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CELANESE PLASTIC MATERIALS COMPANY Chemcel Plant Bishop, Texas TO: P. M. Sykes FROM : R. L. Bunkley RLB-41-79 July 17, 1979 Quality Control Monthly Report June, 1979 cc: Dr. R. A. Daniel - Chatham Mr. J. W. Beltz Mr. A. R. Kurkowski Mr. R. W. Murphy Mr. F. M. O'Neill Dr. M. L. Druin (6) - Summit Mr. C. Gottfried Dr. M. Meisters Mr. F. B. McAndrew Mr. W. L. Shearer Mr. .M. M. Wilson Mr. D. Zimmerman Summit Data Files Mr. A. C. Abshier - Bishop Mr. W. S. Allen Mr. C. A. Amond Mr. G. Artripe Dr. J. D. Bennett Dr. H. L. Davis Mr. J. C. Doedyns Mr. D. L. Dotson Mr. R. D. Fuchs Mr. D. E. Guthland Mr. C. L. Hammond Ms. A. R. Hancock Mr. L. N. Harvey Mr. H. P. Hohon Mr. J. L. Merian Mr. W. H. Meyer Mr. A. B. Milam Ms. P. J. Moede Mr. E. Munoz Mr. K. A. Rose Mr. R. G. Rothenberg Mr. J. D. Saladino Mr. A. G. Salinas-^' Mr. ?. N. Thomas Mr. E. D. Wendler Mr. K. A. Wolf File: 3.017 301.014 501.009 Central Files (3) - CCCTC 003894 GENERAL SUMMARY: Celcoi^ product yaivers amounted to 18.6% of the month's production total of 7.4MM lbs. Natural Finishing waivers were due mainly to out of specification melt index and off size pellets. Quality waivers in Special Products were the result of out of specification' melt index with off size pellets and Kd problems accounting for the other major quality deficiencies. Celane^ quality waivers amounted to 6.3% of the month's production total of 1.89MM lbs. Major quality waivers were due to out of specification color matches, ash content of the fiberglass filled resins and failures of the bum test by some VO products. Nylon product waivers totalled-19.6% of the month's production of 2.2MM lbs. Major quality variances were out of specification natural color, volatiles content, and realtive viscosity. Support for the start-up of the modified SH-1 unit continued during the month. Polymer quality continues to look good. Bulk density has been between 13-14 lbs./ft.3. Recommendations were made and are being evaluated which, if successful, should significantly reduce the loading of the Westfalia separators and allow the unit to operate at. higher methanol concentrations. te , I. CELCO^S) A. Customer Complaints - Dotson/Tijerina/Heraandez 1. Huron Plastics entered a complaint (P-5513) indicating that they received only 4800 lbs. of "acceptable" resin in a 7200 lb. shipment of Celcon C-243 natural from lot 9010552. One gaylord in the shipment was found without a box liner and the remaining gaylords were damaged. One gaylord was also missing from the shipment. The material left Bishop properly packaged. It appears that due to the damages, a gaylord of material was repackaged in a box without a liner during transit to the customer. The complaint has been referred to the distributing warehouse and the carrier by Distribution. (DLD-113-79) 2. A complaint was entered by Wolf Engineering (P-5514) stating that a shipment of C-243 natural from lot 9010552 had three damaged gaylords with a third of the contents missing and another gaylord without a plastic l-iner. This complaint involves the same lot of material and type of damages as cited in complaint P-5513. Distribution was requested to investigate this complaint with the distributing warehouse (Omega) and the carrier (Rodeway). (DLD-112-79) 003895 RLB-41-79 -2- July 17, 1979 A complaint (P-5509) was entered by Dixon Industries Corp. indicating that a shipment of M25-01 natural