and closures where excellent mould flow and flexibility is required Melt Index according to ASTM D1238 unless otherwise annotated Density according to ASTM D1505 unless otherwise annotated FOI Document 17 Y t he na E lt f Duality AUSTRALIAN MADE 50 9001 y gA ai pa x rok ol i m A A i f ear Covel l A ed a e gi ua i i i ni ha A i y j it gt i a 4 n 2 a Jenos A Bluestar Company INJECTIO
109. ecorating Treated Polyethylene Pre treatment Because polyethylene is non polar and cannot be dissolved in any known solvent at room temperature it is not possible to directly apply conventional inks paints and lacquers There are however several ways in which polyethylene can be made polar These are e Chlorination Chemical oxidation e Flaming e Electronic methods Of these chlorination is of little commercial importance and electronic methods are usually restricted to thin films Flaming is a versatile process which can handle any surfaces which do not contain deep or intricately shaped recesses Chemical methods are not used so frequently but they are the most satisfactory for parts of complex design Flame Treatment Flaming a polyethylene moulding results in slight oxidation of the surface This provides a polar surface which is required for good adhesion The flame should be oxygen rich of constant length and should impinge on the surface long enough to result in dulling of the surface The exact technique will vary according to the shape of the part being treated The essential point is that all parts of the surface should be uniformly treated Chemical Treatment Chemical methods of pre treatment involving acid etching are costly and often difficult to operate but they are used for complicated parts and for parts to be vacuum metallised Basically the procedure is simple e The moulding is immersed for 30 sec t
110. eld lines are great In many cases the additional strength conferred by centre gating will permit the use of a polyethylene of high MFI which although poorer in resistance to environmental stress cracking will process easier and faster Where articles of cylindrical shape are highly stressed in an outwards direction and centre gating is not possible serious consideration should be given to diaphragm or ring gating Qenos Technical Guides 17 FOI Document 12 195 5 INJECTION MOULDING Flow Weld Lines These generally occur towards the end of the flow path on a thin walled article of large surface area e g certain types of buckets They are caused by the dividing of the advancing melt front into separate streams which fail to fuse together when the mould is full This effect is aggravated by inadequate pressure on the melt or too low a melt temperature The weld lines formed may be barely visible to the naked eye but they can readily be detected by immersing the moulding in carbon tetrachloride at a temperature of 50 to 70 C where fissures will open up Such weld lines are quite common and cause splits in the walls of thin containers see Figure 22 UN 2 WAI YU A A eN A AAA Figure 22 Failure Due to Flow Weld Lines CONDITIONS FOR MOULDING POLYETHYLENE In the injection moulding process the moulder is able to control several operating variables each of which can influence the quality
111. en highly reliable assurances as to the resistance of the pipe material to rapid crack propagation Qenos Technical Guides AS FOI Document 6 a PIPE AND TUBING EXTRUSION 7 weaving crack Figure 30 Example of Rapid Crack Propagation Fracture in Pipe Which Shows the Actions of Residual Stresses on the Cracked Pipe During RCP S4 Test Commonly employed testing methodology for RCP is based on the ISO 13477 standard It is known in industry as the 4 test small scale steady state test The 4 test is carried out as follows a weight with a knife attached to the end is dropped onto a pipe of standardised length and under a constant internal gas pressure near one of its ends to produce a rapidly progressing axial crack The crack initiation process should damage the pipe as little as possible The term crack propagation is used if the crack length a is greater than or equal to 4 7 dn 4 7 times the nominal outside diameter See Figures 31 and 32 for details Crack propagation zone test zone gt 5 d test specimen diameter dn ls buttress decompression limiting retainer ring impact plate Figure 31 Schematics of a Test Rig for the S4 Test Qenos Technical Guides Figure 32 Actual Test Rig for the S4 Test A series of tests at 0 C but varying in testing pressure lead to the determination of the critical pressure at which there is a sharp transition from abru
112. ength which can be tolerated Moulding Conditions Obviously the ideal moulding conditions would be those which give no orientation in the moulding and thus no warping In practice such conditions can never be achieved It has been found that long injection dwell times and high pressures because they reduce the overail level of shrinkage can often reduce warpage but these conditions give rise to packing stresses and may cause the mouldings to split across the sprue The best compromise in moulding conditions has been found to consist of a very high melt temperature i e 50 C higher than that normally used for a given polyethylene and a very cold mould i e as cold as can be achieved Qenos Technical Guides INJECTION MOULDING 5 Weld Lines Weld lines can occur in any plastic moulding when the melt stream is divided as it flows round some obstruction or can arise through non uniform filling of the mould caused by for example eccentricity of cores see Figure 21 Figure 21 Mouldings Illustrating the Formation of Weld Lines When Two Melt Fronts Meet Weld lines are particularly troublesome in polyethylene mouldings which are stressed in service because failures are likely to occur some considerable time after the part has been installed With many plastics weld lines are immediately obvious as a physical weakness in the moulding which is detectable by brittleness on impact or flexing With polyethylene the fau
113. ents and fats and yet the externally applied stresses to which they are subjected to are not sufficient to cause failure through environmental stress cracking 13 FOI Document 18 J4 5 INJECTION MOULDING Careful consideration needs to be made of the choice of polymer that will meet the demands of the finished product and the environment s that it will be exposed to e g oils fats alkalis acids and temperature etc To make the best resin selection customers are advised to discuss their specific end product requirements with their Qenos Technical Service Representative Mechanical Stress Cracking Under certain conditions the moulding process itself can create high levels of interna stress in polyethylene This is due to the semi crystalline nature of the polymer which enters the mould in a molten state and undergoes crystallisation as the resin solidifies The different polyethylenes undergo different degrees of crystallisation which is dependent on their molecular structure in general the polyethylenes can be ranked in terms of their crystalisability shrinkage in the following order HDPE 2 LLDPE gt LDPE The internal stress that is also commonly referred to as frozen in strain or residual strain may cause similar effects to those seen where polyethylene is exposed to external stresses in service The occurrence of frozen in strain is due to both the crystalline nature of the resins used and
114. equired cooling cycle as specified by the supplier Additional cooling time is recommended before tapping if the pipeline is to be field pressure tested as soon as practical DN40 saddle minimum 10 minutes for field test pressure lt 6 bar and minimum 30 minutes for field test pressure gt 6 bar lt 24 bar DN63 DN560 saddle minimum 20 minutes for field test pressure lt 6 bar and minimum 60 minutes for field test pressure gt 6 bar lt 24 bar Top load Electrofusion Branch Saddle Jointing Top load electrofusion branch saddles are typically used for large diameter branch connections gt 90 mm Applications include new installations renovation repair and under pressure live branch connections on existing PE mains for sizes to DN630 mm Typical installation instructions are detailed below 36 Ensure hands and tools are free from surface contaminants such as barrier hand cream sun screen detergent and surfactant used in horizontal directional drilling Clean pipe in the fusion area with an approved alcohol wipe as detailed above in the Jointing Procedure then remove the oxidised layer with a rotary peeler see Figure 47 Figure 47 installation of Detachable Rotary Peeler to Service Pipe iii Clean pipe in the fusion zone with an approved alcohol wipe see Figure 48 Figure 48 Illustration of Prescribed Cleaning of Pipe Fusion Zone iv Mount the fitting to the pip
115. erial prior to peeling Ensure the fusion area is completely dry before proceeding see Figure 37 Do not use detergent or surfactants to clean pipe surfaces NOTE Refer to fitting supplier for recommended alcohol wipes Personal cleaning wipes may contain lanolin and detergent and are not to be used in electrofusion vi Check ovality as described above and use re rounding tools as appropriate With the fittings still in the bag place alongside the pipe end and put a witness mark on the pipe at half the fitting length plus about 40 mm to enable visual checking of the scraped area after jointing is complete NOTE Do not remove the fitting from its packaging at this stage vii Check that the pipe clamps are of the correct size for the pipes to be jointed Only use the correct size pipe clamps vill Check the peeling tools are clean of dirt or other contaminants prior to use X Using an appropriate peeling tool remove the entire surface of the pipe to the depth of the witness mark Metal files rasps emery paper etc are not suitable end preparation tools and should not be used xi Mechanical peeling tools are strongly preferred as they achieve a consistent pipe surface preparation Hand scraping particularly for larger diameter pipes is time consuming and onerous to adequately prepare a complete pipe end Qenos Technical Guides FOI Document 6 x1i It is important in Australia that pipe and fittings are
116. ers the mould in a molten state and undergoes crystallisation as the resin solidifies The different polyethylenes undergo different degrees of crystallisation which is dependent on their molecular structure In general the polyethylenes can be ranked in terms of their crystalisability shrinkage in the following order HOPE S LLDPE 2 LDPE The internal stress that is also commonly referred to as frozen in strain or residual strain may cause similar effects to those seen where polyethylene is exposed to external stresses in service The occurrence of frozen in strain is due to both the crystalline nature of the resins used and also as a result of the moulding conditions and the design of the finished part see Conditions for Moulding Polyethylene section on pg 18 Once a polyethylene has been selected HDPE LLDPE LDPE for fabrication of the finished part internal stresses can be negated minimised through careful mould design and by controlling the processing conditions on the injection moulding machine Many mouldings however are also subjected in service to externally applied mechanical stresses which can cause cracking Examples of such mouldings are those containing metal inserts e g knobs and those used for interference applications e g snap on closures ferrules or feet for tubular furniture For such finished parts careful selection of the polymer is important Within the polyethylenes a balance is
117. ervice trials that mouldings made at low melt temperatures can contain enough frozen in strain to overcome the structural integrity of the part and result in failure whereas those made under optimum conditions are perfectly satisfactory see Figure 22 It may be concluded that the optimum cylinder temperature is the lowest at which full glossy mouldings can be obtained and that under these conditions frozen in strain will be at a minimum Too high a temperature will lead to sticking and long cycles and too low a temperature will lead to strained mouldings Mould Temperature The mould temperature chosen should be that at which good mouldings can be produced with a minimum cycle time The colder the mould the faster the melt will cool and the greater will be the tendency for frozen in strain to develop Therefore to reduce frozen in strain a warm mould is recommended and for the minimum amount of strain a heated mould as hot as possible would be required However the use of a very hot mould would slow down the cooling rate and thus not only prolong the moulding cycle but also substantially increase the density of the moulding This is particularly true for mouldings that contain thick sections As explained in the Impact Properties section pg 11 certain polyethylenes can under these conditions be brought from the tough region into the brittle region see Figure 16 In practice mould temperatures in the
118. es FOI Document 6 20 PIPE AND TUBING EXTRUSION 7 SDR Pipe to Fitting Fusion Compatibility The following table provides recommendations of the fusion compatibility of PE pipe to PE electrofusion fittings see Table 11 Table 11 SDR 11 Electrofusion Fittings Electrofusion Fittings Branch Fittings Electrofusion SDR11 SDR11 Saddles SDR11 PE Pipe SDR Rating 7 17 17 6 17 17 6 17 17 6 pa pa 16 25 32 40 50 63 75 90 110 125 140 160 180 200 225 250 280 315 355 400 450 500 560 630 4 4 2 4 4 4 4 4 4 4 4 4 4 4 4 4 4 Fl gt 4 4 4 4 4 4 4 4 1 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 444 where corresponds to suitable and corresponds to unsuitable Consultation with the fitting supplier or manufacturer is advised for confirmation of fusion compatibility Qenos Technical Guides 25 FOI Document 6 19 ASN et AA A A A A A A eee Y PIPE AND TUBING EXTRUSION Electrofusion socket jointing Electrofusion socket jointing incorporates an electrical resistance element in the socket of the fitting which when connected to an appropriate power supply melts and fuses the materials of the pipe and fitting together from contamination and that t
119. es closures and sealant cartridges where a good balance between flow and impact resistance is HD1090 10 0 956 desirable a Mouldings requiring long term weatherability including industrial pails crates and tote boxes where a good balance HD1099UV 10 0 956 between flow and impact resistance is desirable HD2090 20 0 956 Housewares thin walled containers and closures where excellent mouid flow and flexibility is required HD3690 0 956 Housewares thin walled mouldings and closures where excellent mould flow and flexibility is required Melt Index according to ASTM D1238 unless otherwise annotated Density according to ASTM D1505 unless otherwise annotated FOI Document 5 47 Qenos Pty Ltd a ADAD ED AEA DEN F ARN OZ etsy LO I f f Ba y ALUSTRALIAN MADE 0 ay aai ee a 7 D y a Front Cover e a f 3 Rear Cover T ii Eil VOVE z k G a t J E ely les C w gt ji 4 o W S z y gis al XCiUde S al g C j e rio e a Or r E r r r 4 r exis a US ers S Tis L S 9 gt gt 4 UL hil Kamen WRaLu y Ne K ne and Aikale e rage ifs Qe 105 Pt Ie enos A Bluestar Company EXTRUSION TECHNICAL GUIDE Front Cover Polyethylene pipe is an engineered product required to withstand internal pressure and external influences for up to 100 years Qenos has invested in the largest pipe pressure testing facility in the so
120. ficient gating Melt temperature too low Flow of polymer too low Injection speed too low Gate s too far from weld line Change to higher melt flow index grade Increase melt temperature Increase venting Increase thickness Increase injection speed Increase gate size or number Increase temperature settings Use higher melt flow grade Increase injection speed Move gate or increase number of gates The proposed solutions in this guide are based on conditions that are typically encountered in the manufacture of products from polyethylene Other variables or constraints may impact the ability of the user to apply these solutions Qenos also refers the user to the disclaimer at the beginning of this document 26 Qenos Technical Guides FOI Document 18 i INJECTION MOULDING 5 BIBLIOGRAPHY FURTHER READING i de 3 Rosato D V Rosato D V Rosato M G Injection Moulding Handbook 3rd Ed Kluwer Academic Publishers 2000 Johannaber F Injection Moulding Machines A User s Guide 4th Ed Hanser Verlag 2008 Bryce D M Plastic Injection Moulding Manufacturing process fundamentals Society of Manufacturing Engineers 1996 Osswald T A Turnig L Gramann P J Injection Moulding Handbook Hanser Verlag 2008 Potsch G Michaeli W Injection Moulding An Introduction 2nd Ed Hanser Verlag 2008 Rueda D R Balta Calleja F J Bayer R K J Mat Sci 16 3371 1981 Influence
121. fore assembling the joint Refer to the electrofusion fitting supplier for the correct selection of alcohol wipes ENSURE THE PREPARED SURFACES ARE COMPLETELY DRY BEFORE PROCEEDING DO NOT TOUCH THE PREPARED PIPE SURFACE Figure 42 illustration of Pipe Preparation Required Prior to Welding of Pipe Fitting Remove the fitting from its packaging and check that the jointing surface of the saddle fitting is clean The bore of the fitting may be wiped with a recommended alcohol wipe if necessary NOTE Ensure that the bore is completely dry before proceeding 34 Figure 43 Installation of Saddle Fitting onto Pipe Prior FOI Document 6 ii Position the fitting base onto the prepared pipe surface Bring the lower saddle into position Then gradually and equally tighten the bolts and nuts until the upper saddle makes firm contact with the prepared surface of the pipe see Figure 43 Carefully inspect the fitting to ensure a firm contact with the pipe is achieved over the entire upper saddle contact area Install re rounding tools if pipe out of roundness exceeds 1 5 or if a firm contact is not achieved over the entire upper saddle contact area to Welding iii Check that there is sufficient fuel for the generator to complete the joint Start the generator and check that it is functioning correctly NOTE Ensure the generator is switched on and running satisfactorily before connectin
