A Cost Effective Alternative for Polyurethane Foams Overview

A Cost Effective Alternative for Polyurethane Foams

Overview • Ecomate Product Review • Usage & Market Applications • India Trials • Considerations • Ecomate’s Success & Availability • Conclusions

® What is ecomate ? • A liquid blowing agent or a foam expansion agent • An alternative blowing agent for rigid and flexible applications • Cost competitive & economical • Been in Commercial use for more than 10 years • Meets regulatory standards as an alternative in PU foams

Regulatory • US EPA SNAP Approved • Ro. HS and WEEE Compliant • GRAS Approved • Non-Toxic • VOC-Exempt • Montreal & Kyoto Protocol Compliant

Properties & Comparison Ø Ø Ø Well-suited blowing agent for PUR & PIR foams Similar to HCFC-141 b Liquid at room temperature Ø Ø No special equipment needed when handling Non-ozone depleting and virtually zero GWP Properties ecomate® 141 b Boiling Point °C 31. 5 32 Gas Lambda Value @ 25°C 10. 7 10 60 117 Specific Gravity 0. 982 1. 24 Flash Point -19°C ND LEL (ppm) 50, 000 72, 000 Ozone Depletion Potential 0 0. 11 Global Warming Potential ~1 725 Molecular Weight

UNDP Validation Report

ecomate® Sector Usage Rigid Foams Flexible Integral Skin XPS

® ecomate • Applications Rigid Foams ‣ Pour-In-Place Rigid Insulating Foams ‣ ‣ Commercial Foodservice Equipment/ Commercial Refrigeration Discontinuous Panels - ‣ Houses – Modular Transport Continuous Panels - ‣ Cold Stores Flex Faced Metal Faced Block Foams - Sheets Pipe Sections ‣ Spray Foams ‣ ‣ Industrial Dwellings

ecomate® Applications • Flexible Foams ‣ Integral Skin Foams - Automotive - Furniture - Leisure/ Toys - Medical Applications ‣ Flexible Molded Foams - Hypersoft Foams - HR Foams - Viscoelastic Foams ‣ Slabstock Foams - Continuous process - Box foaming process

Ecomate Trials- India • FSI partnered with independent system houses • January 2014 agreed to trial ecomate • FSI supply base formulation(s) • Must be present during trials • Provided technical support

Qualification Testing • 4 Base Formulations • Modified formulations to achieve target reactivity and density • Cream: 25 -30 sec • Gel: 150 -180 sec • Free Rise Density: 25 -30 kg/m 3 • Lab Testing • Viscosity • Compressive Strength • Dimensional Stability (Heat, Humid, and Freezer) • Closed Cell • K-factor • Shelf-Life Stability

Formula 1 Formula 2 Formula 3 Formula 4

FSI In House Testing • Formula 1 & Formula 4 were tested using high pressure equipment • 1. 22 m x 2. 44 m • Thickness: 50 mm and 100 mm Equipment Settings

High Pressure Testing Results

India Demo • Both Formula 1 and Formula 4 were given to 3 system houses • Systems were made with locally available polyols • Substitutions were made to the guideline formula • Systems were optimized for reactions speed etc. • Respective System houses chose - one or both formulas to trial at their end-users (panel foamers)

India Demo – continued • 5 panel producers were chosen by the Independent systems houses • Panels were shot though HP equipment • Panels of various lengths and thickness were used • Density was maintained as per the current (141 b) system in use • Equipment parameters were kept the same • Equipment was calibrated based on the new system ratio

Royal Industries (Delhi) • Formula 4 was tested in the lab Only • No equipment was available to run the trial • Lab Mold was used to simulate a panel production • Reactivity and density was recorded. • The lab made sample carried to FSI labs for evaluation

Royal Industries (Delhi) Foam Supplies Testing Results

Industrial Foams (Delhi) • Trialed Formula 1 & Formula 4 ‣ Want to trial both formulas • Reaction profile was faster – end user preference • A few block molds were filled – used for flooring applications • Blocks molds were filled at 36 kg/m 3, 38 kg/m 3 & 40 kg/m 3 • Metal faced and PE film panels ‣ 5 panels total ‣ 50 mm & 60 mm thicknesses

Industrial Foams (Delhi) Equipment Settings Foam Supplies Testing Results

Industrial Foams (Delhi) Industrial Foams Testing Results • Measured thickness at various locations on the panel • After 3 weeks, remeasaured the thickness at the same locations. • No apparent shrinkage!!!

Jindal Mectec (Delhi) • System House A tested Formula 1 and Formula 4 ‣ Formula 4 chosen to trial • No changes made to guideline formula • Metal faced and PE film panels made ‣ 6 Panels total ‣ Thicknesses of 40 mm, 60 mm, 80 mm, 100 mm, 120 mm ‣ Various lengths and widths

Jindal Mectec (Delhi) Equipment Settings Foam Supplies Testing Results

Modern Prefab Systems (Delhi) • System House A also provided them with Formula 4 ‣ • • Exact same batch that was sent to Enterprise 3 Panels with various types of facers ‣ Metal, Aluminum Foil, PE film, Plywood/Metal, Gypsum/Cement ‣ 10 panels total of various lengths, widths, and thicknesses True Test 10 m long panel!!

Modern Prefab Systems (Delhi) Equipment Settings Foam Supplies Testing Results

Blessed Stars (Chennai) • System House B tested Formula 1 and Formula 4 ‣ Made changes to guideline formula - • • Used their own polyols Changed ratio to 100/142 Formula 4 chosen to trial 2 metal faced panels ‣ Underfilled panel - ‣ 36 kg/m 3 Too overpacked panel - 57. 5 kg/m 3

Blessed Stars (Chennai) Equipment Settings Foam Supplies Testing Results

India Trial Results Summary

India Trials Summary • Formula 4 was the preferred system by all parties • No changes were made to equipment, operation, or production • Adhesion to all facings (steel, PE film, etc. ) was excellent • Foam Supplies addressed all concerns during trials ‣ • Will give assistance where needed Successful trials!!!!

Considerations • Not a Drop-in replacement for all systems • Optimization is REQUIRED! • Minimal Capital Expense • Fractional compared to hydrocarbon technology • Cost Efficient • Environmentally Benign • Meets Montreal Protocol • Meets Kyoto Protocol • Thermally Efficient • Flash Point ecomate – pure form ecomate – polyol blend ecomate – mdi blend flammable nonflammable -19⁰C flash point >35⁰C flash point

Considerations ecomate is not a corrosive species § ecomate stored and shipped in metal containers § Potential issues arise from: § Unoptimized system § Improper use of equipment § Plastic seal compatibility must be checked! § PTFE & Kalrez seals recommended

Why is ecomate successful? § Compatible with most PU raw materials § Meets or exceeds energy standards § Can process through standard and/or existing equipment § No additional capital investment necessary § Available worldwide

Why is ecomate successful? § Compatible with most PU raw materials § Meets or exceeds energy standards § Can process through standard and/or existing equipment § No additional capital investment necessary § Available worldwide

ecomate® Availability – Worldwide

Conclusions • Environmentally safe • More compatibilizing than other blowing agents • Minimal to no change in equipment • Successful in various applications • Not a Drop-in replacement for all systems • Optimization is recommended for success • Increasing the functionality of polyol blend • Changing the surfactant type and amount • Not all polyols OR surfactants are created equal

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