lot 8120801 was contaminated with black specks, straw, paper from bags and other assorted debris. The total shipment (in drums) was returned to the plant. The material was released from the plant as specifica tion material. Examination of the returned material failed to reveal any of the contaminants listed in the customer's complaint. B. Manfacturing Support SH-1 Start Up Support - Guthland SH-1 was on stream 15 days during the month of June. The unit was shut down on 6/5 due to problems transferring product from the fluid bed dryer and on 6/22 due to "plating out" on the 1st precipitator cooler. Kd's, color, and physical properties were well within specs. Bulk density averaged 13.10 lbs/cu.ft. Extremely high . extractable formladehyde levels occurred concurrently fe on 6/14 and 6/15 with high wt.% volatiles of the fluic$5bed dryer product. High extractable formaldehyde con-; tinued to be a problem until the plasticized fluid bed dryer coils were cleaned. Sieve screen analyses of the fluid bed dryer product showed that high weight percent volatiles was independent of particle size. SH-1 Bulk Density - Guthland To date, bulk densities have averaged 13-14 #/cu.ft. in SH-1. A tentative method has been made available for determining bulk density at the screen bowl centrifuge (DEG-9-79). This method will provide a means of deter mining bulk density prior to the fluid bed dryer thereby reducing the response time needed to affect changes in the product. Fines in SH-1 - Guthland High fines levels and their separation via the Westfalia separators have been a problem since the initial start up attempt. Particle size analysis of the- second centrate has shown that 88-96 wt.7 of the fines are between 0.07 and 0.05 mm and 4-12 wt.% between 0.05 and 0.01 mm. These fines have been shown to settle out quickly at a low "g" force (l6ss than one minute at 100 g's). It has been recommended that a "partial separating device be placed in series up stream of the Westfalia-s to reduce the solids load on the separators. If successful, UU3S9t> i RLB-41-79 -3- July 17, 1979 this modification would make it possible to process more of the fine slurry, thus allowing the unit to run at higher methanol concentration in the hydrolysis-precipitation loop. To this end, Process Engineering is currently investigating the applicability of a wet cyclone. In addition to the above, a recommendation was made to increase the polymer particle size exit the kokneader to reduce water carry-over from the first centrifuge. Process Engineering is investigating the use of a larger grinder screen to effect this particle size increase. If successful, this process change will allow a reduced' load on the Westfalia separators and maintenance of higher methanol concentration in the system. 4. Trioxane Reactor Paraforming Problems - Moede Iron and sodium are highly suspect of inducing solids formation in the trioxane reactor. A method for the analysis of iron in 50% formaldehyde was developed in order to monitor the iron impurities in TO-2 formaldehyde feed. The development of a method'for sodium in 50% te formladehyde is in progress. - !p- Laboratory experiments have been designed to determine;-* if and to what extent (1) iron, (2) soidum, (3) "pH" and (4) phosphoric acid influence paraforming in the trioxane reactor. In addition, work being conducted in the Chemcel Lab by Mr. M. E. Harris on the stabilization of formladehyde will be evaluated to determine if it is applicable to our process. 