122. g the electrofusion control box to the power source iv Switch on the control box Check that the reset button if fitted is in the correct mode v Connect the control box output leads to the fitting terminals and check that they have been fully inserted see Figure 44 Qenos Technical Guides FOI Document 6 10 PIPE AND TUBING EXTRUSION 7 COOLING Figure 44 Attachment of Control Box Leads to Pipe Fitting Figure 45 Diagram illustrating Locating of Melt indicators on Fitting vi The jointing time is indicated either on the fitting label or on a data carrier supplied with the fitting Check that Refer to the fitting supplier or manufacturer for details on the correct time is shown on the control box display If branch outlets and specific installation instructions required enter the fusion jointing time into the control x If the fusion cycle terminates before completion of the countdown check for faults as indicated by the control box warning lights or display Check for a possible cause of the break e g inadequate fuel in the If the control box is equipped with a barcode reader or generator or power supply failure etc barcode scanner scan the fusion data barcode into the machine to ensure a fully automated and controlled data entry Barcode reading control boxes automatically adjust for variable temperature conditions For manual input of the heat fusion time into the control box refer to
123. g these assumed temperatures the total cooling zone length can be calculated as follows L Lepec Q M where Lspec Specific cooling zone length m hr kg Q output kg hr Lspec relative to the pipe dimension is outlined in Table 4 below Table 4 L Relative to the Pipe Dimension Pipe SDR 41 33 28 1476 i 74 Loaec for HDPE 0 016 0 02 0 024 0 036 0 06 0 08 SDR Standard Dimension Ratio a nominal ratio of the pipe outside diameter to its wall thickness Downstream Equipment Downstream equipment covers all other plant units besides the extruder die Sizing and cooling systems see Figure 13 Most pipe manufacturing lines will have e Ultrasonic Thickness Meter that continuously measures the wall thickness around the circumference of the pipe Caterpillar Haul Off Unit with concentrically arranged caterpillars held under pneumatic pressure against the pipe to transmit the haul off forces For start ups the haul off unit can be switched to operate in the reverse to enable a pipe to be run back through the cooling and sizing systems to the point where the melt exits from the pipe die There the pipe can be welded to the extrudate e Marking Unit where the pipe is marked with standard specifications Automatically Adjustable Saw mounted on a table cuts the pipe into the desired lengths e Coiling Unit where smaller diameter pipes can be wound into coils or onto reels up to the appreciable pipe s
124. general purpose applications wherea M0 gt gt p medium level of slip and antistatic are required LD0220MS 25 0 922 High quality low gauge film for lamination and overwrap applications where a medium levei of slip is required High quality low gauge film primarily intended for bread bags and overwrap but LDJ225 25 aM Ba also general purpose applications where a very high level of slip is required XLE197 55 High quality very thin gauge and high clarity film primarily intended for food and i i packaging wrap and for drycleaning film Additive free Notes Based on antistat additive VH Very High Slip H High Slip M Medium Slip Alkatuff LLDPE Film Grades Applications Heavy duty sacks agricultural films lamination and form fill and seal packaging where enhanced toughness and sealing characteristics are desired General purpose industrial agricultural and heavy duty films and as a blend component to improve film handling in converting and packaging operations Generai purpose industrial agricultural and heavy duty films and as a blend component fo improve film handling in converting and packaging operations High quality cast film for applications that require toughness high clarity and processability Notes VH Very High Slip H High Slip M Medium Slip Melt Index according to ASTM D1238 unless otherwise annotated Density according to ASTM D15
125. gn has an excellent capability to homogenise melt and shape it into pipe without generating any imperfections which could compromise the final quality or integrity of the pipe see Figures 7 and 8 ALO DA O A i j y a Z TH W eae F7 e a Pai La i f Y LLLI aut 4 DOO 0 o b 1 adapter e 7 die housing 2 spiral distributor 8 holding plate e 3 distributor housing 9 intermediate plate 4 rupture disk 10 centering e 5 distributor heater 11 die 6 feed plate 12 mandrel Figure 7 Schematic Diagram Detailing the Components of a Spiral Mandrel Die FOI Document 6 SS 7 PIPE AND TUBING EXTRUSION These concerns are associated with potential of building up excessive internal pressure within the pipe and leading to an uncontrolled rupture including release of the floating plug Vacuum sizing technology enables quick starting up of an extrusion line In addition the melt emerging from the die can be drawn down to obtain a range of final pipe diameters so that it is possible to produce at least two standard pipe sizes with a single die calibrator combination The pipe is shaped by a slotted sizing sleeve commonly referred to as a calibrator The calibrator is placed at the entrance of the first vacuum tank and it is the first downstream piece of line that the polymer melt sees Figure 8 A Spiral Distributor and its Operating Principle after having ex
126. good WNC199 8 0 0 918 i a melt strength and low odour and taint are desirable Additive free Liquids packaging and other sensitive food packaging laminates where low extractables and low odour and taint are LDN248 7 6 0 922 desirable Additive free Liquids packaging and other sensitive food packaging laminates where high line speed low neck in low extractables and low odour and taint are desirable Additive free 1101217 12 0 918 Melt Index sa ss 9 10 min 190 C Density Applications 2 16kg grem Small part injection moulded caps and closures Additive free Thick section mouldings caps and closures industrial containers where a high level of toughness is desirable Additive free Injection moulded caps and closures and thick walled sections Additive free Injection moulded caps and closures Additive free High flow resin for reseal lids housewares and toys where excellent gloss low warpage and flow to toughness ratio are desirable Additive free High flow resin for lids and other thin wall injection moulding applications Additive free Melt Index 9 10 min 190 C 2 16kg Density hi Applications Stackable crates for transport storage and bottles and industrial mouldings where very good mechanical properties are desirable Mouldings requiring long term weatherability including mobile garbage bins crates and industnal mouldings where HD0397UV i very good m
127. h resistance to Slow Crack Growth SCG High resistance to Rapid Crack Propagation RCP Hydrostatic Pressure Tests Undoubtedly the most important property of plastic pipes is their hydrostatic strength behaviour under internal pressure or Creep Strength This is what determines the service life expectancy of the pipe under internal pressure The equivalent stress resulting from the action of the applied pressure within the pipe corresponds in practice to the hoop stress acting on the pipe internal surface Knowledge of the permissible stress for the material concerned forms the basis for designing a pipe under a given internal pressure using the calculation formula for pressure vessels The pressure to be used in the test is calculated from the equation below knowing the dimensions of the pipe and the required hoop stress P 2ST Dm min I where P maximum working pressure at 20 C MPa S hoop stress of hydrostatic design stress at 20 C MPa T minimum wall thickness mm Dm min Minimum mean inside diameter mm Creep Test Under Internal Pressure The stress that leads to rupture in plastic pipes depends on the time under stress and the temperature of the test Creep behaviour has been studied in long term tests over many years in some cases since 1956 see Figure 20 ISO 9080 standard Plastics piping and ducting systems Determination of the long term hydrostatic strength of thermoplastics materi
128. he assembly and clamping instructions are correctly followed The pipe is prepared for jointing by removing a layer maximum of 0 2 mm for pipes up to DN25 0 2 mm to 0 3 mm for pipes up to DN75 and 0 2 mm to 0 4 mm for pipes larger than DN75 The minimum allowable outside diameter of the prepared pipe is shown below see Table 12 The effectiveness of this technique depends on attention to preparation of the jointing surfaces in particular the removal of the oxidised surface of the pipe over the socket depth ensuring the jointing surfaces are clean and free Table 12 DN of Pipe Versus Minimum Outside Diameter of Prepared Pipe Minimum outside diameter OD of prepared pipe Minimum outside diameter OD of prepared pipe DN of Pipe 16 20 25 32 40 50 63 TS 90 110 125 140 160 180 If entry of the pipe or fitting spigot into an electrofusion coupling is still restricted after the oxidised layer has been removed the pipe can be scraped down to the permissible minimum outside pipe diameter as in the above table In this case the thickness removed may be greater than the thickness stated above Pipe should also be checked for out of roundness ovality Some coiled pipes may be too oval to fit into electrofusion sockets and must be re rounded with rounding tools or clamps to enable sockets to be fitted The equipment and procedures described below relate to fittings with centre stops If fittings without ce
129. he moulding but also on frozen in strain In the following sections each variable will be discussed in the light of these two considerations together with other relevant factors such as the use of mould release agents Finally a table summarising some common moulding faults their causes and remedies is given see Appendix 2 Cylinder and Melt Temperatures The melt temperature is the temperature of the polyethylene as it enters the mould Depending on the grade of polyethylene being used the temperature should lie in the range 160 280 C In practice it is not convenient to measure the melt temperature directly and it is therefore necessary to use the machine cylinder temperature as a guide to the value of the melt temperature The important point to note is that the cylinder temperature as indicated on the control panel instruments is not necessarily the same as the melt temperature because the melt temperature depends on the rate at which the material passes through the cylinder and through the gate of the mould as well as on the cylinder temperature For example if the shot weight is almost as large as the shot capacity and mouldings are being produced very rapidly the material will be in contact with the heated cylinder for only a short time before being injected and may not have time to reach the temperature of the cylinder but may be as much as 30 C lower On the other hand in a machine of larger capacity that is worki
130. he surface that is about to be welded and the presence of contaminates can readily result in a poorly welded joint see Figure 42 Do not under any circumstances use methylated spirits acetone methyl ethyl ketone MEK or other solvents Do not use rags or other cloth soaked in these materials to wipe the prepared fusion surface as they have the potential to contaminate the surface with dirt grease and fabric conditioner These are not suitable options for wiping the prepared surface Other important factors relating to this procedure e Ensure wipes are saturated with alcohol i e have not dried out e When using the wipe work from the prepared peeled surface towards the unprepared area and discard the wipe after it has come in contact with any unprepared areas Wiping from unprepared areas towards the prepared surface can contaminate the fusion surface and similarly using a wipe which has been used on an unprepared can also introduce contaminants Only use the wipe once Do not wipe over the witness mark Do not touch the prepared pipe surface sweat sunscreen barrier cream soap detergent dirt and skin oils are all potential sources of contamination Disposable latex or nitrile gloves are recommended when handing the wipes for preparation of the surface 33 7 PIPE AND TUBING EXTRUSION e Ensure alcohol left by the wipe on the cleaned surface has evaporated and the prepared surfaces are completely dry be
131. his in mind increasing plant production capacity might not be as straight forward as installing larger and higher throughput extruders Pipe Dies Today manufacturers of pipe extrusion lines supply pipe dies see Figure 6 which they have developed themselves but which are essentially based on a common design principle Figure 6 Photograph of a Pipe Die Qenos Technical Guides PIPE AND TUBING EXTRUSION 7 High production extruder throughput has resulted in the polymer experiencing low residence times in the extruder This lack of residence time can lead to concerns about melt homogeneity and whether an even temperature distribution has been achieved throughout the melt Modern pipe resin grades also have high melt viscosity and elasticity that are required for the strength of the final product as well as for the ability to make large and thick walled pipes within dimensional tolerances respectively These polymer features make the extrusion line die absolutely essential for the successful manufacture of pipe especially with respect to its capacity to even up any melt inhomogeneity and shape it into the pipe without the generation of weld lines or any other memory effects which could potentially compromise the strength or appearance of the final product One of the established die designs is a Spiral Mandrel The wide acceptance of this die has seen it incorporated into many new pipe production line designs This die desi
132. ia are covered by two Australian Standards e AS NZS 4131 Polyethylene PE compounds for pressure pipes and fittings e AS NZS 4130 Polyethylene PE pipes for pressure applications The maximum allowable working pressure and therefore class of the pipe at 20 C is determined by e The type of compound used to make the pipe and The dimensions of the pipe Polyethylene compounds for pipe extrusion are designated by the material type PE and an appropriate level of Minimum Required Strength MRS details of which are given in Table 2 Table 2 MRS and Hydrostatic Design Stress Requirements for PE 100 and PE 80 Compounds Minimum Required Strength MRS MPa Design Stress Designation The value of the minimum required strength is based on the long term hydrostatic stress in the pressure pipe when extrapolated to a 50 year life at 20 C The hydrostatic design stress is arrived at by applying minimum safety factor of 1 25 to the value of MRS Reference should be made to the data sheets for Alkadyne pipe grades for details of their conformance to these requirements For each of the above designations there are several pressure Classes with different wall thicknesses for each nominal pipe diameter Qenos Technical Guides Hydrostatic MPa PE MRS100 10 0 8 0 PE MRS80 8 0 6 3 PIPE AND TUBING EXTRUSION 7 PIPE EXTRUSION TECHNOLOGY A pipe extrusion line consists of a number of pieces of equ
133. iated with orientation of the polyethylene molecules as they are injected into the mould cavity At high temperatures the viscosity of the polyethylene is low and the mould is filled rapidly only the layer of material immediately adjacent to the mould surface has frozen before the mould is filled so that during cooling the maximum relaxation of orientation can take place Qenos Technical Guides INJECTION MOULDING 5 At low moulding temperatures the melt viscosity is higher the mould fills relatively slowly and the polyethylene freezes quickly so that relatively little relaxation of the polymer orientation can occur It has been shown quite conclusively not only by laboratory tests but also by extensive service trials that mouldings made at low melt temperatures can contain enough frozen in strain to overcome the structural integrity of the part and result in failure whereas those made under optimum conditions are perfectly satisfactory see Figure 22 lt may be concluded that the optimum cylinder temperature is the lowest at which full glossy mouldings can be obtained and that under these conditions frozen in strain will be at a minimum Too high a temperature will lead to sticking and long cycles and too low a temperature will lead to strained mouldings Mould Temperature The mould temperature chosen should be that at which good mouldings can be produced with a minimum cycle time The colder the mould the faster th
134. idised when exposed to the atmosphere This oxidised outer layer will interfere with the bond between the pipe and fitting and must therefore be removed before joint assembly 32 Electrofusion tapping saddles are available to fit all commonly used main sizes from DN40 to DN560 with service connection outlet sizes from DN20 to DN63 and branch saddle spigot off takes from DN32 to DN125 NOTE Some saddle type fittings are limited to SDR11 Refer to the fitting manufacturer for further details Tapping tee saddles are usually supplied complete with the manufacturer s recommended installation procedure Generally recommended installation parameters are similar to the procedure described here which refers to fittings supplied with an underpart with bolts for assembling the two parts on the pipe The nominal pipe diameter should be within the tolerances specified in AS NZS 4130 Pipe ovality in excess of 1 5 of the nominal pipe diameter DN will require re rounding tools to allow satisfactory contact between tapping saddle and pipe Some full circle tapping saddles may effectively re round pipe when correctly fitted but a constant and reliable joint quality can always be achieved by using re rounding tools If in doubt refer to the fitting supplier Equipment i The control box input supply should be from a nominal 240V generator suitable to drive inductive loads and phase cut systems commonly of about 5kVA capacity Some fitting
135. iffness toughness and UV protection such as ue water and chemical tanks septic systems and kayaks 0 935 Applications requiring high ESCR chemical resistance toughness stiffness and high level UV stabiliser such as leisure craft playground equipa and agricultural tanks 0 935 Applications requiring high ESCR chemical resistance buaine sa stiffness Incorporation of suitable UV i stabilisation is required for outdoor applications High speed intricate applications requiring good ESCR chemical resistance toughness and UV protection such as consumer goods and playground equipment 0 930 Notes The level of chemical resistance is a function of product design and environmental conditions Contact Qenos for further information Melt Index according to ASTM D1238 unless otherwise annotated Density according to ASTM D1505 unless otherwise annotated FOI Document 17 72 Alkathene LDPE Film Grades Additives Applications Melt Index 4 g 10 min 190 C Density Applications 2 16kg gicm Heavy Duty Bags Carry Bags Antiblock Cling Wrap Freezer Film Heavy duty sacks pallet wrap and industrial applications requiring heavy gauge film Additive free Heavy duty sacks pallet wrap and industrial applications requiring medium to heavy gauge film with increased stiffness General purpose medium to heavy gauge film for heavy duty bags and shrink film and
