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A. \, CPi iA, /7/OCifSC-f^ <*:.' U EECAKPlA PLANT UJC, itrr ero ma k\s mo:;aw a u m To: A. R. Donaghy From: J. H. Williamson Re: Monthly Sales Samples Summary for May, 1971 Less than 50# Samples Date: Copies: Juno 2, 1971 A. R P. K J. M V. J D. J R. R R. V Adams B rown e Davidson Grande Mann Spiegclhalter Whitaker FVC N/C SHIPMENTS Customer Date Type Lot Lbs. Shipped Per B, F. Goodrich Chemical Co. it n 1! - 5-4-71 11 6l80 ii 7338 7340 Skid 1-21 Skid 1-19 P. R. Browne n ii W\i\kit IncorpT| oration 5-S-71 9010 6616 5 J. L. Harvey 6l0o 7303 5 B. F, Goodrich Chemical Co* ti n ii 5-5-71 n 6l0o 1! 7^15 7421 Skid 1-15 Skid 1-21 P. R. Browne 11 11 Vitek it Research ii Conrp. ii ii 5-10-71 ii IT Sob in Chemicals If ii Ashland Oil & Re-fining 5-11n -71 5-18-71 B, F, Goodrich Chemical Co. ii ii ii ii n ii ii ii ii ii n , ii IT n 5-19-71 H it ii ti ii 9-21-71 2160 2185 3185 1200 1225 2200 6l80 u ti u IT II It 6l80 6070 5990 4821 5953 58l 72 S9 7521 7494 7495 7492 7518 7515 7517 7520 5 5 5 5 5 5 Skids 1-18 1-8 1-10 1-11 1-21 1-18 1-18 1-20 P. Rn . Bro11wne 11 ti V. J11 . Gra11 nde W. C. Kueance P. R. Browne nm t: n IT It 11 TI IT II AP00047I83 A. R. Donaghy Customer Jo1h! n II IT IT 11 IT 1! IT Barr, 1! n !! IT 11 11 >1 A PCI 11 ii il 11 IT 11 II J erry Lavender, APCI Scott Graphics B. F. Goodrich ii it Jerry Lavender, APCI JHW: es -2- June 2/1971 Date Lot Lbs. 5-20ii -71 ii n ii ii ii 5-24-71 6ln8o ii ii 1! 11 II 8225 1225 7314 7322 732h 7326 7330 7332 7288 7290 7287 b/t 310 2 2 2 2 2 2 2 2 2 5 5-24-71 61*15 6700 5 5-26-Tl 11 6180 n 6496 6499 Skid 1-8 Skid 1-20 5-27-71 122 5 b/t 1328 5 Shipped Per ?. R. Browne II 1! II It 11 It 11 11 11 II 11 11 11 IT 1! It P. R. Brovne Bob Carnpenella P. F. Brovme 11 11 P. R. Brovin s ------- J, H. 'Williamson AP00047I84 S' t /7'7>.'7/.'<\C <>(< PUI IT IH WRITING DATE: June g, 1973 TO: FROM; A. Ross Adams G. J, Mantcll SUBJECTS Highlights of Plastics Division RuD May 1971 ____ _ __ APPLICATION RESEARCH AND DEVELOPMENT 1. Bottle Compounds Room temperature organoleptic tests at Seagrams continue to look promis ing. Their more meaningful high temperature accelerated tee is on a number of promising compounds arc underway. These tests may continue for as long as three months for a final decision. Work at Brovn-Forman is somewhat loss promising. None of the compounds which look promising at Seagrams passed Brown-Forman's initial testing. I believe that their test procedures are suspect and that we are no worse than a B, F. Goodrich compound they now use. We will continue to work with Brovn-Forman on their testing procedures. We have not given up here. II. Film and Sheeting A new compound (C-500) was developed to overcome the printing ink blocking problem Which Orchard Corporation found with our experinentai eonpoumi C-U82. a Calvert City run and a trial at Orchard Corporation are scheduled for early June. Products B-175 &nd C-351 were nm at Calvert City with help and assistance from Middlesex personnel. Both products were successfully made and ran well at Apache. There is a need for equipment modification at Apache if C--351 is to be operated successfully. We are working closely with the customer in this regard. Another lot of C-l*80for extrusion of crease-whitening resistant clear sheet, va3 successfully made at the Calvert City plant. A trial at Hallmark will be run in June. Ill. Injection Holding Four research candidate compounds for the Bell Telephone handset were delivered to Bell and evaluated for stability and processability in their Brabender, Initial reports were quite promising. They have injection molded samples for more complete physical property study and data should be available from them during the first week of June, "COMPARE CONFIDENTIAL" AP00047185 '7'f\ am/ C/U'ttlthtfd TO: A. Hoes Adams -2- June 2, 2971 The compound development vork for Ostcr has not succeeded in developing a creen that can be