5. TO-1 Unit Support - Moede Training for TO-1 unit laboratory personnel was completed on all methods of analysis required for TO-1 operations support. v The laboratory was surveyed, and the additional chemicals and glassware required for TO-1 start up were supplied. C. Analytical Development 1. Cross Contamination in Black Celcon, Celanex, andgNa^yalo^jn_no- A test procedure (CL 1-94) has been issued (JDS-9-79) that can"detect cross contamination in black Celcon, black Celanex, and black Nylon. The cross contamination in black Celcon, black Celanex, and black Nylon can be detected by melting any Celcon in the sample at 200oc, 00389/ 1 RLB-41-79 -4- July 17, 1979 then-refluxing any unmelted pellets in propylene glycol-chloroform-HCl for one hour. Nylon will dissolve, Celanex will not. A letter has been published (JDS-8-79) describing the development and verification of this procedure. 2. Talc Filled Celcon - Saladino A letter was published (JDS-11-79.) describing the development and verification of a -procedure for analyzing CAO-5 stabilizer in talc-filled Celcon by U.V. spectrophotometry. The method for black Celcon (CL 1-20) was revised to include talc and is being , used by the Spec Lab for routine analysis. 3. Liquid Chromatographic Analysis of Celcon Stabilizers and Nylon Effluent - Allen/Saladino Recent work in collaboration with Varian Associates indicates that High Pressure Liquid Chromatography (LC) would be a viable technique for routine Q.C. analyses of stabilizers in colored Celcon formulations and inte formulations containing mixed stabilizers. The totalis analysis time is approximately 1.5 hours and involves1 ^ simple techniques. The LC analysis of adipic acid in nylon effluent was also demonstrated. This analysis would allow identifi cation of nylon salt losses. It also involves simple techniques and requires a total analysis time of 15 minutes. A report is in progress. D. Routine Analytical - Salinas Sample count, overtime hours, holiday overtime hours and formaldehyde feed concentration for June are summarized in Table I. The sample count for June was 5221 compared to 5031 in May. The overtime hours for June were 418 compared to 324 in May. The increase in overtime was due to the resignation of a technician. This slot was covered with overtime. Special analytical support was provided to the following projects: 1. K_. H. Patel \ - PBT High I.V. Trial Batch No. 6 & 7. 2. SH-1 Start Up Support - David Guthland. 3. MH-2 Special Trials - David Guthland, hydrolyzables. 00389b RLB-41-79 -5- July 17, 1979 II. CELANEX A.. Customer Complaints - Dotson/Tijerina/Hernandez 1. A precautionary complaint was entered by ITT Cannon (United Kingdom) stating metal contamination in material from both a Kelanex 2012 natural shipment and from a Kelanex 3310 natural shipment. The lots involved were numbers 8071344 and 8081343 for the 2012 material and lot 8112841 of the 3310 material. III. NYLON Plant records showed that the lots in question were free of any metal contamination upon release. Re-examination of our shipping lot retains confirmed the original examination results. Further examination of plant manufacturing records failed to reveal any operational problems during the production of these lots that could have contributed any metal contamina tion. The lack of an unopened bag of material prevented any further evaluation of the