136. ii On completion of the heating cycle both melt indicators Figure 38 Illustration of Pipe Clamps and Fitting within the processed part of the fitting should have Attached to Pipe Ends Prior to Welding risen If there is no apparent movement of either SS C indicator the joint could be unsatisfactory see Figure vi Check that there is sufficient fuel for the generator to 40 refer to discussion on electrofusion indicator complete the joint Start the generator and check that pins below it is functioning correctly NOTE Ensure the generator is switched on and running satisfactorily before connecting the electrofusion control box to the power source vil Switch on the control box Check that the reset button if fitted is in the correct mode terminals and check that they have been fully inserted see Figure 39 ix The jointing time is generally indicated either on the fitting or on a data carrier supplied with the fitting Check that the correct time is shown on the control box display If required for the control box enter the fusion jointing time into the control box timer vill Connect the control box output leads to the fitting Figure 40 Diagram illustrating Locating of Melt indicators 30 Qenos Technical Guides FOI Document 6 4 xiii If the fusion cycle terminates before completion of the countdown check for faults as indicated by the control box warning lights or display Check for a possible
137. imen accompanied by an apparent decline in tensile stress since the stress is related to the initial cross section and not to the necked down cross section at the yield point When the necking down has progressed along the entire length of the test specimen to the clamps tensile stress increases again as a result of material strengthening due to macromolecular network straining and orienting until the breaking point is reached ultimate tensile strength elongation at break Because of the special deformation characteristics of polyolefins it is advisable to use an extensiometer to determine elongation at break Assessment is only possible when the necking down has progressed beyond the measuring zone at each end A polyolefin only retains its useful application properties up to the yield point and so it is better to dispense entirely with measurement of ultimate tensile strength and elongation at break 3 3 Stress MPa pe a Percent Strain E E a a a SS SE Figure 15 Typical Stress Strain Curves for HDPE Measured in a Tensile Test on Test Specimen Prepared from Compression Moulded Sheet Test Temperature 23 C Testing Rate 50 mm min 13 FOI Document 6 al 7 PIPE AND TUBING EXTRUSION The effect of temperature on the yield stress ultimate tensile strength and elongation at break of a typical HDPE pipe grade is shown in Figure 16 pd a o cl x E a _ Mm v Q v O
138. in production YES CJ NO If the answer is no when did production cease If production has ceased and goods are held in stock please estimate the date by which stock is expected to be sold based on past sales information and attrition rate of the local goods FOI Document 8 37 9 Provide any additional information in support of your objection Cost analysis based on the bill of materials provided for Qenos grade HD3690 packaged in 20 tonne NOTES a Section 269K and 269M ofthe Customs Act 1907 require that a submission opposing the making of a TCO bein writing be in an approved form contain such information asthe form requires and be signed in the manner indicated in the form This is the approved form for the purposes of those sections b A submission will be date stamped on the day it is first received in Canberra by an officer of Customs The submission is taken to have been lodged on that day c For the submission to be taken into account it must be lodged with Customs no later than 50 days after the gazettal day for an application for a TCO nolater than 14 days after the gazettal day for an amended application for a TCO or where the Chief Executive Officer has invited a submission within the period specified in the invitation d Every question on the form must be answered e Where the form provides insufficient space to answer a question an answer may be provided in an attachment The
139. ion between MFI g 10 min and Number Average Molecular Weight as the melt temperature increases and it can be processed over a wide temperature range without decomposition Qenos Technical Guides FOI Document 12 Lo DENSITY Density is related to the crystallinity of the polyethylene and is measured in g cm Because polyethylene molecules are long and contain branches complete crystallisation cannot take place when polyethylene is cooled from the molten state and amorphous regions occur between the crystallites The smaller the number of branches the more crystalline the polyethylene will be and the higher its density Although MFI and density are the most important variables which characterise a polyethylene it must be emphasised that all polyethylenes with the same MFI and density are not necessarily identical Each polyethylene producer has specific manufacturing processes and by varying reactor conditions it is possible while maintaining a constant MFI and density to alter various features of the polymer such as the molecular weight distribution and the degree of long and short chain branching that cause changes in the processing behaviour and the physical properties of the polymer Effect of MFI and Density on Moulding Characteristics The injection moulding process is shown diagrammatically in Figures 4 and 5 For any given machine and mould the MFI and density of the polyethylene will
140. ipe dimensions output operating data yelp feeder pipe haul off ultrasonic pipe die speed wall thickness Sah centring measurement device Figure 14 Computerized Process Contro System for a Pipe Production Line The most commonly employed control system operates on the basis of interaction between the following options Weigh Feeder the extruder is equipped with a weigh feeder Weighed granule portions are fed to the extruder operating at required speed to achieve set off take of the weighted granulate feed Any deviation from the set output resulting from the constant weight feed is compensated for by speed adjustment of the extruder screw via the control system e Haul Off Control the haul off is set to a speed calculated from the specified output and the required weight per metre of the pipe Pipe wall thickness is measured around the circumference with an ultrasonic wall thickness meter Qenos Technical Guides PIPE AND TUBING EXTRUSION 7 MECHANICAL PERFORMANCE OF POLYETHYLENE PIPE GRADES Short term Behaviour at Low Deformation Rates A typical stress strain curve for HDPE pipe PE 100 type pipe Compound is shown in Figure 15 The tensile test reveals the characteristic stress strain curve for cold stretching of an unreinforced partially crystalline polymer Initially tensile stress increases up to the yield point This is followed by spontaneous necking down of the test spec
141. ipment An extruder converts the polyethylene raw material to a continuous tubular melt by extrusion through an annular die The molten pipe then proceeds through a sizing or calibration device which fixes its dimensions to a cooling trough After being cooled the pipe passes via a haul off to handling equipment for cutting into final lengths or coiling Printing devices may also be inserted into the line to mark the extruded pipes with specific details A portion of a pipe extrusion line is shown in Figure 1 Figure 1 Illustration of a Pipe Extrusion Line Granule Pre treatment Polyethylene is a hydrophobic material However for polyethylene compounds that contain carbon black that is hygroscopic in nature problems can arise if the moisture content of black polyethylene compound reaches gt 0 03 w w During extrusion moisture could cause formation of voids in pipe wall and rough pipe surface I Figure 2 Photograph illustrating a Pipe with Voids and a Rough Pipe Surface due to Excessive Moisture in the Polymer Compound FOI Document 6 37 7 PIPE AND TUBING EXTRUSION Such problems can be overcome by drying the polymer granules in a hopper dryer at 70 90 C for 1 5 2 hours immediately before feeding them into the extruder The duration of drying and the drying temperature should be such that the moisture content is reduced to lt 0 02 w w Extruder For processing HDPE and MDPE into pi
142. is method has been used by most European countries and in Australia The single pressure parameters Specified are very Similar to those previously Specified by PIPA Welders familiar with those parameters will adapt easily to the ISO Single pressure low fusion jointing method Qenos Technical Guides PIPE AND TUBING EXTRUSION 7 e Dual pressure low fusion jointing pressure This method is used by the water industry in the UK and in Europe for pipes with a wall thickness greater than 20 mm These parameters are not commonly used in Australia Single pressure high fusion jointing pressure This method has been used extensively in Northern America The weld interface pressure is approximately three times the low pressure method and as a consequence more of the molten material is extruded from the weld zone thereby enabling a reduced cooling time Extra attention is required to ensure that 1 Welding machines have sufficient structural strength and hydraulic capacity to achieve the high pressure parameters in a safe manner Confirmation should be sought from the machinery manufacturer 2 The welding operator is sufficiently experienced and proficient with the parameters Where the pipe or fitting wall thickness exceeds 70 mm welding parameters should be agreed between the asset owner and the installer Under these circumstances the pipe and fitting supplier and the equipment supplier should also be consulted Schematically
143. ited the die Calibrators are usually made for Melt Homogenisation from non ferrous metal for rapid removal of heat see ee Figures 10 and 11 A film of water is fed to the inlet of the calibrator to enable rapid cooling e g below the cyrstallisation temperature of the polymer to solidify the external pipe layer in order to pull the pipe into the calibrator without tearing the molten tube apart Water also acts as a lubricant to reduce frictional forces on the pipe s surface whilst it is being pulled through the calibrator The vacuum tank in which the calibrator is placed applies a vacuum which pulls the still hot malleable tube against the wall of the calibrator thereby setting the outer pipe diameter to ensure conformance to the pipe s dimensional specification The vacuum is operated at about 0 05 MPa absolute pressure which could vary depending on the pipe dimensions The calibrator is usually 3 5 larger than the required final outer pipe diameter to provide for shrinkage which takes place during pipe cooling Another die design which has found wide approval and use in pipe manufacture for its performance is the Lattice Basket type die This design results in relatively low extrusion melt pressure and consequently relatively low melt temperature both favourable for high extruder output see Figure 9 Figure 9 A Lattice Basket Die and the Basket Part of the Die Sizing and Cooling In the state of
144. ize of 250 mm pipe diameter 1a FOI Document 6 Y 7 PIPE AND TUBING EXTRUSION Automatic parting saw Muiti track take off machine Raw material feed hopper Spray cooling system Die head assembly Raw material i j dryer RU A WS alar High pressure pump filter and control valves a Sizing sleeve brass Extruder and screw with zone healing Motor gear box assembly Figure 13 Schematic of a Pipe Extrusion Line showing Haul Off and Automatic Pipe Cutter Lal Qenos Technicai Guides FOI Document 6 32 Process Control In new pipe production lines process control computers are used to automate production To produce pipe in the required dimensions the relevant operating data is entered for example Required throughput e Pipe dimensions e Screw speed e Haul off rate The set point values and permissible deviations are suitably fed back to the controller for process data monitoring In pipe manufacture material costs represent a substantial proportion of the overall costs of production It is therefore advisable to use computerised process control for optimum production of pipes with the least possible waste of material and the best possible thickness uniformity around the pipe circumference Figure 14 shows a schematic diagram of a computerized process control system for a pipe production line p
145. l appear to be tough initially because of the decrease in density but may become brittle as the density increases over time Qenos Technical Guides FOI Document 18 a INJECTION MOULDING 5 Table 1 Effect of Cooling Rate on the Density of Polyethylene MFI 20 Cooling Rate Density g cm Annealed at 140 C and cooled at 5 C per hour Annealed at 140 C and cooled at 30 C per hour Fast cooled in injection moulding FRACTURE RESISTANCE MELT FLOW INDEX DENSITY AT 23 C g c c Figure 16 Variations in the Tough Brittle Transition as defined by fracture resistance contours at 40 and 20 with MFI and Density Environmental Stress Cracking Environmental stress cracking is the name given to a phenomenon by which polyethylene under high stresses may crack in contact with certain active environments such as detergents fats and silicone fluids The resistance of polyethylene to environmental stress cracking decreases rapidly as the MFI is increased Figure 17 indicates how test specimens of polyethylenes of different MFI and of constant density behave when subjected to a severe stress in the presence of an active environment Comparison of polyethylenes of constant MFI but of different densities is more complicated because in such tests the Specimens are tested under constant strain and therefore the higher density polyethylenes will be under greater stress because they are stiffer Never
146. l in the interior this orientation is unable to relax and becomes frozen into position Thus a highly oriented layer is formed the thickness of which depends on the temperatures of the melt and of the mould surface On the other hand the material on the inside Is insulated from the cool mould by a layer of polyethylene and consequently it remains molten until near the end of the moulding cycle Not only is this material less oriented during mould filling but most of the orientation that does occur can relax during the cooling stage Therefore an injection moulded section has a composite structure consisting of a skin which is highly strained and inner layers Containing a much lower degree of molecular orientation Figure 25 is a greatly magnified picture of a section cut through an injection moulding which shows clearly the different layers that are formed In service the oriented chains will tend to revert to their normal coiled configuration and this tendency is reflected in a reduction in the dimensions of a specimen parallel to the direction of flow and an increase in the dimensions at right angles to the flow If these dimensional changes are resisted by the shape of the moulding mechanical forces arise which can produce internal stresses large enough to cause cracking in the presence of an active environment At elevated temperatures the tendency for the oriented molecules to revert to their normal configuration is increased and some
147. laming a polyethylene moulding results in slight oxidation of the surface This provides a polar surface which is required for good adhesion The flame should be oxygen rich of constant length and should impinge on the surface long enough to result in dulling of the surface The exact technique will vary according to the shape of the part being treated The essential point is that all parts of the surface should be uniformly treated Chemical Treatment Chemical methods of pre treatment involving acid etching are costly and often difficult to operate but they are used for complicated parts and for parts to be vacuum metallised Basically the procedure is simple e The moulding is immersed for 30 sec to 2 min in an acidified dichromate solution a typical solution is 100 cm of concentrated sulphuric acid 50 cm water and 15 g of potassium dichromate Removed from the bath washed thoroughly and dried 22 Qenos Technical Guides FOI Document 18 Wy The big disadvantage of this method is the need to handle acid solutions the main advantage is that every part of the surface provided it is clean is treated in the same way Tests for Pre treatment It is obviously desirable to be able to test the effectiveness of any pre treatment to ensure good adhesion of the finished coating Several tests can be used of which those based on wettability of the surface are popular because of their simplicity Peel Test Thi
148. lia which are substitutable forthe goods for which a TCO is being sought and the names and addresses of the manufacturers of those goods e PRODUCTION OF GOODS IN AUSTRALIA j Goods other than unmanufactured raw products will be taken to have been produced in Australia if a the goods are wholly or partly manufactured in Australia and b notless than 1 4 of the factory or works costs of the goods is represented by the sum of i the value of Australian labour and ii the value of Australian materials and i the factory overhead expenses incurred in Australia in respect of the goods Goods are to be taken to have been partly manufactured in Australia if at least one substantial process in the manufacture of the goods was carried out in Australia Without limiting the meaning of the expression substantial process in the manufacture of the goods any of the following operations or any combination of those operations DOES NOT constitute such a process a operations to preserve goods during transportation or storage b operations fo improve the packing or labelling or marketable quality of goods c operations to prepare goods for shipment d simple assembly operations e operations to mix goods where the resulting product does not have different properties from those of the goods that have been mixed A Are the goods wholly or partly manufactured in Australia YES C NO B Does the total value of Australian labour Au
