Document x1Jz0bagR2pnMN3n7wYewYMBb

ijH (>mj INTER. off.ce memo TENNECO CHEMICALS, CONTfOFM? INC. APR 3 -1972 To M. W. Williams at Flemlngton date March 28, 1972 From H. B. Carr at Flemlngton Subject Quality Control and A&E Monthly Report - March, 1972 copy to P. Gawason H. R. Horton E. J. Hourihan ' E. L. Kanyok F. W. Kanzler M. C. Sp&lrtTng File, RESIN PLANTS Gate Raw Materials 1. DHW-80 (F. W. Kanzler, H. R. aUr' uu On 3/22/72, a meeting was held in Burlington with P.E*, C. W. Johnston and M. W. Williams to develop an approach for characterizing DHW-80 variables that affect plant processing. The program will emphasize a "sample library"; namely, samples will be retained and when plant upsets occur, these samples will be characterized analytically to define differences vs. control samples. Part of the program will be to define optimum.sample storage condi tions. June is targeted for an initial status report. 2. Lauroyl Peroxide (F. W. Kanzler) Noury (Cadet) has been approved and Lucidol has been reapproved as sources of supply for lauroyl peroxide. Approval is based on extensive laboratory testing that includes assay and bottle polymerizer kinetic runs. The material will be monitored in the plant by Q. C. and P.E. 3. Methocel (F. W. Kanzler, E. L. Kanyok) High metallic counts in PD-01118 (390 resin) for Nixon prompted a review of 90HG100 Methocel quality. Other Methocel types are filtered through a 5 micron filter, but. the 90HG type is not. Metallic counts ranged between 200-600 particles per pound, with ca. 4C^ imbedded and 60/ as free metallic particles. Jim Holton, Dow Q.C. Manager, was advised of these intolerable counts. Mr. Holton reviewed Dow manufacturing records and found that these lots were manufactured prior to installation of magnetic separators. As an interim step, Q.C. fabricated a lab- scale Syntron setup for removing metallic from the 90HG100. Dow has promised to step up their perusal and correction of metallic sources in their process. COLORITE 011365 M. W. Williams -2- March 28, 1972 Finished Resin 1. Hatfield (M. C. Spalding) i' A joint Q.G., Resins Group and F.E. effort has resulted In the necessary improvements in resin to meet Hatfield requirements. Steps that were taken and supported by .C./A&E testing were revisions in charging procedures !eliminates glassy beads) and a reduction in Methocel coarsened the particle size and tightened the distribu tion). Hatfield currently will be receiving 225/16r resin meeting customer instruction sheet requirements on dry blend and screen. 2. Control Charts (M. C. Spalding, F. W. Kanzler, E. L. Kanyok) Control charts for dispersion resin have been completely revamped in that rheological properties will now be plotted as log distributions. Control charts in Burlington and Flemington are now up-to-date and will be utilized to alert Manufacturing of process shifts. As part of this program, a process capability and specification review was held in Flemington on 3/28/72 to review Flemington plant control and areas requiring Manufacturing and/or P.E./Q.C. attention. General* * 1. Nixon FDA (H. B. Carr) On 3/17/72, S. Frankel, Foam and Plastics Division Q.C. Coordinator, visited Flemington to review FDA procedures and guidelines with W. C. Champion and H. B. Carr. The Nixon FDA program was reviewed extensively and attention was directed to BUDRUG, CMS and general handling of FDA related matters. It is felt that as a result of this meeting, Nixon will now be able to handle FDA coordination. One further step that is anticipated will be a visit by Messrs. Champion, Carr and Frankel to BUDRUG and CMS. * 2. R&D Time Accounting (H. B. Carr) An R&D time accounting system adaptable to time share computer operation was devised and circulated to R&D managers for comments. A meeting will be held early in April and the finalized system will be put fnto effect. COLORITE 011366 M. W. Williams -3- March 28, 1972 3- Display Cabinet (R. J. Eckman, H. R. Horton) A display cabinet was installed in the Burlington Q.C. laboratory hallway. The idea behind the display cabinet is to show Burlington employees the many Interesting end use applications of our resin products. As an initial display, the manufacture of a phonograph record has been shown from dry blend to record stamper, to initial cut and to the final product. Response from plant personnel has been gratifying. We feel that this approach should be expanded to other areas. COMPOUND PLANT 1. National Lead (P. Gawason) Two separate meetings were held with National Lead to review quality requirements of dibasic lead stearate (DS-207) and tribasic lead sulfate (CR-l). National Lead has assured us that we will receive record grade quality stabilizers. Record grade is based on an "agglomeration count." Our purchase orders now stipulate an agglomera tion count maximum of 5 in each product. Compound Q.C. does not currently have the capability of checking this agglomeration count. Compound Development is working in support of Q.C. to develop an appropriate test to assure that optimum quality National Lead stabilizers are uti lized in our formulations. The importance in developing this capability of course is our recent complaints at All Disc Records wherein we feel that subquality National Lead stabilizers contributed to plateout. 