complaint. (DLD-115-79) - %$ A. Customer Complaints - Dotson At months end, six nylon complaints are pending. B. Manufacturing Support 1. Nylon Nucleant Production - Saladino/Salinas The inventory status of nylon nucleant is summarized below: Inventory 6/1/79 Inventory 6/30/79 Nucleant Produced in June Nucleant in Process Inventory 6/30/79 (KF) Inventory 6/30/79 (CaAc2) IV. INDUSTRIAL HYGIENE - Hancock, Pritchard, Grey 10 drvims 13 drums 9 drums 14 drvims 13 drums 30 drvims A. Formaldehyde Survey The formaldehyde survey in the Special Products unit is complete. No formaldehyde exposure problems exist under normal operating conditions. A report is in progress. uu3yy fc RLB-41-79 -6- July 17, 1979 B. Dust Sampling A nuisance dust survey in the Natural Finishing unit is still in progress. Short-term ceiling concentration samples taken on the pellet blender operators show exposures (40-250 mg/m3) above the suggested 20 mg/m3 ceiling level. The survey will continue to better document the exposure levels. The nuisance dust survey in Special Products is complete. No apparent dust problems exist. A report has been issued A survey for nuisance dust in the Celanex unit has begun. The survey will be concentrated around the SEO production runs. Exposure to dust is greater during these runs than others. So far, exposure levels have been under the 5 mg/m3 action level for nuisance dust. C. Miscellaneous Formaldehyde personal samples were taken in the Nylon .unit and compounder building when T-302 residue line "broke" || in T02. The wind direction carried the formaldehyde vapcrfs, across from T02 into the Nylon units. All exposures were^., below the 1.85 mg/m3 action level for formaldehyde. Area:"' samples were also taken with concentrations ranging from 3 mg/m3 to 12 mg/m3 (directly downwind of the spill). A report will be issued. To obtain operating permits for SHI from TACB, T-30,000 and T-30,009 scrubber vents have been sampled. The vents will be sampled once more to verify emissions before results, are ^ submitted to TACB. A report will be issued. D. Analytical Load The OSHA/environmental analytical load, to date, is summarized below. Month OSHA Environmental YTD OSHA Environmental SH1/T01 SH2/T02 MH2 Nat. Finishing Spec. Prod. Celanex Nylon Chemical Co. 0 0 0 4 70, 10 6 0 5 40 0 222 0 99 0 226 0 312 0 32 0 30 00 6 0 1 2 2 1 1 3 uusyuu RLB-41-79 -7- July 17, 1979 V. COLOR SERVICE - Artripe, Rothenberg, Harvey General Summary Color Service developed 29 color matches this month. The distribution of color match work for each marketing group was 13 Celcon, 11 Nylon, and 5 Celanex matches; of this 2 Celcon, 3 Nylon, and 3 Celanex were reworked from existing formulations. v 215 pounds of products were extruded and shipped. A total of 227 chips were sent out in the process of filling 14 sample requests for chips only. We have scheduled 25 color matches for July, leaving our backlog of unscheduled work at 37. This backlog is for reformulation of existing formulas. Reformulation is necessary due to pigment obsolescence or chip replenishment. There are no new marketing requests on backlog. , Fisher Body Claret WPH 4887 and Blue WPH 7130 have been reformulated using a more U.V. stable pigment. These colors are tinder Fade-Ometer testing. The testing should be completed 7-9-79. Color Service work load remains very high, turnaround time per match was slightly below last month. 