149. lt may not appear so serious and it may only be when stress is applied over a period of time in service particularly in contact with an active environment that failure will occur Weld lines can be minimised by the use of high melt and mould temperatures and also by utilisation of high injection pressures Although care must be taken not to create greater difficulties by introducing packing around the sprue A better solution however is to avoid weld line formation wherever possible by suitable positioning of the gate On many bottle closures for example a centre pin gate can be used instead of a side gate The mould may cost more with centre gates but with bottle caps in particular which are stressed in an outwards direction the advantages of mouldings free from weld lines are great In many cases the additional strength conferred by centre gating will permit the use of a polyethylene of high MFI which although poorer in resistance to environmental stress cracking will process easier and faster Where articles of cylindrical shape are highly stressed in an outwards direction and centre gating is not possible serious consideration should be given to diaphragm or ring gating 17 FOI Document 18 o 5 INJECTION MOULDING Flow Weld Lines These generally occur towards the end of the flow path on a thin walled article of large surface area e g certain types of buckets They are caused by the dividing of the advancing melt fro
150. m are notched to a depth of 0 020 cm and subjected to a blow from a pendulum The energy lost by the pendulum in striking the specimens is termed the impact energy although much of this energy is expended in bending the specimen as the pendulum swings past it Polyethylene specimens are rarely broken by the first blow and therefore after a short rest period they are given a second blow The energy absorbed by this second blow expressed as a percentage of the energy absorbed by the first blow is termed the fracture resistance This quantity is found to be a useful measure of the amount of damage caused by the first blow 11 FOI Document 18 YE 5 INJECTION MOULDING q Figure 15 Impact Machine Showing Sample Holder and Process of Use 12 Impact energy and fracture resistance depend on both MFI and density as may be seen from Figure 16 For some polyethylenes the impact energy may increase at first with increasing density and then decrease This initial increase in impact energy is due to the contribution from the energy used in bending a specimen of increased stiffness Ultimately however the increase in density trends towards brittleness which becomes the dominant factor and results in the measured impact energy falling to very low levels It can be seen quite clearly that in order to avoid brittleness the higher density polyethylenes must have a low MFI Consequently if toughness is required in the higher
151. may be seen from Figure 16 For some polyethylenes the impact energy may increase at first with increasing density and then decrease This initial increase in impact energy is due to the contribution from the energy used in bending a specimen of increased stiffness Ultimately however the increase in density trends towards brittleness which becomes the dominant factor and results in the measured impact energy falling to very low levels It can be seen quite clearly that in order to avoid brittleness the higher density polyethylenes must have a low MFI Consequently if toughness is required in the higher density polyethylenes poorer processability poorer mould filling and in general higher processing temperatures will be required It can also be seen that with polyethylenes of lower density a much wider choice of MFI is possible without sacrificing toughness The dependence of brittle failure on density is also complicated by the fact that the density of any polyethylene is affected by its rate of cooling from the molten state This effect is illustrated opposite in Table 1 Values for densities quoted in the literature usually refer to specimens prepared in a standard way involving slow cooling In injection moulding however the polyethylene is cooled rapidly and the molecular chains have no time in which to pack into their equilibrium positions and consequently the density is reduced to below the equilibrium value Subsequently o
152. mperature and time The relaxation modulus See Figure 19 can be used in design calculations for moulded parts that are to be exposed to constant strain or compression over an extended period of time Behaviour at High Deformation Rates Information on the toughness characteristics of polymer materials at high deformation rates is provided by flexural and tensile impact strength tests The results of impact strength tests values for impact strength notched impact strength and tensile impact strength are considerably influenced by the conditions under which the test specimen is prepared Injection moulded test specimens because of their rapid cooling rate are less crystalline when solid and therefore more impact resistant than those prepared from compression moulded sheet The orientation produced by injection moulding also has an effect Qenos Technical Guides PIPE AND TUBING EXTRUSION 7 QUALITY TESTING OF POLYETHYLENE PIPE PE 100 A Package of Good Properties The designation PE 100 indicates that a PE HD material has been assigned to performance class MRS 10 where MRS stands for Minimum Required Stress The minimum creep strength is thus 10 MPa stress in the pipe wall at 20 C and 50 years However creep strength alone does not determine assignment to material class 100 but rather a whole range of improved properties resulting from the much improved toughness of these materials the most notable being e Hig
153. n Australia on a one off basis to meet a specific order rather than being the subject of reguiar or intermittent production and that is not produced in quantities indicative of a production run Capital equipment means goods which if imported would be goods to which Chapters 84 85 86 87 89 or 90 of Schedule 3 to the Customs Tariff Act 1995 would apply Goods that are made to order capital equipment are taken to be produced in Australia in the ordinary course of business if a a producer in Australia i has made goods requiring the same labour skills technology and design expertise as the substitutable goods in the 2 years before the application and ii could produce the goods with existing facilities and b the producer in Australia is prepared to accept an order to supply the substitutable goods E Have goods requiring the same labour skills technology and design expertise as the goods the subject of the application been made in Australia in the last 2 years YES C NO If yes describe the goods made during this period IIA A ADD AAA DADA DAA ASA AAA AAA AAA DADAS ISA A AAA SRP RAR ALCALA AAA ICAA ARAUCA AAA CAIRO dad IMA LAIA AA ARAFAT AA IL AIRIAIIRA AIMAR AAA UURIA AIF IIA AICA RU AED YES F Can the goods be produced with existing facilities C YES NO G Are you prepared to accept an order for the goods C YES NO What was the first date on which you were prepared to accept an order 11 1980 Are the goods still
154. nces ease of mould filling is MFI Although density undoubtedly has an effect on the spiral flow length for polymers with constant MFI this effect is relatively small Qenos Technical Guides FOI Document 18 gt See CONSTANT DENSITY LENGTH OF SPIRAL cm MELT FLOW INDEX Figure 9 Effect of MFI on the Mould Filling Properties of Polyethylenes of Constant Density A feature of the spiral flow test is that it can be applied to all injection moulding materials Figure 10 shows a chart on which the spiral flow length has been plotted against a series of cylinder temperatures for a range of polymers For most materials the temperatures used range from the lowest at which a readable flow length can be obtained to the highest that can be used without degrading the material However for polyethylenes of high MFI with the particular equipment used the upper temperature was set by the first observance of flashing thin films of excess polymer on the moulded part Qenos Technical Guides INJECTION MOULDING 5 ae fl TAM TA ae MLL LOW DENSITY POLYTHENES mam GP POLYSTYRENE me POLYPROPYLENES NYLON HIGH DENSITY POLYTHENE Typical injection moulding grade PLUNGER PRESSURE 20 000 ib jin 1400 kg Jom CYLINDER TEMPERATURE C SPIRAL FLOW LENGTH in Figure 10 Spiral Flow Curves for some Typical Thermoplastics Surface Finish The second facto
155. nded for use with any alcoho solvent to clean the fusion area given the possibility of dirt detergent or fabric conditioner being transferred into the fusion zone Other important factors relating to this procedure e Ensure wipes are saturated with alcohol i e have not dried out To avoid contamination ONLY wipe the peeled fusion zone area e Only use the wipe once Do not touch the prepared pipe surface sweat sunscreen barrier cream dirt and skin oils are all potential sources of contamination Disposable latex or nitrile gloves are recommended when handing the wipes for preparation of the surface Ensure alcohol left by the wipe on the cleaned surface has evaporated and the prepared surfaces are completely dry before assembling the joint Refer to the electrofusion fitting supplier for the correct selection of alcohol wipes Remove the fitting from its packaging and check that the bore of the fitting is clean The bore of the fitting may be wiped with an approved isopropyl wipe if necessary NOTE Ensure the cleaned bore is completely dry before proceeding It is good practice to install the fitting to both pipe ends at the same time However if this is not possible open only one end of the fitting package and install the fitting to the pipe end The package can then be fixed in place to enclose the exposed end of the fitting to keep the fitting bore free from contamination 29 FOI Document
156. ne is high and that a change of 5 C in room temperature will alter the length of a moulding by as much as 0 001 cm cm Some examples of shrinkage are illustrated in Figure 18 Because it is usually on small mouldings that close dimensional control is required Figure 18 shows where sink marks and warping are likely to occur in such finished items INJECTION MOULDING 5 As Designed As Molded Boss in corner Thinner walls on boss causes sink eliminates sink Thinner walls give Thick walls accurate parts causes sink warp 2 excess shrink Figure 18 The Effects of Processing Conditions on Shrinkage and Warping Qenos Technical Guides 16 FOI Document 12 5 INJECTION MOULDING Distortion of Polyethylene Mouldings Distortion or warping of polyethylene mouldings can be a problem on flat articles which do not have a solid rim or walls to keep the base firmly held in position The explanation of this warping is mainly due to polymer orientation and differential crystallisation across the moulding see Figure 19 Figure 19 Processing Conditions Causing Polymer Orientation which Leads to Warping When the mould is first filled a hot moulding will be made As the mould fills the long thread like polyethylene molecules would tend to be oriented in the direction of flow i e radially outwards but as the moulding cools a radial shrinkage will occur which is greater
157. ng at slower output rates the time of contact will be longer and consequently a lower cylinder temperature can be used and the difference between it and the melt temperature can be reduced to about 5 C Similarly a moulding containing a thick section will require a lower cylinder temperature than will a moulding of equal weight but of thinner section This is because the thick moulding will require a longer cooling time and thus a longer cycle time than the thinner moulding therefore the material will be in contact with the heated cylinder for a longer time and its temperature will more nearly approach that of the cylinder A less common cause for the melt temperature to be different from the cylinder temperature is frictional heating of the material as it passes through the gate Qenos Technical Guides FOI Document 18 Y if material is injected rapidly through a small gate the heat generated may be sufficient to raise the melt temperature above that of the cylinder From these examples it is clear that it is not possible to predict the exact cylinder temperature that must be used to obtain a given melt temperature but that it is necessary to choose a Suitable cylinder temperature as a starting point and then to make adjustments based on visual inspection ofthe mouldings and on considerations of frozen in strain For grades with MFI above 20 g 10 min the suggested starting temperature is 210 C and for grades with MFI below
158. ng it by prepaid post to the National Manager TariffBranch Australian Customs Service Customs House 5 Constitution Avenue CANBERRA ACT 2601 or delivering it to the ACT Regional Office located at Customs House Canberra or sending it by facsimile to 02 6275 6376 or e e mailing it to tarcon customs gov au Polyethylene m ata Glance FR Alkadyne PE100 Pipe Extrusion Grades High Density olack PE100 type resin certified to AS NZS 4131 for use in pressure pipes and fittings Excellent low 0 961 sag properties and throughput suitable for the majority of PE100 pipe dimensions High Density black PE100 type resin certified to AS NZS 4131 for use in pressure pipes and fittings Exceptional 1 ena l iii low sag properties and throughput suitable for the most challenging pipe dimensions HDF193N 0 9520 High Density natural resin for extrusion into a full range of non standard pipe products and as a base for PE100 l type striping and jacket compounds Notes ASTM D1505 D2839 Alkadyne PE Pipe Extrusion Grades MD0898 0 952 0 9420 Medium Density natural resin for extrusion into a full range of non standard pipe products and as a base for PE80 type striping and jacket compounds AAA 0 954 High Density natural high molecular weight resin for extrusion into a full range of non standard pipe products DN 0 943 Medium Density natural high molecular weight resin for extrusion into
159. ns where outstanding stiffness toughness optical and sealing properties are desirable or for downgauging of existing film structures Stretch cling films with addition of appropriate cling additive and other film applications where outstanding toughness optical and sealing properties are desirable or for downgauging of existing film structures Notes VH Very High Slip H High Slip M Medium Slip Alkatane HDPE Film Grades Melt Index E Grade 9 10 min Density 190 C 2 16kg gom GM4755F 0 10 0 955 0 960 Notes ASTM D1505 D2839 Applications LDPE and LLDPE films for heavy duty applications Moisture barrier and blend component into LDPE and LLDPE films to enhance stiffness Blend component in core layer for high clarity coextruded films Alkatane HDPE Blow Moulding Grades Melt Index Grade 9 10 min 190 C 2 16kg HDCAA0 0 06 HD1155 0 07 GM7695 0 09 GF7660 0 30 GE4760 0 60 HD51 48 0 83 Notes ASTM D1505 D2839 Density g cm Applications 0 9531 Large part blow mouldings especially blow moulded self supported drums and tanks 25 220 litres Exceptional ESCR 0 9531 Large part blow mouldings including 25 litre to 220 litre tanks and drums Exceptional ESCR 0 95411 Blow moulded containers including household and industrial chemical HIC Suitable for la
160. nt into separate streams which fail to fuse together when the mould is full This effect is aggravated by inadequate pressure on the melt or too low a melt temperature The weld lines formed may be barely visible to the naked eye but they can readily be detected by immersing the moulding in carbon tetrachloride at a temperature of 50 to 70 C where fissures will open up Such weld lines are quite common and cause splits in the walls of thin containers see Figure 22 9 k wit nN A ntti AN 4 56 6 2 Figure 22 Failure Due to Flow Weld Lines CONDITIONS FOR MOULDING POLYETHYLENE In the injection moulding process the moulder is able to control several operating variables each of which can influence the quality of the mouldings or the rate at which they are produced These variables are The temperature of the machine cylinder The temperature of the mould The injection variables i e the injection pressure and speed and the cycle time 18 The aim of the moulder must be to choose for each particular material and moulding the correct combination of variables which will produce perfect mouldings as easily and as quickly as possible The position is somewhat complicated by the fact that a moulding that looks perfect may not in fact be so because of the presence of frozen in strain and therefore the choice of moulding conditions must take into account their effect not only on the appearance of t
161. ntly long testing times the typical pipe curve obtained from this plot shows three different regions or stages see Figure 23 Hoop Stress Application Pressure l Il brittle failure O lt 0 Figure 24 Pipe Failed in Ductile Mode i Slow crack growth PE A AS AA Ductile failure indicates ultimate pressure bearing capability of the pipe The flat branch therefore marks the stress limit for ductile failure 1 Ductile Failure o gt S i 1 ill ait Temperature C i e aro CE ee Oxidation and degradation fi TTT ia of polymer Application Time Z j Figi tue E a Figure 23 Representation of Pipe Curve According to the ing 3 stage Model Illustration by Studsvik Material AB now Sin LHS known as Exova nef ae ee ee ir a ate A Time to failure Ars Starting with short endurance times a flat straight A branch can be seen which is followed by a straight steep Figure 25 Qualitative Interpretation of Pipe Curve as branch With the PE 100 grades currently used this steep Generated on PE 80 Pipe Grade Testing was According branch does not begin for 10 000 hours even at elevated to ISO 9080 temperature e g 80 C After very long endurance times a vertical stress independent branch of the curve could be expected to follow for testing at 80 C effectively indicating resin has degraded due to long exposure to high temperature
