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2007 PLACE
Conference
September 16-20
St Louis, MO
The Theory and Practice
of Extruder System Purging
Presented by:
John D. Vansant
DuPont Packaging
Tappi Place Conference 2007
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What Worry about Purging?
Effective transitions / Set-ups
Cleaning out the gels
Proper shut down
Preventing corrosion
Coming in quickly on specification
Avoiding heat seal problems
Good manufacturing practice
Tappi Place Conference 2007
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Velocity Profile - Flow Through a Pipe
* Shear Stress (force) increases with Shear Rate
Low Shear High Shear
Tappi Place Conference 2007
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Purging Theory Velocity and Shear Rate
High velocity / RPMs
Shear rate needed to move material away at
the metal surfaces
Tappi Place Conference 2007
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Effect of Viscosity on Purging

A
>>
B

A
<<
B
A
B
B
A
B
B
Dont make large steps down in viscosity
Low shear
Ineffective Purge Effective Purge
Tappi Place Conference 2007
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Purging Theory Consider Viscosity
High viscosity = low Melt Index
Large steps up in Melt Index = slow purging
Tappi Place Conference 2007
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Melt Viscosity vs. Temperature
temperature
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Ionomer
Acid Copolymer
LDPE
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Tappi Place Conference 2007
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Purging Theory Temperature & Viscosity
Consider how the viscosity of different
materials responds to temperature changes
Some materials decrease in viscosity faster with
temperature
Use this to your advantage, not disadvantage
Use temperature differentials to aid in
purging
Cool the barrel
Keep the rest hot
Tappi Place Conference 2007
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Effect of Shear Rate
log shear rate
Short-chain
branched
Linear
Long-chain
branched
Constant M
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Purging Theory Shear Thinning
Linear polyethylenes dont shear thin as
much as LDPE
Purging into linear resins high RPMs
Purging out of linear resins moderate
RPMs
Tappi Place Conference 2007
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Dead Spots
Tappi Place Conference 2007
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Purging Theory Dead Spots
Circulation dead spots can occur at higher
throughput (RPM)
Low throughput doesnt move cross-linked
material out of dead spots (not enough shear)
The best throughput rate may be somewhere
in the middle, but hard to predict
Tappi Place Conference 2007
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Purging Theory Resin Compatibility
Resins that are more compatible (similar)
purge more easily
Resins that adhere to one another purge
more easily
Note: Gels can not be effectively removed
without adhesion. To accomplish this, short (5
minute) periods of very low (~10) RPMs should
be incorporated into the purging process.
Tappi Place Conference 2007
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Purging Theory Resin Compatibility
Some resins should not be directly mixed:
EVOH & Nylon 6
EVA and Acid Copolymers (>230C)
EVOH/Nylon and tie resins
Tappi Place Conference 2007
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Purging Theory Resin Stability
Some resins crosslink (form gel)
if run too hot
EVA
EAA
EMAA
EVOH
Even PE (from oxidation)
Tappi Place Conference 2007
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Purging Theory Purge Compounds
Typically have very high viscosity to push
hard (high shear rate / shear force)
Often contain abrasive materials to scour die
surfaces, etc.
May contain blowing agents foaming helps
to reach dead zones such as:
Breaker plates
Valved adapters
Coextrusion elbows
Remember that you must purge out the purge compound
Tappi Place Conference 2007
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Purging Practice
You must run a wide range of RPMs
Never just let it drool be active in purging
Purge compounds can help clean up a very dirty
extruder, but it takes time to purge out the purge
compounds
We prefer the Disco Purge Procedure as the
standard transition purge
Rule of thumb: Drop the temperature before
purging into a copolymer resin, and purge out
completely before increasing the temperature
Tappi Place Conference 2007
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Disco Purge Method
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Mi nute
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Disco Purge Procedure*
MAXIMUM EXTRUDER RPM = __ RPM
1st min: 30% of max = 0.3 __ RPM = __ RPM
2nd min:90% of max = 0.9 __ RPM = __ RPM
3rd min: 50% of max = 0.5 __ RPM = __ RPM
4th min: 15% of max = 0.15 __ RPM = __ RPM
5th min: 70% of max = 0.7 __ RPM = __ RPM
6-10 mins: 10% of max = 0.10 __ RPM = __ RPM
(small extruders 20% of max =0.20 __ RPM = __ RPM )
minutes 11-15: Repeat the cycling steps of the first 5 min.
Continue with additional 10 minute cycles until the web looks clean at all
RPMs
developed by Al Soutar
Tappi Place Conference 2007
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Disco Purge Method
Varies the shear rate to change flow patterns
Slow periods allow resins to bond together
Slow periods interrupt flow circulation
Often effective without purge compounds
Minimizes time and resin over let it run
Does not scour tough die deposits
Not always effective in removing tough gels
Tappi Place Conference 2007
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The information herein is intended for guidance only.
While believed reliable, DuPont neither warrants or
guarantees its completeness, efficacy or safety in use. It
is intended for use only by competent personnel. The
user accepts full responsibility for its use and fully
indemnifies and holds DuPont harmless from any loss,
claim, damage, or injury arising out of its use regardless
of cause, unless user shows such to have been caused
directly by ill will or willful misconduct of DuPont.
Also, no license is granted or implied, and no
recommendation to infringe any patent is made.
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Thank You
PRESENTED BY
John D. Vansant
DuPont Packaging
john.d.vansant@usa.dupont.com
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in your evaluation sheet...