1. Nylon Color Formulations - Rothenberg All active Nylon color concentrate formulations were furnished to R. W. Murphy and A. Serle. This information will be used in obtaining U.L. color approvals and meeting more stringent 1980 U.L. color requirements (RGR-48-79). 2. Oster Colors The four Oster color formulations (with information on pigments used in the formulations, chemical identification of the pigments, and manufacturers) was submitted to Nylon Marketing for transmittal to Oster. The only Oster formulation currently using FDA approved pigments (for a food contact application) is NA 3144-K20 White (RGR-53-79). 3. Formulations for NSF Approvals Complete formulation' data on Celcon FDA-grade color concentrates CA 31989-K20 (white) and CG 32013-K20 (blue) were furnished to A. Serle. This information was needed to complete-material formulation confidential reports for NSF for one of our customers (RGR-54-79) . 003901 RLB-41-79 -8- July 17, 1979 4. Reformulation of Nylon Color Concentrates from Outside Vendors Attempts have been made for approximately the last year to ascertain the formulations for Nylon color concentrates from various vendors. Due to lack of response and increasing pressure from the Commercial Hazards Committee to know all colorant safety data, Bishop Color Service will reformulate Nylon concentrates manufactured by outside vendors for which the formulation of the concentrate is not known (RGR-57-79). 5. Colorant Evaluation In June two new pigments were added to our approved colorant list bringing the total number of colorants used to 73. In order to insure that a colorant meets all the criteria to produce an acceptable color, current evaluation of new colorants will be expanded to include Fade-Ometer exposure of the masstone and tint plaques. This additional testing of colorants will help minimize product color fading problems under particular end-use conditions in'the field. To sumnrarize, the colorants used in Celcon,. Celanex and Nylon must have^he following characteristics: . f * 1. Relative consistency in color and color strength. ^ 2. Stable to extrusion temperatures. 3. They must be light fast; i.e., they must not fade. 4. Cannot cause deterioration of the polymer. 5. Cannot bleed out of the polymer. 6. Must disperse easily in the polymer. 7. They must be stable in the chemical environment of the polymer, including stabilizers and other additives. During the month, 10 new pigments have been received. Final evaluation of these colorants will be completed shortly. VI. STATUS OF LAB BUILDING CONSTRUCTION - Rose/Artripe The 2-story hood was found to have inadequate face velocity. Temporary measures have been taken to boost this to 125-150 ft/min. A meeting was held with Each and Assoc., and they have agreed to modify the existing ductwork and, if necessary, the exhaust blowers to achieve 150 ft/min. velocity with one door of the hood open on each floor. Thermocouples have been installed, and the temperature recorders are operational on each floor. Many leaks are present in the lab roof. Significant repair will be necessary to make this tar paper roof watertight. Leakage of water into the color measurement room during rainy weather is jeopardizing critical equipment. 