FLAME RETARDANTS
Figure 3- Effect of Actilox PA-B2 & PA-14 on smoke development and heat release in the cone calorimeter
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35 phr Apyral 40T1 + 15 phr CaCO 3 + 5 phr ZnB |
50 phr Apyral 40T1 35 phr Apyral 40T1 + 15 phr CaCO 3 + 5 phr Actilox PA-14 |
35 phr Apyral 40T1 + 15 phr CaCO 3 + 5 phr Actilox PA-B2 |
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maximum average heat release rate( MAHRE) of this compound series.
The ZnB-containing compound shows the same TSR as the compound filled with just Apyral 40T1 at 50 phr. The latter results in a lower MAHRE. The two compounds containing the mineral Actilox PA synergists give a further very significant reduction of both measured values. The Actilox PA-B2 containing compound is the best performing formulation, even though the LOI reached only 27 % O 2
. Analysis of the heat release rate curves further confirms this trend. The formulations containing Actilox PA show lower peak heat release rates than the ZnB system, indicating more effective control of the combustion process. Thus these mineral synergists not only limit flame spread but also reduce smoke exposure during a fire.
Cost comparison
Due to significant price hikes for ATO compounds and masterbatches, the substitution of ATO is no longer a health and safety topic alone but is of significant commercial relevance. Figure 4 compares the compound formulations previously discussed technically in the above paragraphs.
Despite increasing compound densities, the formulations with the highest ATH contents are most attractive. Compound 5 based on Apyral 40T1 and Apyral 120E results in a 29 % volume cost reduction compared to the reference based on ATO and ZnB(-32 % based on compound mass).
When identical physical properties compared to reference are requested, compound 6 with the reduced content of CaCO3, combining Apyral 40T1 and Actilox PA-B2, is still offering a cost benefit of 18 % on volume basis( 16 % on mass basis).
Summary
The investigations demonstrate that highly filled PVC systems based on ATH in combination with suitable mineral synergists represent a technically compelling alternative to established ATO / ZnB systems. By using surfacemodified Apyral 40T1 and functional additives such as Actilox PA-B2 or Actilox PA-14, ATO and ZnB can be fully substituted.
FR performance and thermal stability were maintained at a high level and significant compound cost reductions can be realised. These optimised filler combinations also enable compound formulations without any comprise on mechanical performance, still allowing substantial savings on compound material costs. ●
*- APYRAL and ACTILOX are registered trademarks of Nabaltec
Dr Reiner Sauer wein
HEAD OF R & D / TECHNICAL SERVICE DIVISION
Figure 4 – Cost comparison
Note: Compound costs in €/ kg and in €/ l are displayed and the relative compound mass and compound volume cost in relation to the reference compound. Calculation was done based on raw material prices valid in Q1 2026
J j
NABALTEC sauerwein. reiner @ nabaltec. de www. nabaltec. de
All formulations contain 100 phr PVC 5 phr Ca / Zn-stabiliser 50 phr DINP
Reference Compound 2
50 phr CaCO 3 |
50 phr CaCO 3 |
5 phr ATO |
35 phr AP 40T1 |
2 phr ZnB |
5 phr ACT PA-B2 |
Compound 3 Compound 4 Compound 5 Compound 6
50 phr CaCO 3 |
50 phr CaCO 3 |
50 phr CaCO 3 |
15 phr CaCO 3 |
35 phr AP 40CD |
35 phrAP 40T1 |
25 phr AP 40T1 |
35 phr AP 40 T1 |
5 phr ACT PA-14 |
5 phr ACT PA-14 |
15 phr AP 120E |
5 phr ACT PA-B2 |
Compound cost [€/ kg ] |
1.92 |
1.44 |
Relative compound cost |
1 |
0.75 |
Compound density [ g / cm ³] |
1.46 |
1.52 |
Compound volume cost [€/ l ] |
2.80 |
2.19 |
Relative comp. volume cost |
1 |
0.78 |
1.33 |
1.44 |
1.30 |
1.62 |
0.69 |
0.75 |
0.68 |
0.84 |
1.51 |
1.51 |
1.53 |
1.42 |
2.01 |
2.17 |
1.99 |
2.30 |
0.72 |
0.78 |
0.71 |
0.82 |
74 SPECIALITY CHEMICALS MAGAZINE ESTABLISHED 1981