162. ntre stops are used the maximum insertion depth should be clearly marked on the pipe ends after the pipe surface has been prepared and cleaned prior to jointing 26 mm DN of Pipe mm 15 6 200 199 2 19 6 228 224 2 24 6 250 249 2 31 4 280 279 2 39 4 316 314 2 49 4 356 354 2 62 4 400 399 2 74 4 450 449 2 39 2 500 499 2 109 2 560 559 2 124 2 630 629 2 139 2 710 709 2 159 2 800 1992 TOZ Equipment 1 Control Box The control box input supply should be from a nominal 240V generator suitable to drive inductive loads and phase cut systems commonly of about 5kVA capacity Some fitting suppliers may consider smaller capacity generators acceptable for small diameter fittings The nominal output of the generator should be 240V 10 between no load and full load It should be noted that electrofusion control boxes may generate considerable heat Refer to the supplier of the controller to ensure the box has an integrated cooling system Qenos Technical Guides FOI Document 6 14 AR A AA A AN a A ee gt PIPE AND TUBING EXTRUSION 7 Control boxes should include safety devices to prevent The benefits of alignment clamps are that they voltages greater than 42V ACfor a 40V system being present at the control box output The safety device should operate in less than 0 5 sec e Allow for re rounding of pipes particularly coiled pipes that are oval e Provide correct assembly and alignment of the pipe with the fitting
163. o 2 min in an acidified dichromate solution a typical solution is 100 cm of concentrated sulphuric acid 50 cm water and 15 g of potassium dichromate e Removed from the bath washed thoroughly and dried Qenos Technical Guides FOI Document 12 Oy The big disadvantage of this method is the need to handle acid solutions the main advantage is that every part of the surface provided it is clean is treated in the same way Tests for Pre treatment Itis obviously desirable to be able to test the effectiveness of any pre treatment to ensure good adhesion of the finished coating Several tests can be used of which those based on wettability of the surface are popular because of their simplicity Peel Test This test involves the use of a solvent free pressure sensitive tape Such a tape has little affinity for an untreated polyethylene surface and is removed fairly easily whereas it will bond strongly to a treated surface A suitable tape is No 850 supplied by Minnesota Mining and Manufacturing Co Ltd 3M The tape is rolled on to the moulding by means of a rubber roller and is then peeled off under standard conditions using a tensometer By noting the peel strength recorded a quantitative indication of the treatment level can be obtained Since decorative coatings vary in their adhesion to polyethylene surfaces there is no basic correlation between peel strength and adhesion However it has been found that t
164. ocedure for each joint should be kept as required 2 Equipment Servicing and Calibration Electronic or written records of appropriate servicing and calibration should be kept The minimum information to be recorded is given in Appendix 1 3 Training Instructions should be provided by Registered Training Organisations RTO s that are accredited by State Territory Training Authorities under the Australian National Training Authority ANTA guidelines and complying with PMB 01 Competency Standards prepared by Manufacturing Learning Australia Qualification Framework for the plastics rubber and cable making industry The RTO s providing training in all forms of welding plastics pipeline systems must have staff qualified in presenting courses that meet competency standards covered by sections PMBWELD301A through to PMBWELD311A in PMB 01 The RTO s normally issue an accreditation certificate to successful candidates completing the training course and maintain a register of accredited welders Quality Assurance To achieve consistently good quality fusion joints as outlined by these guidelines manufacturers and installers should operate a quality system in accordance with the principles of AS NZS ISO 9001 Assessment of the achievement would take the form of an audit against the points below Independent testing of fusion joints may also be required 37 FOI Document 6 7 PIPE AND TUBING EXTRUSION Management Responsibili
165. ocument 6 7 PIPE AND TUBING EXTRUSION NOTCH RESISTANCE SCG OF PE PIPES Behind the phenomenon of creep strength and notch resistance lays the process of slow crack propagation The brittle fracture observed is initiated by small defects or notches in the pipe An increase in temperature accelerates this process The fracture diagram see Figure 23 shows a small crack running lengthwise along the pipe As a partially crystalline polymer polyethylene reacts to the stress concentration at the crack tip notch root by forming a crazing zone This crazing zone develops into a fully propagating crack that leads to a brittle type failure Application stress which could lead to craze initiation and crack propagation is of the magnitude that is observed for the hoop stress the pipe experiences in operation due to the presence of an applied operating pressure Therefore it is widely accepted in the field that the most application relevant pipe property is its resistance to slow crack growth in other words its susceptibility to brittle failure Notch Test The notch test according to ISO DIS 13479 may be regarded as a variant of the pressure creep test in which crack propagation resistance is specially assessed Unlike the creep test under internal pressure the failure point in this test is predetermined by notching In this test four notches are cut in the outer surface of the pipe specimen in the longitudinal direction
166. of the melt temperature The important point to note is that the cylinder temperature as indicated on the control panel instruments is not necessarily the same as the melt temperature because the melt temperature depends on the rate at which the material passes through the cylinder and through the gate of the mould as well as on the cylinder temperature For example if the shot weight is almost as large as the shot capacity and mouldings are being produced very rapidly the material will be in contact with the heated cylinder for only a short time before being injected and may not have time to reach the temperature of the cylinder but may be as much as 30 C lower On the other hand in a machine of larger capacity that is working at slower output rates the time of contact will be longer and consequently a lower cylinder temperature can be used and the difference between it and the melt temperature can be reduced to about 5 C Similarly a moulding containing a thick section will require a lower cylinder temperature than will a moulding of equal weight but of thinner section This is because the thick moulding will require a longer cooling time and thus a longer cycle time than the thinner moulding therefore the material wil be in contact with the heated cylinder for a longer time and its temperature will more nearly approach that of the cylinder A less common cause for the melt temperature to be different from the cylinder temperature is fri
167. of the mouldings or the rate at which they are produced These variables are The temperature of the machine cylinder e The temperature of the mould e The injection variables i e the injection pressure and speed and the cycle time 18 8 NN The aim of the moulder must be to choose for each particular material and moulding the correct combination of variables which will produce perfect mouldings as easily and as quickly as possible The position is somewhat complicated by the fact that a moulding that looks perfect may not in fact be so because of the presence of frozen in strain and therefore the choice of moulding conditions must take into account their effect not only on the appearance of the moulding but also on frozen in strain In the following sections each variable will be discussed in the light of these two considerations together with other relevant factors such as the use of mould release agents Finally a table summarising some common moulding faults their causes and remedies is given see Appendix 2 Cylinder and Melt Temperatures The melt temperature is the temperature of the polyethylene as it enters the mould Depending on the grade of polyethylene being used the temperature should lie in the range 160 280 C In practice it is not convenient to measure the melt temperature directly and it is therefore necessary to use the machine cylinder temperature as a guide to the value
168. oning the Customs Information Centre on 1300 363 263 agree in submitting this form by electronic means including facsimile that for the purposes of Sub Section 14 3 of the Electronic Transactions Act this submission will be taken to have been lodged when itis first received by an officer of Customs or if by e mail when itis first accessed by an officer of Customs as specified in Sub Section 269F 4 of the Customs Act Full Name Position Held Az Date 24 October 2014 NOTE SECTION 234 OF THE CUSTOMS ACT 1901 PROVIDES THAT IT IS AN OFFENCE TO MAKE A STATEMENT TO AN OFFICER THAT IS FALSE OR MISLEADING IN A MATERIAL PARTICULAR WHEN THIS FORM HAS BEEN COMPLETED LODGE IT WITH CUSTOMS BY posting it by prepaid post to the National Manager Tariff Branch Ausiralian Customs Service Customs House 5 Constitution Avenue CANBERRA ACT 2601 or delivering it to the ACT Regional Office located at Customs House Canberra or sending it by facsimile to 02 6275 6376 or e mailing it to tarcon customs gov au 26 os 90 20 CE 51 Alkadyne PE100 Pipe Extrusion Grades HDF1938 EA P i High Density black PE100 type resin certified to AS NZS 4131 for use in pressure pipes and fittings Excellent low sag properties and throughput suitable for the majority of PE100 pipe dimensions High Density black PE100 type resin certified to AS NZS 4131 for use in pressure pipes and fittings Exce
169. ontrol The installer should ensure that fusion jointing procedures as well as servicing and maintenance of fusion jointing equipment are carried out in accordance with the specified guidelines 38 3 Inspection and Testing a Inspection of goods received and used on site The installer should ensure that incoming pipe fittings and fusion jointing equipment are not used until they have been inspected and confirmed as conforming to specified requirements including appearance and marking Any non conforming items should be identified recorded and segregated b Final inspection and testing At the commencement of each contract the frequency and type of inspection by the installer should be agreed with the client and documented c Inspection and test records The installer should establish and maintain electronic and or written records of appropriate fusion jointing procedures servicing and calibration details in accordance with these guidelines 4 Corrective Action The installer should establish and maintain procedures to show evidence of e Review of non conformities including customer complaints as a result of poor quality joints e Determining the causes of poor quality joints Evaluating the need for action to ensure poor quality joints do not recur Determining and implementing action needed e Recording the results of action taken and e Reviewing corrective action taken 5 Preservation of Product The installer
170. out degrading the material However for polyethylenes of high MFI with the 3 TE particular equipment used the upper temperature was set by the first observance of flashing thin films of excess polymer on the moulded part 8 8 CYLINDER TEMPERATURE F mm LOW DENSITY POLYTHENES GP POLYSTYRENE POLYPROPYLENES NYLON meam HIGH DENSITY POLYTHENE Typical injection moulding grade 2 PLUNGER PRESSURE 20 000 Ib Jin 1400 kg Jem CYLINDER TEMPERATURE C 8 SPIRAL FLOW LENGTH Figure 10 Spiral Flow Curves for some Typical Thermoplastics Surface Finish The second factor which may prevent moulding being carried out at the peak of the output curve is the requirement to obtain a good surface finish on the moulded article It can be seen from Figure 11 that the gloss of a polyethylene moulding improves with increasing cylinder temperature and that mouldings produced at the lower temperatures have chevron marks or rings on the surface see Figure 12 When mouldings with an even glossy surface are required it may be necessary to mould at a cylinder temperature which is higher than that which corresponds to the fastest output rate Qenos Technical Guides 9 5 INJECTION MOULDING 110 KAT FAA N o AAA in AP TTD Figure 12 Photo Illustrating Chevron Rings on an Injection Moulded Surface OUTPUT RATE NUMBER
171. pes single screw extruders are used To achieve the high throughput required for pipe production high speed extruders with forced conveying feed systems have been developed and widely used throughout the industry See Figure 3 Spiral grooved feed bush Figure 3 lllustration of a Single Screw Extruder with a Spiral Grooved Feed Bush used for High Polymer Throughput These extruders have a cooled grooved feed bushing which is thermally insulated from the extruder barrel As a result the conveying efficiency of the pelleted feedstock is greatly enhanced achieving higher extruder throughput For optimal operation of a grooved bush system it is required to keep the bush cold to prevent melting of the pellets and fouling of grooves In order to ensure effectiveness of the grooved zone these systems are cooled with a high flow of chilled water e g water flows of 10 L min and water temperature of approximately 10 20 C Recent developments in screw design have seen the creation of barrier screws with enhanced melting capability through the incorporation of a second spiral flight that separates the polymer melt from the unmelted product see Figure 4 In addition to the barrier screw mixing elements are generally used at the melt delivery end of the screw to assist with homogenisation of the polymer melt see Figure 5 Figure 4 Schematic of a Barrier Flighted Screw incorporating a Pin Mixer
172. pipe sag Ensure minimum of 1 5 hrs drying of resin at 70 90 C Adjust extruder temperature setting and back pressure accordingly The proposed solutions in this guide are based on conditions that are typically encountered in the manufacture of products from polyethylene Other variables or constraints may impact the ability of the user to apply these solutions Qenos also refers the user to the disclaimer at the beginning of this document 42 Qenos Technical Guides FOI P 6 PA A a A A A PIPE AND TUBING EXTRUSION 7 BIBLIOGRAPHY FURTHER READING 1 Janson L E Plastic Pipes for Water Supply and Sewage Disposal 4 Ed Borealis 2003 2 Bromstrup H PE100 Pipe Systems 2 Ed Vulkan Verlag GmBH 2004 3 Hensen F Plastic extrusion Technology Hanser Verlag 1997 4 Michaeli W Extrusion Dies Hanser Verlag 2003 5 Technical Manual Materials for Pipe Extrusion Hostalen Lupolen Processing and Applications Basell Polyolefins 6 Reliable Pipelines with Hostalen CRP 100 Properties Practical Experience and Standards Hoechst 7 Battenfeld Extrusionstechnik SMS Group Pipe Extrusion Plant 8 AS NZS 4131 2010 Polyethylene PE compounds for pressure pipes and fittings 9 AS NZS 4130 2009 Polyethylene PE pipes for pressure applications 10 ISO 9080 2003 Plastic piping and ducting systems Determination of the long term hydrostatic strength of thermoplastics materials in form by extrapolation
173. polyethylene should be used b What are the correct moulding conditions To do this it is necessary to know how the different types of polyethylene used for injection moulding differ from each other first in the way in which they are processed and j Screw second in the physical properties of the moulded article 2a Classification of Polyethylenes The most important variables which characterise a polyethylene are its Melt Flow Index MFI and density a gt na 7 16 Melit Flow Index MFI MFI is a measure of melt viscosity at low shear rates and is defined as the weight in grams of polyethylene extruded in 10 minutes from a Special plastometer under a given load at 190 C Thus a low MFI corresponds to a high melt viscosity Figure 3 shows how the MFI is related to the number average molecular weight of the polymer 1 000 000 Met Viscosity poises 100 000 As caleudelod from e Mardi mel Eos Hras Sete lada a Number avergae molecular weight g MELT VISCOSITY Poisesr 8 Injection Moulding is fundamentally simple easy to operate MELT FLOW INDEX and is capable of producing a very wide variety of industrial and domestic articles Of all thermoplastics polyethylene is one of the easiest to injection mould The resin flows easily into difficult cavities its viscosity changes smoothly 02 07 2 3 2 n 200 NUMBER AVERAGE MOLECULAR WEIGHT Figure 3 Relat
174. proper extruder temperature settings Poor resin extruder design match versus extruder OEM specifications for throughput Extruder not set as per OEM design specifications Resin contains foreign particles contaminated with gels etc Degraded resin coming off the die during extrusion Potential Solution s Action s Refinish tip or die exit edges to sharp and uniform about the diameters Adjust temperature of the die exit accordingly Check OEM guaranteed extruder throughput and run extruder within specifications Adjust temperature setting according to OEM recommendations Discuss with resin supplier and implement actions to ensure extruder runs within OEM specifications Check with OEM and ensure compliance with design specifications Check with resin supplier for presence of gels etc Check regrind for contaminants Follow proper shut down procedures for extruder to avoid long exposure of resin to excessive temperatures Adjust the die setting spots in pipe wall Pipe out of round Improper die setting Hot and cold spots in die profile temp Uneven pipe drag downstream of the extruder Haul off slippage Vacuum calibrator and die not levelled well Check for uniformity in die heating Check for spots in cooling baths which could cause pipe drag Check and adjust haul off Uneven melt delivery from die extruder surging Check remedies for extruder surging Adjust the position of the vacuum bath rel
175. pt arrest of the initial crack to continued steady state crack propagation This method arrives at the Critical Pressure at which RCP occurs Alternatively tests can be carried out at the set pressure but varying test temperatures to determine the Critical Temperature at which RCP occurs see Tables 7 and 8 In designing a pipeline to carry gas at high pressure or at sub zero temperatures the RCP property of pipe resin needs to be considered and a safety factor must be taken into account For gas pipelines made from Qenos Alkadyne PE 100 grades the high RCP property ensures safe pipe line operation at high operating pressures as well as sub zero temperatures ZE UW FA Table 8 RCP Testing of PE 100 Pipe at a Fixed Temperature and Varying Pressure ESA FOI Document 6 US AAA AAA A AA AA A gt A A ER Y PIPE AND TUBING EXTRUSION Table 7 RCP Testing of PE 100 Pipe at a Fixed Pressure and Varying Temperature Crack Length AJo NO ae 5 Temperature Pressure C MPa 5 05 10 09 15 g5 20 05 25 OS le mm 120 135 165 360 300 l d dd 12 15 33 2 7 Results Crack Arrest Crack Arrest Crack Arrest Crack Arrest Crack Arrest The critical temperature T of the PE pipes 110 mm diameter SDR11 Qenos grade Alkadyne HDF145B at a pressure of 0 5 MPa is lower than or equal at 25 C Y 2 3 4 5 Pressure MPa 0 0 0 4 0 6 0 8 1 0 Crack Leng