003902 i '* RLB-41-79 -9- July 17, 1979 A broken steam vent pipe above the ASTM room has not been repaired. During periods of high steam usage, condensate leaks into the ASTM room. Backs for the island bench sink units have not been received or installed. Incomplete PER's (Spec Lab) #9676 #9680 1/31/79 4/11/79 6-Hole Steam Table Lab Utility Modifications The following is a list of'items remaining to be completed in the Color Lab: Complete bottle rack (top has sharp edges) Complete Lydon air oven vent Complete Van Dorn vents Complete 1" extruder drains Complete cooling to minijector oil coolers Complete insulation on Van Dorn Thermolator lines Connect water and drain to sink in 2 1/2" extruder room Complete ceiling in janitor closet Replace bad wall clock (new - does not keep time) Plug holes in walls and repaint walls as necessary Re-concrete around drain plug in front of elevator Make covers for funnels on therminol make-up tank Complete counter tops and repair bad drawers (short 1 drawer) Install legs and tops on 3 small-tables and paint Move bell on telephone Eliminate noise over offices Clean light fixtures in ceiling Therminol system not operating properly Complete 2 1/2" extruder (make operational) Move 8 file cabinets to closet Broken ceiling tile by 2 story hood No fire extinguisher on north ramp VII. PERSONNEL James A. Remlinger, chemist assigned to the Finishing Area, resigned-July 1. Effective July 9, W. S. Allen, Nylon Support Chemist, is assigned to the Finishing Area. At the same time, J. D. Saladino, Analytica__l Develov pment Chemist, is assigned to Nylon Area Support. Richard A. Gray, Specification Lab Technician, resigned June 29. 003903 RLB-41-79 -10- July 17, 1979 During the month, Mr. Arturo Contreras and Mr. David Clapper jointed the company as Technicians in the Specification Laboratory. RLB.-slh Attachments X ET! Bunk ley 003904 I (A ll Types) (A ll Types) % o f Total Total No. Spies. Nylon Non- Routine Routine Total rH OV ov o VO o VO vO CN o o VO o rH in pH pH CO <r o CN rH o o o rH H pH tH pH CM o rH rH H o iH iH CO o Mf CN r- o pH CM r** CM - VO o pH pH CO 00" m CM CO m VO CM vO VO r- CN r-M o CN rH m m o rH VO vO rH rH vO <r CO rH CO rH rH CN CN m vO m CN av vO m Nf* to --- r<d- ato; O. CL E to h>~> r r-- ^ -Ao-3--<--C- CD 4Cp-> cO3n r<cv H3 zcOocni CO O'* MT av CN >Si 1> syT t--i r3 O r- LO O CD CO O O pH rH <fr oo rH rH < <r CN CM -<aaui <aa>u oo CN CN CN CN o3= o 3OC No. Spies. Celaneic Non- Routine Routine Total No. Spies. C elcoir*^ Non- Routine Routine Total CN CN CN CN CM CM O rH r-i cn CM CM VO o iH pH cn in VO CM VO vO o CM cn CO rH o CM ON cn CO CM CM n. cn rH r- p* CTv CO V 00 00 ON o 00 CM CTV Mf m iH o rH CO MT CN CM m vO r** ooO o Mt CM cn 00 pH o 00 m m o CM vO CO CO CM o o CT C to r* H < H x: U to 3 to C H r -o cO +* (0 uC LU a. r0 u r-- <u r-* J< a. H rero <0 S- rTM 0) to c H s CM CM 1 3 4-> u <u fMtO o p" 3 to C SO <1> -C z qJ V rd u ,C U 30 00 C HOO so VmOO <u H s n) to < H rM T3 H U 3-rl O )-l 60rM H 0) <U O > Pi X o s H o ! Area________ Gross Production Total Packaged Off Specification Quality Waivers TABLE IICelcon Quality Summary M Lbs JUNE. Percentage 7345.2 * 100.0 1801.0 1369.0 24.5 18.6 Year to Date M Lbs Percentage 40845.3 100.0 10261.6 8406.6 25.1 20.6 TABLE III Celcon Experimental Products Product C240A C243 . C244 C267 C300 C301 Production 131,010 80,950 511,650 20,400 81,600 150,000 Releases 131,010 80,950 511,650 20,400 81,600 150,000 * I 003906 <1 TABLE IV Analysis of Celcon Packaged Off Specification Natural Finishing - June Defect Lots Melt Index Discolored Pellets Black Specks Stabilizer Content Ash Content Natural Color Ext. HCHO 10X Melt Index Kd