successfully molded in the Oster blender base mold. We are unable to eliminate a fine black streak with their equip ment and as veil, at equipment in our own plant at Morristown* B-617 a modification of 2003-A in the sane color also shows the streaking problem* We are somewhat at a loss on how to solve this problem. It is of interest that the sane compounds in white do not show the black streak, but a line does appear as a "scratch" in the same part of the molded item, A program was initiated in cooperation with General Electric and Rohm & Haas to develop a PVC compound suitable for injection molding a room airconditioner housing now employing the more expensive Lexan polycarbonate. A number of experimental compounds were sent to GE for evaluation of flow properties only, GE's input on this is critical to further development vork on this project. IV. Floor Tile We had an excellent visit with the Research and Development Group at GAF in Vails Gate, Hew York* They outlined specific problems faced in the present manufacturing floor tile operations and we have begun screening vork to identify resins that nay be helpful in solving some of their problems, V, Rigid Wire Compounds We have reformulated our rigid vire compound to improve the ultimate elonga tion of vre coatinge. Initial vork looks promising and ecjuples have teen sent to Western Electric for their evaluation. These evaluations will be completed in the early part of June. VI. Pine Fittings We have two pipe fitting compounds based on resins 1200 and 2200 which appear competitive in preliminary screening with a commercial compound from Ethyl Corporation. One-hundred pounds of each of the two compounds will be prepared at Middlesex in early June and trials will be run at the Grinnel company, Wc plan also to prepare a compound based on the ^00 Resins to be run at the same time to determine the commercial value, if any, for 400 com pounds in this application. YII Sayan Resins and Fi3m Cryovac's interest in our saran resin was not strong enough to break through their arrangement with Dow. Heat stability and barrier properties were rated good with shrinkage rated fair in our visit of May 3. Dow temperature flex ibility emerged as the next important property. Trade-off of barrier properties for low temperature flexibility is a necessary though unwelcome compromise, according to Cryovne, Daran resin demand pcakdng in 1971 is predicted by Cryovp.c and carried soma weight in their .Irek of interest in a working arrange ment with Al'CI. Hco; spa: CCJFIDDHTIAL" AP00047186 7v / TO: A Ross Adams 3- June 2, 1J?71 Crude torsional stiffness data show that Dow 86*4 and Cryovac "bag film are tetter in low temperature flexibility than SV-1706-E resin compounded (2 phr) with cither dibutyl sebacate or acetyl tributyl citrate. Higher levels of either of these would be needed to attain competitive low temperature flexibility, with cor.Mensuratc loss of barrier properties. Additional direct-blow film processing of saran compounds on the Killion line has had a few successful periods but is plagued with the difficult control of the post-extrusion stage process parameters. VIII, Fusion Resins A laboratory fluidized bed unit is operational at Linwood. Selfsupported (stripped) coatings have been prepared for a Tech Service Job, Improved methods are being studied and materials accumulated to evaluate a number of Escambia and competitive resins wider both adhered and stripped conditions, IX, Delco Remy Tyo samples have been submitted for evaluation at Delco Remy. One is a Pearl resin prepared in the Calvert City pilot plant by a preemulsification process, The second sample was a 3105 resin ground in the Trost Kill. Both products performed well in laboratory screening tests in terns of fusion, strength properties of the fused sheet and porosity. Neither product meets the molecular weight specification set by Delco Kenty based on their use of Ethyl resins. The