176. ptional 1 iis low sag properties and throughput suitable for the most challenging pipe dimensions 0 9520 High Density natural resin for extrusion into a full range of non standard pipe srodlets and as a base iof PE100 i type striping and jacket compounds Notes ASTM D1505 D2839 Alkadyne PE Pipe Extrusion Grades MD0898 0 7 0 952 Medium Density black PE80B type resin certified to AS NZS 4131 for use in pressure pipes and fittings e sid 0 9421 Medium Density natural resin for extrusion into a full range of non standard pipe products and as a base for PE80 type striping and jacket compounds GM 7655 EE 0 9541 High Density natural high molecular weight resin for extrusion into a full range of non standard pipe products MDF 169 Medium Density natural high molecular weight resin for extrusion into a full range of non standard pipe products LLO228 1 7 0 923 Linear Low Density resin for use in pipe extrusion applications Notes ASTM D1505 D2838 D1238 190 C 2 16kg Alkadyne PE Wire and Cable Grades MDOS32 12 0 942 Designed for extrusion into a full range of wire and cable products where natural Medium Density resins are required MD0898 1 0 953 Designed as general purpose jacketing compound for buried wires and cables where abrasion and cut through l l resistance is required Notes ASTM D1505 D2839 Alkatane HDPE Tape and Monofilament Grades Melt Index me ne g 10 min 190
177. r which may prevent moulding being carried out at the peak of the output curve is the requirement to obtain a good surface finish on the moulded article It can be seen from Figure 11 that the gloss of a polyethylene moulding improves with increasing cylinder temperature and that mouldings produced at the lower temperatures have chevron marks or rings on the surface see Figure 12 When mouldings with an even glossy surface are required it may be necessary to mould at a cylinder temperature which is higher than that which corresponds to the fastest output rate FOI Document 18 78 5 INJECTION MOULDING OUTPUT RATE NUMBER OF MOULDINGS PER HOUR ies RIA AAA IAN UN OVA AS fe NO TO AMAN Cylinder Temperature Gloss is assessed both visually and by measuring the light reflected from the surface of mouldings made under standard conditions By the latter method gloss temperature curves can be plotted as shown in Figure 13 This not only shows the effect of cylinder temperature on gloss but also the very marked effect of MFI With a higher MFI high gloss mouldings can be produced at a lower cylinder temperature which allows for a faster output see Figure 13 10 Figure 11 Variations of Surface Gloss of Mouldings with 5 qe Figure 12 Photo Illustrating Chevron Rings on an Injection Moulded Surface UNITS OF GLOSS 140 160 180 200 20 240 260
178. re accredited by State Territory Training Authorities under the Australian National Training Authority ANTA guidelines and complying with PMB 01 Competency Standards prepared by Manufacturing Learning Australia Qualification Framework for the plastics rubber and cable making industry The RTO s providing training in all forms of welding plastics pipeline systems must have staff qualified in presenting courses that meet competency standards covered by sections PMBWELD301A through to PMBWELD311A in PMB O1 The RTO s normally issue an accreditation certificate to successful candidates completing the training course and maintain a register of accredited welders 31 FOI Document 6 3 7 PIPE AND TUBING EXTRUSION Electrofusion Saddle Jointing Electrofusion saddle jointing incorporates an electrical resistance element in the base of the saddle which when connected to an appropriate power supply melts and fuses the materials of the pipe and fitting together see Figure 41 Figure 41 Polymer Fitting that can be Welded onto a Pipe by Electrofusion Saddle Joining The effectiveness of this technique depends on attention to preparation of the jointing surfaces in particular the removal of the oxidised surface of the pipe over an area equivalent to the saddle base and the cleaning of the jointing surfaces and freedom from contamination Although PE is comparatively inert the outer surface of the pipe will become ox
179. reatments giving peel strengths greater than about 120 g cm will result in satisfactory adhesion of most coatings Decorating Methods for Treated Surfaces Two methods that can be used are e Silk screen printing Vacuum metalising Silk screening This is essentially a stencilling process in which the stencil takes the form of a silk nylon or metal screen which has been made porous by a photographic process over areas corresponding to the design to be printed The screen is held taut in a wooden frame which also serves as a reservoir for the ink In use the screen with ink on its upper surface is placed in contact with the article anda rubber squeegee is drawn over the screen thus forcing ink through the porous area on to the article Qenos Technical Guides INJECTION MOULDING 5 Screen printing has the great advantage of low capital cost particularly when the operation is done manually Fully automatic units are available The main disadvantage of silk screening is that no more than one colour can be applied at one pass If additional colours need to be applied then the moulding must be dried before the next colour is applied Vacuum Metallising In vacuum metallising a thin continuous layer of metal is deposited onto a prepared surface by vaporising the metal under high vacuum and condensing it on the surface In practice a lacquer is applied to the pre treated polyethylene as a base coat This serves to smooth o
180. required between the MFI e g for ease of processing and the density e g which affects the level of shrinkage in order to minimise the level of internal stress Generally higher density polyethylenes would require a lower MFI and vice versa For example a polyethylene of MF 20 g 10 min should generally not exceed a density of 0 918 g cm Although such rules of thumb are only general recommendations other considerations of mould design and the generation of weld lines in the finished part are factors that need to be reviewed when assessing the strength of the moulding For articles not expected to be stressed in service cracking caused by frozen in strain is the hazard to be avoided A polyethylene of higher MFI is preferable because it is easier to mould such a polyethylene to give a low level of frozen in strain Summary In general polyethylenes of high MFI and low density are most commonly used for injection moulding because they give the highest outputs have the best mould filling properties and give the glossiest mouldings For applications in which mouldings are likely to be stressed in service polyethylenes of low MFI must be used If increased stiffness is required polyethylenes of higher density are necessary but these must have a lower MFI to prevent them from becoming brittle and to improve resistance to environmental and mechanical stress cracking For non stressed applications frozen in
181. rger part mouldings Exceptional ESCR 0 95911 Household and industrial chemical HIC containers including detergent and pharmaceutical bottles Excellent ESCR 0 964 Blow moulded water dairy and fruit juice bottles FOI Document 17 Applications Purpose Ener Bammer Film lt SS 0 962 High speed dairy packaging applications and other thin walled bottles such as milk cream fruit juice and cordial Qenos imported polymers and additives Complementing our Australian manufactured Polyethylene grades Qenos acts as a local distributor for a wide range of imported polymers and additives including rubbers elastomers adhesives plastomers EVA BOPP Film EPS antioxidants and titanium dioxide For the full Qenos range please refer to the Qenos website Customer Service or your Account Manager Melt Index according to ASTM D1238 unless otherwise annotated Density according to ASTM D1505 unless otherwise annotated FOI Document 17 Alkathene LDPE Extrusion Coating Grades Melt Index m kia Grade 9 10 min 190 C Density Applications 2 16kg glem Applications including milkboard and fabric extrusion coating where very good drawdown low moisture vapour XLC177 45 0 923 eet transmission rates and excellent hot tack are desirable Additive free Liquids packaging and other sensitive food packaging laminates where excellent heat seal low extractables
182. rised Hand Circular Saw Figure 36b Motorised Hand Circular Saw Cutter 5 Weather Shelter Suitable shelter should be used to provide shade and protection for the pipe fittings and equipment against adverse weather conditions and contamination of the jointing surfaces by dust and or moisture which can result in unsatisfactory joints Fittings should only be removed from their original packaging immediately before using for jointing 28 Electrofusion Jointing Method Preparation of Pipe Ends i Ensure hands and tools are free from surface contaminants such as barrier hand cream sun screen detergent and surfactant used in horizontal directional drilling ii Check equipment is complete clean undamaged in working order and protected by shelter ili Ensure there is sufficient space to permit access to the jointing area In a trench a minimum clearance of 150 mm is required all round Larger clearances may be needed for large nominal pipe sizes depending on the tool used iv Check that the pipe ends to be jointed are cut square to the axis and any burrs and swarf are removed v Clean the fitting bore followed by the pipe surface with a new approved alcohol wipe to remove traces of dirt mud and other contamination When using slip couplings clean the entire area where the fitting will pass over the pipe The area of the pipe to be fusion jointed may be washed with clean water if necessary and dried with lint free mat
183. roughput suitable for the majority of PE100 pipe dimensions HDF193N 0 3 0 952 High Density natural resin designed for extrusion into a full range of non standards pipe products and as a base for PE100 Type striping and jacket compounds HDF193N is not UV stabilised High Density black PE100 Type resin certified to AS NZS 4131 for use in pressure pipes and fittings Exceptional low sag properties and throughput suitable for the most challenging pipe dimensions Medium Density black PE80B Type resin certified to AS NZS 4131 for use in pressure pipes and fittings HDF145B 0 2 0 961 MD0898 0 7 03952 MD0592 0 6 0 942 Medium Density natural resin designed for extrusion into a full range of non standards pipe products and as a base for PESOType striping and jacket compounds MDO592 is not UV stabilised Medium Density natural high molecular weight resin designed for extrusion into a full range of non standards pipe products MDF169 is not UV stabilised Linear Low Density resin for use in pipe extrusion applications such as trickle irrigation LLO228 is not UV stabilised MDF169 1 0 0 943 LLO228 Lars 0 923 LLO228 190 C 2 16 kg Melt Index according to ASTM D1238 Density accodring to ASTM D1505 6 Qenos Technical Guides FOI Document 6 CLASSIFICATION OF POLYETHYLENE PIPE AND PIPE COMPOUNDS Specifications for polyethylene compounds for use in pressure pipes and pipes for pressure applications in Austral
184. s almost solidified and therefore orientation introduced at this stage relaxes slowly This can result in a highly strained region being formed near the sprue gate The strain may be sufficient to initiate stress cracking and therefore the dwell time and injection pressure must be kept to a minimum 20 Figure 24 shows mouldings made from the same type of polyethylene at the same cylinder temperature but using different injection dwell times and pressures The samples moulded at high pressure with a long dwell time appear indistinguishable from those moulded under more favourable conditions But when the mouldings are cut open it can be seen that excessively high pressures and long dwell times can result in a thickening of the base near the sprue which in extreme cases can result in thickness increases of approximately 30 When the mouldings were then subjected to an accelerated service test in an active environment the effects of too much packing constituted a very serious cracking hazard Mould Filling Time On some machines the injection speed can be varied virtually independently of the injection pressure by means of a flow control valve In long thin flow paths the polyethylene will cool rapidly and this section will contain a fairly high degree of strain In addition thin walled mouldings require higher pressures to fill the mould and therefore packing may occur before the extremities of the flow path have been reached Th
185. s test involves the use of a solvent free pressure sensitive tape Such a tape has little affinity for an untreated polyethylene surface and is removed fairly easily whereas it will bond strongly to a treated surface A suitable tape is No 850 supplied by Minnesota Mining and Manufacturing Co Ltd 3M The tape is rolled on to the moulding by means of a rubber roller and is then peeled off under standard conditions using a tensometer By noting the peel strength recorded a quantitative indication of the treatment level can be obtained Since decorative coatings vary in their adhesion to polyethylene surfaces there is no basic correlation between peel strength and adhesion However it has been found that treatments giving peel strengths greater than about 120 g cm will result in satisfactory adhesion of most coatings Decorating Methods for Treated Surfaces Two methods that can be used are e Silk screen printing e Vacuum metalising Silk screening This is essentially a stencilling process in which the stencil takes the form of a silk nylon or metal screen which has been made porous by a photographic process over areas corresponding to the design to be printed The screen is held taut in a wooden frame which also serves as a reservoir for the ink In use the screen with ink on its upper surface is placed in contact with the article and a rubber squeegee is drawn over the screen thus forcing ink through the porous ar
186. sequent difficulties in subsequent operation Injection Variables The injection variables will be considered under two headings injection pressure and dwell time and mould filling time Injection Pressure and Dwell Time To produce good mouldings both quickly and economically the injection pressure should be kept to a minimum and the dwell time made as short as possible Increasing the packing of an additional volume of polyethylene into the mould during the dwell time to compensate for the shrinkage of the polyethylene due to crystallisation is also important The degree of packing should be kept to a minimum because the excess polyethylene is forced into the mould cavity when the melt has almost solidified and therefore orientation introduced at this stage relaxes slowly This can result in a highly strained region being formed near the sprue gate The strain may be sufficient to initiate stress cracking and therefore the dwell time and injection pressure must be kept to a minimum 20 Figure 24 shows mouldings made from the same type of polyethylene at the same cylinder temperature but using different injection dwell times and pressures The samples moulded at high pressure with a long dwell time appear indistinguishable from those moulded under more favourable conditions But when the mouldings are cut open it can be seen that excessively high pressures and long dwell times can result in a thickening of the base near the sprue
187. sess the mould filling properties of materials It involves the measurement of the length of spiral obtained when moulding under standard conditions using the special mould shown in Figure 8 In order to compare different types of polyethylene the cylinder temperature mould temperature cycle time injection speed and pressure are all held constant and under these conditions the length of spiral obtained gives a good comparative evaluation of the mould filling properties of the polyethylenes being used id dd Figure 8 Spiral Flow Mould Figure 9 shows that the main factor which influences ease of mould filling is MFI Although density undoubtedly has an effect on the spiral flow length for polymers with constant MFI this effect is relatively small Qenos Technical Guides FOI Document 12 UY INJECTION MOULDING 5 CONSTANT DENSITY 7 o 5 EL 76 102 127 3 SPIRAL FLOW LENGTH cm LENGTH OF SPIRAL cm HA A A 20 a MELT FLOW INDEX 8 g 220 of Polyethylenes of Constant Density AA A feature of the spiral flow test is that it can be applied to all injection moulding materials Figure 10 shows a chart on which the spiral flow length has been plotted against a series of cylinder temperatures for a range of polymers For most materials the temperatures used range from the lowest at which a readable flow length can be obtained to the highest that can be used with
188. sity e g a polyethylene of density 0 930 g cm will shrink more than a polyethylene of density 0 918 g cm Gating shrinkage is usually greater when pin gates are used than when sprue gates are used Because the above variables have such a marked effect on shrinkage it is clear that in order to maintain accurate dimensions close control of moulding conditions is essential Cooling channels must provide adequate and even control of mould temperature over the whole mould Cycle time control is of equal importance especially for precision work Injection pressures should be controlled and the values checked regularly on a gauge A point which must always be kept in mind when specifications call for close moulding tolerances is that the coefficient of thermal expansion of polyethylene is high and that a change of 5 C in room temperature will alter the length of a moulding by as much as 0 001 cm cm Some examples of shrinkage are illustrated in Figure 18 Because it is usually on small mouldings that close dimensional control is required Figure 18 shows where sink marks and warping are likely to occur in such finished items Qenos Technical Guides INJECTION MOULDING 5 As Designed As Molded Thinner walls on boss eliminates sink Boss in corner causes sink Thinner walls give Thick walls accurate parts causes sink warp amp excess shrink Figure 18 The Effects of Processing Conditions on Shrinkage