Volatiles Off Size Pellets 4 1 2 3 0 2 0 0 0 3 2 % of Quantity Total M Lbs. Natural 382.2 42.5 85.5 179.4 0 229.8 0 0 0 123.7 326.6 6.2 0.7 1.4 2.9 0 3.7 0 0 0 2.0 5.3 Lots 44 10 25 13 1 5 4 1 3 4 2 % of Quantity Total M Lbs. Natural 3876.0 451.0 1861.7 740.2 28.3 753.3 108.8 19.1 362.5 168.2 326.6 12.3 1.4 5.9 2.3 0.1 2.4 0.3 <0.1 1.1 0.5 1.0 Special Products - June Defect Lots Melt Index Discolored Pellets Color Match Off Size Pellets Colored Pellets (Contamination) Volatiles Stabilizer Content Kd Black Specks Tensile Strength Natural Color (Glass Filled) 17 7 3 6 0 1 0 13 0 3 1 Quantity M Lbs. 294.0 49.9 25.1 54.2 0 15.6 0 64.3 0 47.6 14.3 % of Total S. P. 24.7 4.2 2.1 4.6 0 1.3 0 5.4 0 4.0 1.2 Lots 59 12 14 38 5 7 11 19 1 5, 14 m of Quantity Total M Lbs. -S. P. 877.1 94.4 92.1 500.8 9.4 1.0 1.0 5.4 22.4 105.8 366.5 119.5 9.4 73.2 0.2 1.1 3.9 1.3 0.1 0.8 177.6 1.9 003907 I tabu; v C.elcon Releases Pornulatron Releases Quantity (M Lbs) JUNE YTD Lots JUNE YTD Qualitv Waivers Quantity CM Lbs) JUNE YTD Lots JUNE YTD M9000 Flake 10.5 26.8 13 M9001 Flake 81.4 862.7 7 72 M27000 Flake M2501 Natural 0 24.9 0 673.8 0 .0 2 15 313.2 8 M2504 Natural O' 814.2 0 17 480.2 10 M2514 Natural 0 25.7 * 0 1 M9004 Natural 3448.5 17458.4 45 148 959.6 4279.1 11 34 M9014 Natural 349.5 2127.9 ' 4 17 134.7 750.5 2 7 M90210 Natural 0 30.2 01 30.2 1 M14014 Natural C143 Natural 0 366.7 49/6 2179.5 01 5 28 195.2 2 M27004 Natural 336.4 1795.4 2 14 68.4 1 M2 7014 Natural 274.8 1188.3 3 23 225.1 6 U1011 Natural 0 144.3 06 67.4 3 M2501 Color 0 21.8 02 M9004 Color 306.5 1305.7 21 119 24.6 213.7 2 20 M9014 Color 19.4 22.6 24 1.9 1 M9008 Color 0 98.3 09 M9008 Natural 36.0 222.2 2 14 14.2 1 M9034 Color 50.4 256.3 3 14 50.4 148.5 3 8. Ml4014 Color C143 Color 0 60.5 38.8 80.4 03 8 12 % 5.6 2 M27004 Color 0 107.1 0 10 2.6 1 M27008 Color 94.1 225.1 19 31 29.0 77.9 3 6 M2504 Black 0 107.1 0 13 39.9 1 M9004 Black 378.2 2251.4 10 66 37.3 331.6 1 9 M9014 Black 60.9 403.6 3 21 40.2 200.8 2 9 Cl43 Black 14.7 133.4 28 M27004 Black 56.1 263.4 2 10 16.3 16.3 1 1 U1011 Black 0 20.9 04 GC25A Natural 45.1 440.1 3 35 45.1 159.9 3 12 GC25A Black 0 1296.2 0 53 12.7 1 M9007 Color 0 199.9 0 49 M9007 Black 0 122.6 06 Sale & Peppers 102.4 857.1 7 62 C155 0 124.7 05 85.3 3 C234A 0 735.1 0 26 99.8 4 C240A 131.0 502.6 14 93.8 1 C241 0 64.7 04 18.2 1 C243 80.9 305.0 2 7 31.8 31.8 1 1 C244 511.7 2672.6 4 28 309.6 4 C251 0 211.2 06 133.2 3 C252 0 176.4 02 C254 0 12.6 01 C255 0 5.0 0 1. C257 0 12.0 01 C267 20.4 20.4 22 C300 81.6 717.4 17 C301 150.0 417.5 14 TOTALS 7067.7 41785.2 159 993 1369.0 8406.6 29 161 - 7, COLOR BLACK OTHER GLASS FILLED NATURAL CONCENTRATES Month ~S7!J7 7. 21 2. 75 0. 64 82. 02 0i YTD 5757 9.37 4.24 4.15 75.78 0.77 QUALITY WAIVERS MONTH YTD 19.4 20.1 & 003908 -- Gross Production Total Packaged Off Specification Quality Waivers TABLE VI Celanex Quality Summary M Lbs JUNE Percentage 1885.0 100.0 Year to Date M Lbs Percentage 12195.4 100.0 226.4 118.0 12.0 6.3 943.9 714.6 7.7 5.9 tl ' 003909 TABLE VII -- Defect Flammability Analysis of Celanex Packaged Off Specification Lots 6 JUNE M Lbs58.1* % of Production 3.1 Year to Date % of Lots M Lbs Production 9 177.4 1.5 Discolored Pellets 0 0 0 5 52.3 0.4 Ash Content 2 70.4 3.7 22 480.5 3.9 Off Size Pellets 1 17.8 0.9 2 62.8 0,5_ Volatiles Colored Pellets (Contamination) 0 0 0 0 0 1 39.4 ' -3 t 0 2 51.2 V* 0.4 'blor Match 7 95.3 5.1 7 95.3 0.8 003910 TABLE VIII Celanex Releases Formulation