importance of this for final acceptance of our product remains -to toe established. POLYMER SYNTHESIS Pearl Resins The crusting phenomenon in ^185-SP was studied at greater length in the Swiss reactor. Lower polymerization temperatures, use of CaCl2 in place of calcium phosphate, presence of non-ionic surfactants, lover HgO to monomer ratio, use of dispersants, end removal of latex anionic surfactant did not eliminate crusting. Grunting was minimized by use of a second agitator placed at the midpoint of the agitator shaft. A twin pitched blade turbine was the most effective arrangement. With the twin pitched blade agitator, crusting was completely eliminated at high agitation speed. Decree of crusting is inversely proportional to agitation rate. At the highest speed studied (600 rpm) a very uniform resin of 115^' median particle size and 33 Ibs./cu.ft* bulk density was obtained. "COi-fVWy COHyiDEHTIAL11 AP00047187 'i ,</;>/ {Ytcf/ttca/is i^r TO: A* Rocs Adams --b- June 2, 1971 Reduction of botch size was also observed to eliminate crusting. PVC Pearl 2165 was found to have approximately 10 times the ash content of Dow 2103* 2053 and Vygen 310, The chief component of the ash from 2165 is calcium oxide (Ul%) and from either Dow or Vygen products Jia20 or Fe203 FVC Pearl 2185 contains much less water extractable material than the Dow or Vygen rosins, XI, Polymerization Initiator Studios -- In-Situ and-Other Catalysts Various in~situ initiators have been used to polymerize a 90/10 charged VC1/P copolymer. The chlorofornate components used were ethyl, n-butyl and L-butyl. As a standard IPP has been used for comparison. The IPP and rv-butyl chlorofornate initiator systems react unfavorably with cumene yielding both reduced molecular weight and reduce polymerization yields as the cumene content is increased. The presence of the cumene serves as an agent to prevent "early yellowing". The ethyl chlorofornate and L-butyl chlorofornate initiators also show a trend toward lover molecular weight but no. effect on rate of polymerization as the cumene content is increased. There is a considerable level of cumene still in the polymer, Its importance to FDA acceptance remains to be established. The effects of various parameters on vinyl chloride honopolymerization such as -- 1) alkyl chloroforraate alkyl sulfonyl chloride 2) hydrogen peroxide peracetic acid 3) pH of aqueous phase have been investigated. The following systems polymerize VC1. Alkyl sulfonyl chlorides/peracetic acid Alkyl ehloroformate/hydrogen peroxide Alkyl sulfonyl chlorides/peracetic acid Alkyl chloroformate/peracetic acid e pH = 11.3 5 pH 6,65 @ pli = 6,65 6 pH I4.U5 Several systems described above are not within the scope of the Goodyear patent. "COMPANY CONFIDENTIAL" AP00047188 TO: A, Ross Adams -5- Jure 2t 19J1 XII. Post-Chlor Resins j Post-chlorination of PVC 3185 and neveral porous vinyl chloride/propylene copolymers were completed using a fluid bed method. Chlorinations were also carried out in chloroform solution, All products "look Good" and remain to be compared in depth. Chlorinations in carbon tetrachloride solution to produce post-chlorinated polymers in the 67-68 Cl level of 4o4 and 241 have been made. Our first attempts at post-chlorination in carbon tetrachloride at 60C for four hours produced polymers containing 72# chlorine, Runs of very short duration have been made since, A one-hour rim at 60C in carbon tetrachloride yields a product containing 65* Cl. Ilonopolyme r 2U1 post-chlorinated under the same conditions produced a product vith a chlorine content c-f 67.8/S. XIII. Polymer Characterization The Robinovitch correction of melt viscosity data is demonstrated. The melt viscosities of thirteen samples from different projects (Post-Chlorination of PVC* Copolymer Program and Saran) were measured at two or three temperatures. Theoretical studies of branching in heterogeneous PVC polymerization have been completed. The degree of branching is negligibly small. This work will be separately reported. Besides the thirteen samples for melt viscosity measure ments, service work included two samples for GPC and five samples for densitydetermination, GJM:cnc cc: C. E. Blades J, L. Cost/R.A.Walde G. B, DeL&Hater L. C. Doelp L, Pranikoff D. G. Holland N. C. Robertson/D. G, Kanly R, J, Tedeschi "COM?