Hello maskisen -
Thanks for your question. If you choose to rate this answer, please ask for any
additional clarification or information you may require. Thanks for
your understanding.
I researched your question by locating and talking to a representative
from National Starch (http://www.nationalstarch.com), the 2nd or 3rd
largest company in the world for making such products. They have 40
plants around the world that do the very process described below.
The world of water-based adhesives is divided into two segments:
polymer (synthetic) and natural ("animal glue"). Synthetic represents
around 90% of the market; natural around 10%.
The base of the adhesive, which represents about 60-90%+ of the
product, is generally comprised of the same type of polymer found in
any water-based paint. (Ethylene) vinyl acetate, acrylic and
synthetic rubbers are the vast majority of polymers used. Companies
either make their own polymer or they buy it from polymer
manufactuers.
The polymer is added to any size reactor vessel -- the smallest being
50 gallons, the largest being 5000. The larger the application, the
larger the vessels. For specialty applications, vessel will range
from 100 gallons to 1000 gallons.
The polymer is pumped into the vessel. The manufacturer's special
propietary formula is added to the vessel which changes the
consistency, flow, adhesion, appearanace, and color characteristics.
For example, the formula would alter the consistency to fit the end
product's applicator-type -- whether for brush, squirt bottle, water,
high pressure, etc. Typically included in this formula are tackifiers
or plasticizers to make the polymer stickier (polymer has some level
of adhesive properties inherently; it's sometimes sufficient by
itself). This formula is what gives each adhesive its unique
qualities and is specific to each manufacturer.
Next, the mix is stirred from anywhere around 15 minutes to a couple
hours by a (power-driven) agitator; mix time varies based on the
ingredients. Fungicides/mildicides (preservatives),
defoamers/surfactants, etc. are added. The mix is then filtered and
drained into the containers they're shipped in. pH and viscosity is
measured toward the end. ph is normally betwen 5-9. Turbidity
measurements aren't used. The mix is generally not heated.
A polymer manufacturer such as (http://www.airproducts.com) might be
able to assist in making a formula to be added to the polymer.
Search strategy:
National Starch company
The adhesive & sealant council
[DO NOT DISCLOSE]
John Orloff
National Starch
908-685-5106 |
Request for Answer Clarification by
maskisen-ga
on
21 Jan 2004 07:58 PST
Dear Expert,
Thank you for your helpful information! For our purposes we would we
grateful if you could find out the following:
For a typical plant: (one of National Starch e.g.)
- How many vessels/production lines do they have per plant?
- Are the pH measurements you mentioned at the end of the production line made
in-line or do the just take a sample and analyze it in the lab (off-line)?
- If they are measured in-line, how many do they have per production line
respectively per plant in general?
- Are the measurement(s) placed after the filtration step?
- Do they use liquid, gel or polymer pH electrodes?
- Are there any typical issues with pH measurements, e.g. risk of clogging of
the diafragm on the electrode due to the measurement environment?
- What are typical replacement cycles? (once every x week, month?)
- Don't they have any in-line measurements of conductivity either? (no
turbidity you wrote)
Thank you in advance for your support and fast reply!
Best regards,
Charlotte
|
Clarification of Answer by
jbf777-ga
on
21 Jan 2004 08:34 PST
Hello maskisen -
Thank you for your additional questions.
Because these are essentially questions of a new scope and may require
significant additional research to answer, these would have to be
posted as new questions at some list price.
However, from my researching your original question, I do not believe
this information would be readily available to anyone other than an
employee at an adhesives company or a manufacturing consultant (of
which I am neither).
In my previous research, I came upon such a consultant by the name of Joe Prane.
He charges $1200 per day for consulting work. These additional
questions may take less or more time, and the fee would vary as
appropriate. Mr. Prane resides in Pennsylvania, and I believe is a
retired employee of an adhesives company. He can be reached at
215-635-200 (voice) or 215-635-2008 (fax). He should be able to help
you out with these and related questions.
Please let me know if you have any other questions.
Thank you,
jbf777-ga
Researcher
|
Request for Answer Clarification by
maskisen-ga
on
26 Jan 2004 00:51 PST
Dear jbf777-ga,
thank you for your fast reply and I understand what you mean. But, for
important clarification, during your talk with the representative at
National Starch, "pH and viscosity is measured toward the end. ph is
normally betwen
5-9.", did he meant in-line (pH electrode installed in the production
line) measurements, or do they just take a sample and test it in the
lab?
Thank you for your support!
Best regards,
Charlotte
|
