CSM Cosmo Scientex (M) Sdn. Bhd.

(A Subsidiary of Mitsui Chemicals Inc., Japan)

 A joint-venture company of

and

Mitsui Chemicals Scientex Berhad (M)

 April 2002
JV
Scientex
Mitsui Chemicals
Incorporated
70 30

Cosmo
Scientex
Cosmo Scientex (M) outline
Company name Cosmo Scientex (M) Sdn. Bhd.
Paid-up capital !"#$ million
!"#$
MCI 70%
SIB 30%
Products Urethane prepolymer
Main application For flexible packaging
Functions
Production, sales & technical service for the ASEAN market
Work force approx. 50
Investment U$ 10 million
Commence operation July 2003
Production network to cover ASEAN
Japan
China

Taiwan
Malaysia
Cosmo Scientex


PET, for printing

Al, as barrier

LL, as sealant


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Zone 1 Zone 2 Zone 3

60-70 oC 70-80 oC 70-80 oC
Wind speed = 20 30 m/sec

Gravure roll Unwinder 1 Winder Unwinder 2

Nip roll
Ether = 40 60 oC
Ester = 60 90 oC


EA OH NCO

EA+OH EA+OH Adhesive

EA
EA
OH NCO


Adhesive

 Trouble Shooting
A) Defective Appearance

i) Bubbling
1) Adhesive layer contains air bubble
2) Appearance good just after lamination but bubble formed
after curing.
3) Bubbles have some certain patterns.

ii) Tunneling (Warming)

1) Appear towards traverse direction (TD).
2) Appear towards machine direction (MD).
3) Random and partial tunneling.
i) Bubbling Appearance

Causes:
a) Bubbles were formed in the laminating pan by gravure roll
rotation.
b) Hardener absorbed moisture and formed CO2 gas.
c) Dilution solvent (EA) contained high % of water (moisture).
d) Excess of hardener (NCO) tern to react with moisture from
environtment.
e) Shortage of coating weight (e.g., white and yellow ink)
f) Insufficient wettability of film (PP, PE, etc.) < 38 Dynes/cm
g) Low wettability of adhesive (e.g., too high viscosity)
 Counter Measurement:

a) Mix adhesive carefully in order avoid to form bubbles in the

pan and mixing tank.
b) Dilution solvent containing over 0.05% moisture is unsuitable
to use. (for adhesive manufacturing)
c) Keep the standard mixing ratio of the adhesive
d) Increase the coating weight for yellow or white ink design
printing
e) Check the treated side of the film (Wettability of the surface of
the film 38 mN/m or Dynes/cm).
f) Always dilute the adhesive by fresh solvent.
g) Keep gravure roll clean and not to clog the holes in order to
avoid less coating weight.
ii) Tunneling Problem

Causes:

a) Inappropriate tension control of the films.

b) Wrinkles, slackening or biased thickness of original films.
c) Weak initial bond strength of adhesive.
d) Wrong mixing ratio (less hardener) weak initial bond
strength
e) Excess coating weight
f) Film had too high tension and wrinkled just before nip roll.
g) Adhesive was absorbed by ink less hardener
h) Low wettability of printed ink.
Counter Measurement:

a) Adjust the tension of both films (mainly TD).

b) Check whether the film has no defects in advance.
c) Select the adhesive with higher initial bond strength
(polyester type better).
d) Confirm and keep the recommended adhesive operating
conditions.
e) Keep the recommended coating weight.
f) Select the suitable adhesive with good wettability to the
printed ink.
B) Poor Bonding Strength

i) Stickiness after peel

ii) Decrease of bonding strength with time

iii) Others as comment by each converter

Causes:

a) Excess of main component (OH) not cured and found

stickiness
b) Hardener reacted with water, alcohol, or amine in dilution
organic solvent insufficient mixing ratio.
c) Residual solvent such as IPA and methanol in ink reacted with
hardener.
d) 1-Component PU ink reacted with hardener.
e) Curing speed of adhesive is too slow.
f) Adhesive was used after the expiry date.
g) Additive agent such as slipping agent and anti-static agent
migrated between film and adhesive (LLDPE film).
h) Insufficient corona treatment of the film.
i) Weak adhesion strength of VM layer, ink, PVDC layer to the
film.
j) Unsuitable adhesive for the application.
k) Incorrect corona treatment side was laminated (PE, PP).
l) Insufficient nip roll temperature.
Counter Measurements:

a) Confirm and keep the recommended adhesive operating

conditions.
b) Check the residual solvent in ink by GC in advance.
c) Increase the aging temperature in case of too slow curing
speed.
d) Select the suitable adhesive and film for the application.
e) Check the wettability of the film is 38 mN/m or Dynes/cm.
Do not stock the corona treated film for a long time.
f) Keep the suitable coating weight.
C) Solvent Retention

Counter Measurements:

a) Adjustment of dry zone temperature.

b) Strength of blowing wind at the dry zone.
c) Running speed.
d) Selection of adhesive (polyester or polyether type)(Polyether
easier to release solvent).

Note : Above factors should be adjusted according to the

condition of each lamination machine and operation.
 Cosmo Scientex (M) Sdn. Bhd.
(A subsidiary of Mitsui Chemicals Polyurethanes Inc., Japan)
Tel : +603-3101-1592, Fax : +603-3101-1195
Technical Service Request Form
1) Date :
2) Customer :
3) Adhesive : main component / hardener Mixing ratio ! : !
4) Solid Content : %
5) Films Composition : ( )/ ( )
(Film Maker : ____________ / _____________ / ____________ / _______)
6) Printing Ink No
Yes 1 Component 2 Components
(Ink Maker : )
7) Process Condition
Laminating Speed: m / min.
Gravure Roll lines _____ m
Coating Amount : g/m2
Use of Smooth Roll Yes No
Dry Zone Temperature "C / "C/ "C
Nip Roll Temperature "C
Extruded Resin Temperature "C
8) Curing Condition "C X days
9) Boil / Retort Condition ______ "C X _______ min.
For Retort : Spray System Hot Water Circulation Fixed
Rotate Others
10) Heat Seal Condition "C X bar X s
11) Pouch Size (W) mm X (L) mm
Content : Quantity : g
12) Kind of Problems:


 TS network to cover Asia
China Japan
TS center R&D center
TS center

India

Malaysia - TS data accumulated for

TS center 30 years in Japan
- Top formulation in Japan


CSM