2. Raw Material Control (P. Gawason) In addition to the poorly defined specifications for National Lead stabilizers, we feel that the entire raw material specification area must be upgraded. A program has been coordinated with Purchasing whereby form letters will be sent to all current approved vendors requesting: l) specifications (not-typical properties), 2) test methods, and 3) a statement of FDA sanction status where applicable. Purchasing will maintain a score card on vendor responses and it is planned that by June, Compound Q.C. will have significantly upgraded raw material specifications. 3. Hardness Testing (P, Gawason) As a result of an effort to correlate hardness testing between Compound Q.C., R&D, and Industrial Plastics, it was noted that the Q.C. Constant Temperature Room had a considerable variation in temperature (22-29C). A COLOR!TE 011367 M. W, Williams -4- March 28, 1972 temperature recorder has been purchased and installed to monitor temperature in the CT Room on a 24-hour basis. Based on these recordings. Maintenance.will be requested to improve the temperature control. The recordings will also indicate the veracity of testing results. 4. Standard Product Listings (P, Gawason) Standard finished product lists were issued during the month. R&D and Marketing have been requested to comment on deletions and/or additions of the standard compounds. 5. Personnel Mr. H. Evans bid successfully on a mill operator's job and transferred from the laboratory on 3/10/72. Mr. R. Horvath transferred into the laboratory on 3/18/72. A&E 1. Monthly Time Allocation (M. C. Spalding) As in February, a considerable portion of A&E effort (>6o$) was allocated to Flemington plant support. Physical testing accounted for 20$ of A&E*s allocation and this was distrib uted 100$ to Plastics Development support. A physical testing summary is attached. 2. Flemington Plant Support (M. C, Spalding) A joint program with P.E., Resins Group and Q.C./A&E was directed at resolving Flemington plant particle size prob lems. Highlights of action taken were: a* Glassy Particles JRreviously characterized by A&E as high molecular Weight, nonabsorptive particles, glassy particles have been eliminated via an LOP procedure which revised the reactor charging step (lower water temperature at charge and delay of heatup until all the VCM is charged). b. Particle Size Control While the above LOP corrected the glassy particle problem and reduced gels, particle size 'distribution and loose bulk density dropped off (roughly 6-8$ on +80/+100 and ca. one pound on LBD) across the product mix. We feel confident that these shifts have been corrected via Methocel reductions. Of prime signifi cance in this effort, A&E has developed a procedure in COLORITE 011368 M. W. Williams -5- March 28, 1972 in which iiaihe^el is added to slurry samples to facilitate rapid drying. Utilizing this technique, A&E was able to provide P.E, and the plant with early data on particle size to hone in on optimum Methocel reductions. c. Demineralized Water A testing program for demineralized water has been instituted for the Flemington plant. We were particu larly interested in the iron level since it is known that iron at 2 ppm will chemically Interfere with Methocel and hence reduce its protective colloid properties. Thus far, iron content has been in good control varying from 0.01-0.20 ppm. d. Methocel Solution Makeup A&E is continuing the effort to characterize optimum Methocel makeup procedures. Utilizing a viscosimeter approach, Methocel solutions will be prepared at dif ferent temperatures, different' concentrations, and once prepared will be subjected to elevated tempera tures to assess gelation characteristics. HBC:em Att. COLORITE 011369 ' /`//ys/c./i L Test///<5 /d/rz c A 1<?7Z tYrr}; fief eLh PecAt sad (fsL 22 AUtd-. gt in*/.') ProJcJ J)e tefopiy.&A j Grdcp ReAins ; j Cenipeytfth Rigid* C OMpGUrttfe | fthecfagy 3 -zo 7 A c/diii Ye s CJre>op , A/cy/l/es r<* u/ Ir y/etk Recj-dih C cm pie fed \,RL 2P f / Urehh-eh. ) I Preject VeYa icp'm enf Gfjup Hesms ( | FU* it>(c. Cewppen-M R>qid C. eMpe>itiJs RhetUfi} AJciii'n'e.i 6reap 71Z7a7 COLORXTE 011370 \ f._ _ COLORITE 011371 t ///lT,'gI? lcsoi-7hrv<> /'-:/~s..4^r/*==?~J2/2. 3/ZO/-/2. 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