/::* CO;?FIDE?!TIAL" AP00047I89 \ o-~f`\ /-Y.'-vir# .in/ PUT IT IN WRITING Dole June IS. 3Q71_______ To A. R. Adams Subject Monthly Renorb. Mav 1Q71 From Vi. R. Brynes' ____________________________________________ ( ) Take Action ( ) Foe Your Approval ( ) For Your Info ( ) Discuss Willi Me ( ) For Your Comments ( ) As Requested ( ) File C ) Note fii Return I. Pricing Sensitivity Analysis-400 Resins With the aid of W. R. Whitaker a marketing analysis for 400 resins at lower pricing levels was prepared, and in a slightly revised form fed into a linear programming computer run in Trexlerfcown. The results of this analysis have been submitted in a separate report. In summary it appeared as though a lf per lb. decline in low level pricing for 400 resins would allow penetration of existing PVC markets for more standard PVC resins at a level roughly equivalent to our present ca pacity for 400 resins at Calvert City (approximately 33# of the total Calvert City production capacity.) It v?as further-concluded, that addition? reduction in price to a low level of 15^ per lb. would allow rather rapid increases in sales up to approximately the 50# level. Beyond this point, there is little incentive for further price reduction, because of the relatively low level of profitability resulting. This study is preliminary in a revised form of the market forecast and has already been prepared for submission into the program again. II. Post-Chlorinated 400 Resin Program New market projections for Post-Chlorinated 400 Resins were developed and incorporated with the aid of Dr, C. A. Heiberger, in the research eval uation summary submitted by Dr. Heiberger for approval. III. Meetings Attended A. The AMA Packaging Show in Chicago B, The Chemical Market Research Association Meeting in New York City The writer prepared a separate report covering the CMRA meeting sub mitted independent of this report. Of particular note was Mr. John Auchter't projections for PVC through 1930 which included an over-all growth rate of 11 to 12fo per year. Also a strong need for pricing increase to support further capital investment in our research and development expense in the future. IV. Tariff Commission Summary The aecomvm-nyinr: fjpuron shov? summary.'; for pertinent sales and pro duction data through Marc)'. 1971. Results for both Pub. nnd March for the PVC industry v.-cre far more encouraging than those AP00047190 A. R. Adams V. R. Brynes Monthly Report, May 1971 June 15, 1971 Page 2 recorded in January of this year. For March In particular the total sales results (domestic and foreigh) were the best in the history of PVC reflec ting an annualized rate of sales of 3.^ billion lbs. per year. Later contributors to this improvement were calendered and extruded products as well as piping fittings plus wire cable. March results do not meet the extremely poor results of January and February however. The results of the first 3 months of 1971 are annualized to 3*08 billion lbs. this level is slightly excessive the somewhat disappointing results for 1970. and certainly well below the projected sales for 1971. Continued improvement in the PVC market picture as anticipated. "W. R. Brynes AP00047191 . /-_ / -\ PUT IT III V/nniMG fx.:e__ dune PB, 1971 To____ Aj R. A dm nr. Subjoct MONTHLY REPORT - MAY 1971 Froni J. M, Davidson ( ) Take Action ( ) For Your A|i;*rov;il ( ) For Ycnir Comments ( ) As Requested C ) For Your Info ( ) File ( ) Discuss V.'slli Ye ( ) Note & Rc'lmn Sales for the month of May and year-to-date are as follov.'s: Year to date Much-May May Compound