Releases Quantity (M Lbs) JUNE YTD JUNE Lots YTD 2000 Natural 2000-2 Natural 2002-2 Natural 2012 Natural 2012-2 Natural 3200-2 Natural 3210 Natural 3210-2 Natural 3211-2 Natural 3300 Natural 3300-2 Natural 3310 Natural 3310-2 Natural 3311 Natural 3311-2 Natural 3200 Black 3210 Black 3210-2 Black 3300 Black 30-2 Black jjIO Black 3310-2 Black 3311-2 Black 3300 Color 3210-2 Color 3310 Color 3310-2 Color 3311-2 Color J225 J226 J227 J228 0 116.6 18.4 0 0 0 0 0 0 0 0 108.7 0 0 0 0 123.0 57.0 1057.8 0 52.3 72.0 0 95.2 21.1 0 69.8 0 0 0 0 0 25.9 326.2 18.4 86.3 - 76.1 38.9 694.0 217.8 39.5 2914.1 47.1 1261.6 370.5 15.0 47.0 265.3 224.5 102.2 3653.1 19.1 361.4 172.8 54.4 217.9 21.1 122.7 69.8 53.7 9.7 7.5 13.0 13.0 02 6 31 22 07 08 01 0 46 0 13 01 0 102 01 3 62 0 17 01 01 08 7 12 35 12 49 01 3 21 5 11 02 8 17 11 08 44 04 01 01 01 01 TOTALS 1791.9 11559.6 54 448 Quality Waivers Quantity (M Lbs) Lots JUNE YTD JUNE YTD 30.4 251.0 91.3 . 70.4 47.6 19.5 25.5 194.2 34.7 20.4 47.6 2 7 6 te , ** l l 25 2 1 44 118.0 714.6 ` 6 29 - V * QUALITY WAIVERS 6.6 Month 6.2 003911 r TABLE IX Nylon Quality Summary - JUNE M Lbs Percentage Year to Date M Lbs Percentage Gross Production Total Packaged Off Specification Quality Waivers 2203.0 623.3 433.1 100.0 28.3 19.6 15074.4 5145.7 4336.8 100.0 34.1 28.8 TABLE X Nylon Experimental Products Product N181 N186 N184 N249 ' Production 442,800 198,000 44,000 39,900 Releases 422,400 186,000 44,000 17,000 003912 y \> . TABLE XI Analysis of Nylon Packaged Off Specification Defect Relative Viscosity Volatiles Ash Content Discolored Pellets Off Size Pellets Natural Color Tzod Impact Nucleant Copper Black Specks Lots 6 8 4 3 0 18 0 2 0 5 JUNE M Lbs' 123.3* 160.0 89.2 32.4 0 317.4 0 34.8 0 43.5 % of Production 5.6 7.3 4.0 1.5 0 14.4 0 1.6 0 2.0 Year to Date % of Lots M Lbs Producti 111 2667.7 17.7 81 1830.5 12.1 12 228.0 1.5 8 63.3 ' - 0.* 3 - 0.5 81.0 , 30 637.6 , r 4.2 14 316.9 2.1 11 208.5 1.4 2 42.5 0.3 5 43.5 0.3 003913 1 \ . Formulation 1000-1 Natural -1000-2 Natural 1000-4 Natural 1003-1 Natural 1003-2 Natural 1200-1 Natural 1300-1 Natural 1310-1 Natural 1310-2 Natural 1310-4 Natural 1400-2 Natural 1403-2 Natural 1500-2 Natural 1503-1 Natural 1503-2: Natural 1600-2 -Natural 1603-2 Natural 1000-2 Black 1003-2 Black i310-2 Black 03-1 Black .1.503-2 Black 1603-2 Black 1503-2 Color 1603-1 Color 1603-2 Color N181 N184 N186 N198 N224 N243 N245 N249 N269 N270 N273 N355 N357 TOTALS TABLE XII Nylon Releases Releases___________ Quantity (M Lbs) Lots June YTD June YTD 0 101.0 0 188.0 0 0 0 11.0 299.8 0 0 0 55.2 0 362.0 0 0 0 106.8 0 0 300.9 57.1 0 0 0 422.4 44.0 186.0 0 0 0 0 17.0 0 0 0 0 -0 354.4 1340.0 611.1 365.9 907.0 221.4 58.0 11.0 917.3 331.3 63.0 32.9 320.1 284.3 1266.2 103.0 24.9 195.9 348.3 246.4 39.2 1584.8 108.8 72.6 209.4 12.6 830.8 62.0 302.0 41.2 1209.4 627.6 175.6 17.0 342.0 148.1 147.5 804.9 315.6 * i ' . _ " 0 5 0 9 0 0 0 1 15 0 0 0 3 0 20 0 0 0 4 0 0 9 2 0 0 0 20 3 18 0 0 0 0 2 0 0 0 0 0 18 67 31 18 46 21 3 1 47 16 3 1 11 9 48 4 1 6 14 7 1 46 4 6 18 1 40 4 31 2 60 32 9 2 18 7 7 42 5 "2151.2 1 15053.5* 111 708 Quality Waivers Quantity (M Lbs) Lots June YTD June YTD 40.1 41.3 264.8 116.4 2 2 14 6 142.5 117.7 7 11 78.3 97.4 4 5 245.9 130.7 252.2 1072.7 74.7 52.8 19.9 134.3 266.4 185.2 39.2 603.7 42.9 21.6 52.8 12.6 21.6 61.8 63.7 250.7 12, H- " '< r i - 4 -7 38 2 4 9 5 1 16 2 1 i1 56 3 13 227.6 38.4 433.1 4336.8 12 1 24 174 QUALITY WAIVERS 20.128.8 Month YTD 003914