189. ss Impact Properties Environmental Stress Cracking Mechanical Stress Cracking Summary SOME ASPECTS OF DESIGNING MOULDS FOR POLYETHYLENE Shrinkage of Polyethylene Mouldings Distortion of Polyethylene Mouldings Mould Design Choice of Polymer Moulding Conditions Weld Lines Flow Weld Lines CONDITIONS FOR MOULDING POLYETHYLENE Cylinder and Melt Temperatures Appearance of Mouldings Frozen in Strain Mould Temperature Injection Variables Injection Pressure and Dwell Time Mould Filling Time summary OO NN DOD O O pa es Ss p peo js fa pE mK Roa pA PA RP RR FE OoNNN OD pb hb MW NNNFRP BRB pp OooeGo 6 OG Gf Qenos Technical Guides FOI Document 12 Lp INJECTION MOULDING 5 MOULDING FAULTS 21 MOULD RELEASE AGENTS 22 DECORATING POLYETHYLENE MOULDINGS 22 Decorating Untreated Polyethylene 22 Hot Stamping e Labelling Ez Embossing 22 Decorating Treated Polyethylene 22 Pre treatment 22 Flame Treatment Le Chemical Treatment ao Tests for Pre treatment 23 Peel Test 23 Decorating Methods for Treated Surfaces 23 Silk screening 23 Vacuum Metallising 23 Tests for Finished Coatings 23 Scratch Test 23 Scotch Tape Test 25 APPENDIX 1 FROZEN IN STRAIN 24 APPENDIX 2 INJECTION MOULDING TROUBLESHOOTING GUIDE 23 BIBLIOGRAPHY FURTHER READING 27 Qenos Technical Guides 3 INJECTION MOULDING 5 INTRODUCTION The purpose of
190. stralia in the last 2 years C YES NO Ifyes describe the goods made during this period Po ononno noron oonon nronnoasrororararurs roo rrnrroa rod rr dr dra rd VEC TOO AD OE Hem AIN SS OCA HU PP PRAIRIE PA ICAA rd OF OPEN ES IIA IIA AI AAA PACA III IIA AAA AAA MIAMI dr rr III GOD REFNTOATTTOTTUF ASAP EN AASA RIA IRA EPP ERE SEEKER EPG EE OEE RET ERED EOE KE POSES REF EE ES UE PTET PEPE ERE ATOP OTE SPE SESRF AAA rro PU PPT RT RE ET EOE EST IRALA NEIRA EA BAA ra rd SOUS TO DEAE NETS EP RAID IRALA VETS NANA AAA rr EES CRETE EP EEE PEPER E ESE OO TE SORE OP EP PPE PER PEE PRD PERNA ATE HT AAA DA or rr ED F Can the goods be produced with existing facilities Jyes Ino G Are you prepared to accept an order for the goods YES C NO What was the first date on which you were prepared to accept an order 1 11 2003 Are the goods still in production YES NO If the answer is no when did production cease If production has ceased and goods are held in stock please estimate the date by which stock is expected to be sold based on past sales information and attrition rate of the local goods FOI Document 2 Sb 9 Provide any additional information in support of your objection NOTES a Section 269K and 269M ofthe Customs Act 1901 require that a submission opposing the making ofa TCO bein writing bein an approved form contain such information as the form requires and be signed in the manner indicated in the
191. stralian labour and ii the value of Australian materials and ili the factory overhead expenses incurred in Australia in respect of the goods Good s are to be taken to have been partly manufactured in Australia if at least one substantial process in the manufacture of the goods was carried out in Australia Without limiting the meaning of the expression substantial process in the manufacture of the goods any of the following operations or any combination of those operations DOES NOT constitute such a process a operations to preserve goods during transportation or storage b operations to improve the packing or labelling or marketable quality of goods c operations to prepare goods for shipment d simple assembly operations e operations to mix goods where the resulting productdoes not have different properties from those ofthe goods that have been mixed A Are the goods wholly or partly manufactured in Australia Yes _ No B Does the total value of Australian labour Australian materials and factory overhead expenses incurred in Australia represent at least 25 of the factory or works costs YES LI NO Specify each of the following costs per unit for the substitutable goods s47 Australian labour Australian materials Australian factory overhead expenses e imported content TOTAL Specify the date or period to which the costs relate 12 months to end Sep 2014 Attach a copy of the working papers
192. stralian materials and factory overhead expenses incurred in Australia represent at least 25 of the factory or works costs YES NO Specify each of the following costs per unit for the substitutable goods BN gt Australian labour Australian materials e Australian factory overhead expenses e imported content TOTAL Specify the date or period to which the costs relate 12 months ending 31 Aug 2014 Attach a copy of the working papers that were used to prepare the above costing information Those working papers should be supported by at least two extracts from the accounting records of the business Cc Is at least one substantial process in the manufacture of the goods carried out in Australia YES C NO If yes please specify at least one major process involved AAR E Arras rs grrr IA asa DAP OHASHAPIO FESSOR SEP REE PAP PER ASCE DEER PEERED RES EPASE AAA AAA AAA AAA A AEE ATH E ASE TEETH psa rr Lara sar BARA RAEE ETE PEE SED OLEACEAE ERE ED IA II AAA AAA Ads ss E BRO EAT aha Hate DA DARE ADELA AA ar AMO EEE PAPE THEE eRe tH DH aETREA arar sas sas oa sra aaa Ansa ra das AI AES E HERES LAA ass da AAA ra A AAA aaa naa RE EREAEAS ASE PE DAE SwE SH HASHAMALF HOS HER EH EHH HASH EAH Andar ddr arras COCR TEEPE DADRA THO AF ETE A EFA HATA EOCENE AIDA LAIA LIDERADA daa HRM dd dra HEE RET RAEFE REE FARE AOL EAA DAE ADAPTER TAUPE AICA IAEA AAA AFI AAA UIC DAA IIA EERE PER PDE IA AOC CAAT A PEATE FORRES R ESTEE AER E ENE PARTS RAR OD PEAKE
193. th a Ti mm 85 TIO 120 130 125 0 8 1 0 LL 12 dii Initiation Test Crack Arrest Crack Arrest Crack Arrest Crack Arrest The critical pressure P s4 of the PE pipes 110 mm diameter SDR11 Qenos grade Alkadyne HDF145B at a temperature of 0 C is higher than or equal to 1 0 MPa Table 9 Collation of ISO to Australian Standards for Set Items Equipment Installation and Testing International Standard Subject Matter Australian Standard ISO 8085 2 ISO 4437 ISO 4427 ISO 12176 1 ISO TS 10839 ISO 13593 ISO 1167 1 ISO 1167 3 ISO 1167 4 ASTM F2634 22 Fittings Gas Pipe Water Pipe Equipment Installation Tensile Test Hydrostatic Pressure Test Hydrostatic Pressure Test Hydrostatic Pressure Test High speed tensile test AS NZS4129 Section 6 AS NZS4130 AS NZS4130 Not applicable AS NZS2033 AS NZS 4645 Not applicable AS NZS 4130 Clause 10 1 AS NZS 4130 Clause 10 1 AS NZS 4130 Clause 10 1 Not applicable Qenos Technical Guides FOI Document 6 aa JOINING PE PIPES Butt fusion jointing of PE pipes and fittings Note Information is based on POP 003 prepared by PIPA Polyolefin Industry Pipe Association as a guide to the butt fusion of polyethylene pipe using AS NZS 4130 material as a basis Relevant Standards The butt fusion procedures and parameters are specified in ISO 21307 Plastics pipes and Fittings Butt Fusion Jointing Procedures for Polyethylene PE Pipes
194. that were used to prepare the above costing information Those working papers should be supported by at least two extracts from the accounting records of the business C Is at least one substantial process in the manufacture of the goods carried out in Australia Yes Ino If yes please specify at least one major process involved Horaria ro anar eh AL AAA AAA IA A AIR A ICAA AFI II AAA AAA ALA PA A arar AA A PAI AAA AAA AAA ar dr ar porron AAA AAA AAA AAA AED AAA PA AAA IIA IIA A IIA AAA AAA AAA IA AAA AA AA III AU AAA rereecvrert eC reerirecervererecrcerrererrrer ir eerrrerrere rrr itr rere re etree ee Pee ye CPOE TATA TER RA AI LARA ANA A AAA RANA UIAF PEER ER OND AAA AAA INDRA AAA AA a 44441000 GAOT IRENE REET AEE AEREA RAUL TET EAPO ROMP PAP LAA AAA UAB A ETD 5 FOI Document 2 51 7 PRODUCTION OF GOODS IN THE ORDINARY COURSE OF BUSINESS Answer 7 1 or 7 2 7 1 SUBSTITUTABLE GOODS OTHER THAN MADE TO ORDER CAPITAL EQUIPMENT Substitutable goods other than made to order capital equipment are taken to be produced in Australia in the ordinary course of business if a they have been produced in Australia in the 2 years before the application was lodged or b they have been produced and are held in stock in Australia or c they are produced in Australia on an intermittent basis and have been so produced in the 5 years before the application was lodged and a producer in Australia is prepared to accept an order to suppl
195. the art pipe manufacturing lines produced today vacuum tank sizing is the predominant method used to shape the pipe from the melt This includes the E Er manufacture of the very largest pipes that have dimensions A e Y a io A of 2000 mm Unlike vacuum sizing the internal pressure _ a o sizing method where a positive pressure is built up Figure 10 Sizing Sleeve for Vacuum tank Sizing within the pipe through the use of a floating plug has been rapidly phased out due to safety concerns 10 Qenos Technical Guides FOI Document 6 3y Figure 11 Vacuum Tanks for Sizing Pipes up to 1 400 mm in Diameter Downstream of the 1 vacuum tank there could be another vacuum tank and certainly more cooling tanks to ensure that the pipe completely solidifies by the time it gets to the Saw See Figure 12 The additional cooling is important to achieving the final pipe dimensions within the desired tolerances Figure 12 Photographs of Spray Water Bath The length of the cooling zone is dependent on the output and the given dimensions of the pipe The total length L of the required cooling zone can be calculated on the assumption that a molten polymer extrudate at a temperature of 220 C has to be cooled with water to an external pipe temperature of 20 C at which point the internal surface temperature of the pipe is a maximum eres C Qenos Technical Guides PIPE AND TUBING EXTRUSION 7 Usin
196. the following list additional record sheets may be kept if required Electrofusion socket jointing e Generators e Electrofusion control box e Electrical safety test Electrofusion saddle jointing e Generators e Electrofusion control box Electrical safety test 40 The information recorded on the sheet should include but not be restricted to e The date of servicing or maintenance The name address and telephone number of the undertaking or contractor operating the equipment The name address and telephone number of the company conducting the service or maintenance e The member or members of staff responsible for servicing or maintenance e The serial number of the equipment e The details of service and or maintenance carried out This should include relevant details of test equipment procedures and or manuals used and relevant ambient conditions e The signature s of the member or members of staff responsible for the servicing or maintenance operations conducted Qenos Technical Guides FOI Document 6 PIPE AND TUBING EXTRUSION 7 APPENDIX 2 PIPE EXTRUSION TROUBLESHOOTING GUIDE Problem Issue Die extrudate lines Extruder surging Gels and other contaminations in pipe Localised thick Cause s Damage to the exit edges of the tip or die Die drool or build up on the tip or die faces Too fast extruder throughput relative to OEM Extruder specifications Im
197. the manufacturer s or supplier s parameters which should be supplied with the fitting box timer NOTE Automatic control boxes are available which obviate the need to enter fusion time vii NOTE DO NOT attempt a second fusion cycle until the entire saddle fitting has cooled to less than 45 C Some manufacturers recommend replacement of the fitting rather than a second fusion cycle Refer to manufacturer for details xi The completed joint should be left in the clamps for cooling The time needed will be specified on the fitting label or by its data carrier or in the display of the automatic control box viii Press the start button on the control box and check that the heating cycle is proceeding as indicated by the display xii The connection of the service pipe to the spigot outlet should be carried out in accordance with the procedure of the appropriate section of these guidelines see Figure 46 ix On completion of the heating cycle the melt indicator on the fitting should have risen see Figure 45 If there is no apparent movement the joint could be unsatisfactory refer to the manufacturer s instructions for further information Qenos Technical Guides 35 FOI Document 6 7 PIPE AND TUBING EXTRUSION Figure 46 Illustration of Tapping Process used to Connect Spigot Outlet to Main Service Pipe xiii DO NOT attempt to tap the main with the integral cutter before the completion of the r
198. theless the comparison is a valid one because in many applications for example screwing down a bottle closure or forcing a washing up bow into a sink it is the deformation which is constant rather than the stress Qenos Technical Guides 0 918 0 923 0 927 0 916 0 921 0 925 0 913 0 919 0 922 constant DENSITY A RESISTANCE TO ENVIRONMENTAL STRESS CRACKING cracking time in hours MELT FLOW INDEX Figure 17 Resistance of Polyethylenes of Different MFI to Environment Stress Cracking In practice it is important that high MFI polymers even of low density should not be used for applications in which they will be severely stressed when in contact with active environments For such applications a polyethylene of low MFI is essential and the higher the density of the polyethylene the lower the MFI must be A typical application for which a polyethylene of low MFI is preferred in order to reduce the hazards of environmental stress cracking is that of closures used in contact with liquid detergents soap solutions and certain cosmetics It is important however not to exaggerate the seriousness of environmental stress cracking It has been found that the majority of mouldings made from polyethylene are not subjected to severe enough stressing in service to cause failure even though they may be in contact with active environments For example most polyethylene housewares are in daily contact with both deterg
199. then more quickly The level of adhesion of the coating can be judged qualitatively by the degree if any to which the coating is removed 23 FOI Document 18 Ye 5 INJECTION MOULDING APPENDIX 1 FROZEN IN STRAIN It is believed that frozen in strain develops in the following way As the polyethylene melt is injected into the mould cavity it is subjected to high shear forces which produce a certain degree of uncoiling of the molecular chains and causes them to be oriented in the direction of flow The nearer the melt is to the mould surface the greater will be the shear stress and the greater the orientation Because the material nearest to the mould surface cools more rapidly than the material in the interior this orientation is unable to relax and becomes frozen into position Thus a highly oriented layer is formed the thickness of which depends on the temperatures of the melt and of the mould surface On the other hand the material on the inside is insulated from the cool mould by a layer of polyethylene and consequently it remains molten until near the end of the moulding cycle Not only is this material less oriented during mould filling but most of the orientation that does occur can relax during the cooling stage Therefore an injection moulded section has a composite structure consisting of a skin which is highly strained and inner layers containing a much lower degree of molecular orientation Figure 25 is
200. these solutions Qenos also refers the user to the disclaimer at the beginning of this document 26 Qenos Technical Guides FOI Document 12 JOO INJECTION MOULDING 5 BIBLIOGRAPHY FURTHER READING 1 2 3 al Rosato D V Rosato D V Rosato M G Injection Moulding Handbook 3rd Ed Kluwer Academic Publishers 2000 Johannaber F Injection Moulding Machines A User s Guide 4th Ed Hanser Verlag 2008 Bryce D M Plastic Injection Moulding Manufacturing process fundamentals Society of Manufacturing Engineers 1996 Osswald T A Turnig L Gramann P J Injection Moulding Handbook Hanser Verlag 2008 Potsch G Michaeli W Injection Moulding An Introduction 2nd Ed Hanser Verlag 2008 Rueda D R Balta Calleja F J Bayer R K J Mat Sci 16 3371 1981 influence of processing conditions on the structure and surface microhardness of injection moulded polyethylene Issued January 2014 Qenos Technical Guides 27 FOI Document 12 79 enos A Bivester Company Qenos Pty Ltd ABN 62 054 196 771 Cnr Kororoit Creek Road amp Maidstone Street Altona Victoria 3018 Australia T 1800 063 573 F 1800 638 981 genos com amona FOI Document 13 ILS UNCLASSIFIED From AN O qgenos com Sent Friday 5 September 2014 11 47 AM To TARCON Cc SN O qgenos com Subject Objection Gazette no TC 14 33 TC 1425826 Attachments HD3690 CON item cost xlsx
201. this document is to provide an introduction to the processing of polyethylene by injection moulding The effects of Melt Flow Index MFI and density on moulding characteristics and on the properties of the finished moulding are discussed in the light of which recommendations are made as to the desirable values of these two factors for stressed and unstressed applications Mould design is considered with special reference to questions of shrinkage and distortion and examples are given to illustrate these points The moulding process itself is discussed in some detail guidance being given on all the operations which have to be carried out Moulding faults causes and remedies are also summarised Disclaimer All information contained in this publication and any further information advice recommendation or assistance given by Qenos either orally or in writing in relation to the contents of this publication is given in good faith and is believed by Qenos to be as accurate and up to date as possible The information is offered solely for your information and is not all inclusive The user should conduct its own investigations and satisfy itself as to whether the information is relevant to the user s requirements The user should not rely upon the information in any way The information shall not be construed as representations of any outcome Qenos expressly disclaims liability for any loss damage or injury including any loss arising out
202. tures ML1810PS 0 918 x N S N de E ado a ES gt Heavy duty bags lamination industrial and form fill and seal applications where outstanding stiffness toughness optical and sealing properties are desirable or for downgauging of existing film structures ML2610PN Stretch cling films with addition of appropriate cling additive and other film applications where outstanding toughness optical and sealing properties are desirable or for downgauging of existing film structures ML1710SC 1 0 0 917 S A Y 7 aA S E q ze Notes VH Very High Slip H High Slip M Medium Slip Alkatane HDPE Film Grades Melt Index iy eet Grade ghomin a ee Applications 190 C 2 16kg oO E A s a Carry bags and liners where high impact toughness and stiffness are desirable and as a blend component into 1 VILI iiai vee ees LDPE and LLDPE films for heavy duty applications HDF895 0 960 Moisture barrier and blend component into LDPE and LLDPE films to enhance stiffness Blend component in core l i layer for high clarity coextruded films Notes ASTM D1505 D2839 Alkatane HDPE Blow Moulding Grades Melt Index g 10 min 190 C 2 16kg Density Applications Large part blow mouldings especially blow moulded self supported drums an