Injecticn Molding Film Bottles 802,350 533,^80 53,40'- 200,000 75,480 40,200 Total] 1,389,230 315,680 400 Resin 803,150 149,000 Electrical Appliance BTL Handset Molded samples of four experimental compounds v;ere submitted for preliminary investigation. '..iese materials appea to be equivalent or superior to the present Ethyl 7042, althoug Ethyl has submitted several improvements of this material for testing also. Presently 7042 has tentative acceptance; however, they are low in izod, questionable in HDT, and reportedly went from v?hite to blue over night at 70 C. We have not experienced a color change in this test and feel that we can now offer a superior material. A meeting with BTL is scheduled for June with a resultant molding trial expected. A June 9th meeting of BTL and Western is to be held to set a timetable for future PVC product acceptance. BTL Battery C&D has been the successful bidder for this years requirements. A trial was held but due to machine problems, parts were not molded. Another trial will be scheduled shortly v/ith production expected .at C&D thereafter. AP00047192 . fPr,;tr PUT IT IH V.`UITi:iG Dote June 23, 1973 _ ToA. R. Adam:-Subject MONTHLY REPORT - HAY 19 71 From J. H. Davidson_________________ ________________- Page 2 - ( ) Take Action ( ) For Your Approval ( ) For Your Info ( ) For Your Corrmenls ( ) As Requested ( ) File ( ) Discuss With Me ( ) Note & Return Electrical & Appliance - cont. Black & Decker A meeting has been set for June to review our PVC as a 'competitive material to the KA they presently use (priced 32.5$/#)- is expected that a trial will also be scheduled for June or July. Singer They have received quotes from Drako on a tool part in PVC at a 12% cost reduction in our material. A trial is scheduled for June which could lead to acceptance at Singer for FVC in their tool line. Teletype The Teletype cover was run at Mac-Ray in 2003A and D591. A splay problem was noted, vrhich can be eliminated by proper gating. Presently these parts are in testing at Teletype. The competitive material is KA G 53$ which also has a tendency to sink more than our material. At present our main problems will be in tool design due to shrinkage which would require Teletype to adjust the holes in the molded part for our materials. G .E. - Photo Lamp Adjustments were made to the runners which resulted in our ability to run 482. We still require a high ER as we 11 as a color match for G.E. < the flash cube. G.E. - Air Conditioner Cover Prints were received of the tool and are presently being reviewed. A meeting will be held in June to review mold designs as v;ell as flow properties of compounds which have been submitted. AP00047I93 To A K . A dev Subject VOK'Hh.V PP/POTiT - b;AY jQ'H ( ) Tor Your A|'yifPVl ( ) As Requested P^e_3_( ) For Your Info ( ) Discuss Willi Mo ( ) Note & Relurn Poster Grant Presently rc-tooling for next year's eye-glass frame. We expect production to start in PVC during August or September. American Optical trials. Has purchased 1,000 pounds of our material for Bausch & Lombe They have run both 5011 and 2003A with success and are considering these materials for other applications along with eye-glass frames. Packaging Wheaton A trial material of 701^ as well as an initial truck load order has been obtained. It appears that this account is now starting to obtain PVC bottle business. As previously pointed out we are the only PVC supplier and are forwarding all leads in order to build our business through Wheaton. Creative Packaging They have withdrawn from the PVC bottle market. L- Their volume is estimated at 200MM bottles which will be absorbed by the remaining producers such as Kerr* Wheaton, 0-1* etc. L. j&j Baby oil bottle and CP account will be placed with Kerr or 0-1. The estimated volume v/hen released could be 1MM?? of C-l^`1 if our color problems are resolved. Thera is also interest at J'ftJ in E-4G5 for Future Wax bottles. AP00047194