203. ty 1 Customer Focus The organisation responsible for the jointing operation should ensure that customer requirements are determined and are met with the aim of enhancing customer satisfaction 2 Planning The organisation responsible for the jointing operation should ensure that all aspects of the jointing operation are given adequate consideration prior to the commencement of work 3 Responsibility Authority and Communication On each site where pipes and fittings are to be jointed in accordance with these guidelines a person should be nominated to supervise work affecting the jointing quality The person should e Have the responsibility and authority to ensure effective jointing operations Ensure that processes needed for jointing operations are established implemented and maintained Be able to communicate the requirements for effective jointing operations Control of Documents Document control should ensure that Documents are approved for adequacy prior to use The relevant versions of applicable documents are available at points of use e Documents remain legible and readily identifiable The unintended use of obsolete documents is prevented and to apply suitable identification to them if they are retained for any purpose 1 Purchasing The installer should ensure that purchased items including pipe fittings and fusion jointing equipment conform to specified requirements 2 Fusion Jointing C
204. ty of mouldings made from polyethylene are not in such tests the specimens are tested under constant subjected to severe enough stressing in service to cause strain and therefore the higher density polyethylenes failure even though they may be in contact with active will be under greater stress because they are stiffer environments For example most polyethylene housewares Nevertheless the comparison is a valid one because in are in daily contact with both detergents and fats and yet many applications for example screwing down a bottle the externally applied stresses to which they are subjected closure or forcing a washing up bowl into a sink it is the to are not sufficient to cause failure through environmental deformation which is constant rather than the stress stress cracking Qenos Technica Guides 13 FOI Document 12 12 5 INJECTION MOULDING Careful consideration needs to be made of the choice of polymer that will meet the demands of the finished product and the environment s that it will be exposed to e g oils fats alkalis acids and temperature etc To make the best resin selection customers are advised to discuss their specific end product requirements with their Qenos Technical Service Representative Mechanical Stress Cracking Under certain conditions the moulding process itself can create high levels of internal stress in polyethylene This is due to the semi crystalline nature of the polymer which ent
205. uracies The following major variables affect mould shrinkage Melt temperature the higher the melt temperature the greater the shrinkage will be Mould temperature the higher the mould temperature the greater the shrinkage will be Injection dwell time and injection pressure shrinkage will be smaller for longer injection dwell times and higher pressures Thickness of section the thicker the moulded section the slower the cooling and the greater the contraction of the moulding will be e Orientation shrinkage will be greater in the direction of flow than at right angles to it Density shrinkage is greater with polyethylenes of higher density e g a polyethylene of density 0 930 g cm will shrink more than a polyethylene of density 0 918 g cm e Gating shrinkage is usually greater when pin gates are used than when sprue gates are used Because the above variables have such a marked effect on shrinkage it is clear that in order to maintain accurate dimensions close control of moulding conditions is essential Cooling channels must provide adequate and even control of mould temperature over the whole mouid Cycle time control is of equal importance especially for precision work Injection pressures should be controlled and the values checked regularly on a gauge A point which must always be kept in mind when specifications call for close moulding tolerances is that the coefficient of thermal expansion of polyethyle
206. ural creep test or a tensile creep test lt should be noted that the creep modulus is dependent on the level of stress as well as on temperature and time Typical creep curves are shown in Figures 17 and 18 Tensile Creep Modulus N mm Stress Time Hrs Figure 17 Typical Tensile Creep Modulus Curves of HDPE Determined at 23 C Tensile Creep Modulus N mm Stress Time Hrs Figure 18 Typical Tensile Creep Modulus Curves of HDPE Determined at 40 C Similar tests have been carried out to determine creep moduli under compressive stress Taking scatter into account these gave approximately the same results as those for tensile stress The creep modulus can be used in design calculations for moulded parts which are to be exposed to constant stress over an extended period of time Qenos Technical Guides FOI Document 6 So Relaxation Test In the relaxation test the stress decay with time of a specimen held under constant deformation is measured and from this the relaxation modulus is calculated n yI o be o 200 i S pi o o E E Z 10 2 pa 8 300 3 Cc S y ist o of o 107 10 10 10 10 Stress Time Hrs Figure 19 Typical Relaxation Modulus Curves of HDPE Determined at 23 C it should be noted that the relaxation modulus is dependent on the level of strain as well as on te
207. ut any imperfections and also acts as a key for the metallic film The metallic film usually of aluminium is deposited and a top coat of protective lacquer is applied Low density polyethylene articles are successfully finished in this way Although the flexibility of the material is a disadvantage Tests for Finished Coatings Two simple but effective tests are the Scratch test and the Scotch Tape test Scratch Test A good idea of the adhesion of a coating can be obtained by scratching it with a finger nail or a knife to see if it flakes scotch Tape Test In this test a length of pressure sensitive tape such as Scotch Tape supplied by 3M is stuck on to the polyethylene moulding and then pulled off slowly at first and then more quickly The level of adhesion of the coating can be judged qualitatively by the degree if any to which the coating is removed 23 FOI Document 12 2 5 INJECTION MOULDING APPENDIX 1 FROZEN IN STRAIN It is believed that frozen in strain develops in the following way As the polyethylene melt is injected into the mould cavity it is subjected to high shear forces which produce a certain degree of uncoiling of the molecular chains and causes them to be oriented in the direction of flow The nearer the melt is to the mould surface the greater will be the shear stress and the greater the orientation Because the material nearest to the mould surface cools more rapidly than the materia
208. uthern hemisphere where Alkadyne PE100 pipe resin is extruded for testing and then subject to high pressure and elevated temperature for up to three years This testing is also applied to specially notched pipe samples to ensure damage during installation does not result in premature failure Alkadyne PE1OO pipe resin Engineered to Outperform Qenos and Alkadyne are trade marks of Qenos Pty Ltd FOI Document 6 us FOI Document 6 bir PIPE AND TUB EXTRUSION FOI Document 6 7 PIPE AND TUBING EXTRUSION CONTENTS INTRODUCTION PIPE APPLICATION REQUIREMENTS CLASSIFICATION OF POLYETHYLENE PIPE AND PIPE COMPOUNDS ALKADYNE GRADE SELECTION FOR PIPE PIPE EXTRUSION TECHNOLOGY Granule Pre treatment Extruder Pipe Dies Sizing and Cooling Downstream Equipment Process Control MECHANICAL PERFORMANCE OF POLYETHYLENE PIPE GRADES Short term Behaviour at Low Deformation Rates Long term Behaviour Creep Behaviour Under Uniaxial Stress Creep Test Relaxation Test Behaviour at High Deformation Rates QUALITY TESTING OF POLYETHYLENE PIPE PE 100 a Package of Good Properties Hydrostatic Pressure Tests _ Creep Test Under Internal Pressure Pipe Pressure Curve And Service Life Extrapolation Determining The Temperature Of The Pipe Wall Determining The MAOP Value NOTCH RESISTANCE SCG OF PE PIPES Pipe Notch Test RESISTANCE TO RAPID CRACK PROPAGATION RCP OF PE PIPES S4 Test
209. ver time the density increases towards its equilibrium value a process which is very slow but which is accelerated at elevated temperatures Provided that a polyethylene is chosen with a density and MFI such that the polyethylene when cooled at the slowest rate found in injection moulding lies in the tough region in Figure 16 no detrimental change to the mouldings impact strength will arise But if a polyethylene in the brittle region is chosen for example a material with a MFI of 20 g 10 min and a density greater than 0 927 g cm mouldings produced under conditions of rapid cooling will appear to be tough initially because of the decrease in density but may become brittle as the density increases over time Figure 15 Impact Machine Showing Sample Holder and Process of Use 12 Qenos Technical Guides FOI Document 12 A ee INJECTION MOULDING 5 Table 1 Effect of Cooling Rate on the Density of Polyethylene MFI 20 Cooling Rate Density g cm Annealed at 140 C and cooled at 5 C per hour 0 918 0 923 0 927 Annealed at 140 C and cooled at 30 C per hour 0 916 0 921 0 925 Fast cooled in injection moulding 0 913 0 919 0 922 FRACTURE RESISTANCE RESISTANCE TO ENVIRONMENTAL STRESS CRACKING cracking time in hours MELT FLOW INDEX MELT FLOW INDEX Figure 16 Variations in the Tough Brittle Transition Figure 17 Resistance of Polyethylenes
210. vestigations and satisfy itself as to whether the information is relevant to the user s requirements The user should not rely upon the information in any way The information shall not be construed as representations of any outcome Qenos expressly disclaims liability for any loss damage or injury including any loss arising out of negligence directly or indirectly suffered or incurred as a result of or related to anyone using or relying on any of the information except to the extent Qenos is unable to exclude such liability under any relevant legislation Freedom from patent rights must not be assumed Qenos Technical Guides 7 PIPE AND TUBING EXTRUSION INTRODUCTION Alkadyne polyethylene grades Table 1 are used for the extrusion of pipe The application areas in which Alkadyne pipe resin is typically used include e Mining for conveyance of corrosive and abrasive slurries and tailings Water management projects such as large scale irrigation for agriculture Residential water distribution Civil work such as sewers Residential and industrial gas distribution Gas and water management in Coal Seam Gas extraction e Management of industrial fluids FOI Document 6 of PE HD pipes such as weldability flexibility chemical resistance and abrasion resistance PE 100 pipes also bring marked improvements in important properties such as creep strength notch resistance and resistance to rapid crack propagation
211. wever when the time taken to melt the granules is no longer the limiting factor The greater parameter of importance is then the time taken for the mouldings to cool to a temperature at which they can be extracted easily from the mould Beyond this point as the melt temperature increases the cycle time has to be extended and the output consequently falls FOI Document 18 DO 5 INJECTION MOULDING OUTPUT RATE Number of mouldings pre hour CYLINDER TEMPERATURE C Figure 6 Variation in Output Rate of Mouldings with Cylinder Temperature Figure 7 shows the effect of density on output rate for polyethylenes of the same MFI It indicates that the higher the density the higher the output rate on the cooling side of the curve at any given cylinder temperature The reason for this is that mouldings of higher density can be extracted from the mould at higher temperatures because they are more rigid at these temperatures than are mouldings of lower density The higher density materials however require higher cylinder temperatures to produce adequate melting of the granules particularly if the amount of material being handled is near the plasticising capacity of the machine and the use of such temperatures may slow down the output rate OUTPUT RATE number of mouldings per hour DENSITY G C C Figure 7 Effect of Density on Output Rate for Polymers of the Same MFI To use inje
212. y polyethylenes and melting is more likely to be a limiting factor Thus as far as processing is concerned the type of polyethylene chosen should have as high an MFI as possible However the choice of both MFI and density must also take into account the physical properties required in the finished moulding and this subject is discussed in the next section EFFECT OF MFI AND DENSITY ON THE PROPERTIES OF POLYETHYLENE MOULDINGS The physical properties of polyethylene which are of particular importance in injection moulded articles are Stiffness Impact properties Resistance to environmental stress cracking e Resistance to mechanical stress cracking Stiffness The main factor determining the stiffness of a moulding is the density of the polyethylene Figure 14 shows how the stiffness as measured by the 100 sec tensile modulus increases rapidly with increasing density In the lower density range a change in density of as little as 0 007 g cm will double the stiffness Figure 14 also shows the effect of temperature on stiffness MFI has virtually no effect on stiffness INJECTION MOULDING 5 100 sec tensile modules at 0 2 strain ib fin x 10 Density g c c Figure 14 Variation of Stiffness and Density with Temperature impact Properties One of the outstanding properties of low density polyethylene is its toughness when subjected to impact it will stretch and cold draw before
213. y such goods A Have the goods been produced in Australia in the last 2 years YES J NO B Have the goods been produced and are they held in stock in Australia yes Ino C if the goods are intermittently produced in Australia have they been so produced Yes Lino in the last 5 years D Are you prepared to accept an order for the goods YES NO 7 2 SUBSTITUTABLE GOODS BEING MADE TO ORDER CAPITAL EQUIPMENT Made to order capital equipment means a particular item of capital equipment that is made in Australia on a one off basis fo meet a specific order rather than being the subject of regular or intermittent production and that is not produced in quantities indicative of a production run Capital equipment means goods which if imported would be goods to which Chapters 84 85 86 87 89 or 90 of Schedule 3 to the Customs Tariff Act 1995 would apply Goods that are made to order capital equipment are taken to be produced in Australia in the ordinary course of business if a a producer in Australia i has made goods requiring the same labour skills technology and design expertise as the substitutable goods in the 2 years before the application and it could produce the goods with existing facilities and b the producer in Australia is prepared to accept an order to supply the substitutable goods E Have goods requiring the same labour skills technology and design expertise as the goods the subject of the application been made in Au
214. ylene Mouldings The influence of moulding conditions and the shape of mouldings is so great that it is almost impossible to predict the exact shrinkage of polyethylene mouldings It is recommended therefore that trials under controlled moulding conditions should be carried out before the mould is hardened and polished The mould may then be adjusted accordingly To allow for any after shrinkage the dimensions of mouldings should not be checked until at least 24 hours after removing the mouldings from the mould Qenos Technical Guides FOI Document 18 JA Measurements must be checked in all important dimensions because mould shrinkage varies with the direction of flow and checking only one dimension and applying proportional corrections to the others may lead to major inaccuracies The following major variables affect mould shrinkage Melt temperature the higher the melt temperature the greater the shrinkage will be Mould temperature the higher the mould temperature the greater the shrinkage will be Injection dwell time and injection pressure shrinkage will be smaller for longer injection dwell times and higher pressures Thickness of section the thicker the moulded section the slower the cooling and the greater the contraction of the moulding will be Orlentation shrinkage will be greater in the direction of flow than at right angles to it Density shrinkage is greater with polyethylenes of higher den
215. ylene or masterbatch Incompatible masterbatch Change masterbatch to one with a PE base Poor colour Back pressure too low Increase back pressure homogenisation Masterbatch not compatible Barrel size too small insufficient shots in barrel Masterbatch add rate too low Temperature too low Ensure PE based masterbatch is used Move to a larger machine Use masterbatch with lower pigment concentration at higher add rate Increase temperature settings Qenos Technical Guides 25 FOI Document 12 5 INJECTION MOULDING Cause s Potential Solution s Action s Problem Issue Short shots PE melt flow index too low a Change to higher melt flow index grade Incompletely Melt temperature too low Increase melt temperature i filled mouldings inadequate vent size Increase venting Inadequate thickness Increase thickness Insufficient injection speed Increase injection speed insufficient gating Increase gate size or number Weak weld lines Melt temperature too low Increase temperature settings Flow of polymer too low Use higher melt flow grade Injection speed too low Increase injection speed Gate s too far from weld line Move gate or increase number of gates Disclaimer The proposed solutions in this guide are based on conditions that are typically encountered in the manufacture of products from polyethylene Other variables or constraints may impact the ability of the user to apply

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