Preblending granules of Sodium Benzoate with antioxidants such as Antioxidant 1010 (Irganox 1010) and Antioxidant 168 (Irgafos 168) is a common process used in various industries, particularly in polymer stabilization, food packaging, and other materials sensitive to oxidation. Here’s an overview of these components and the preblending process:
Ingredients:
1. Sodium Benzoate
Sodium Benzoate is commonly used as a preservative in food and beverages, but in industrial applications, it can act as an anti-corrosion agent or contribute to stabilizing formulations.
2. Antioxidant 1010 (Irganox 1010)
Chemical Name: Pentaerythritol tetrakis (3-(3,5-di-tert-butyl-4-hydroxyphenyl) propionate.
A primary antioxidant used to stabilize organic polymers, preventing degradation caused by oxidation during processing and end-use.
3. Antioxidant 168 (Irgafos 168)
Chemical Name Tris(2,4-di-tert-butylphenyl) phosphite.
A secondary antioxidant that acts as a processing stabilizer, protecting materials from thermal degradation by decomposing hydroperoxides.
Preblending Process
Preblending these compounds ensures a homogenous mixture for use in various formulations, such as plastics, rubber, or other polymers. The blending process typically involves:
- Weighing Precise amounts of Sodium Benzoate, Antioxidant 1010, and Antioxidant 168 are weighed according to the required formulation.
- Blending A high-shear mixer or blender is used to evenly distribute the antioxidants within the Sodium Benzoate granules. Mixing parameters such as speed, time, and temperature need to be controlled to prevent degradation of the components.
- Granulation (if required) The preblended material can be processed into granules to ensure consistent handling, dosing, and distribution in further processing.
Storage Once preblended, the granules should be stored in a cool, dry environment to prevent moisture absorption and degradation, especially of the antioxidants.
1. Mixing
Sodium Benzoate, Antioxidant 1010, and Antioxidant 168 are loaded into a granulator (high-shear mixer, fluidized bed, or other appropriate equipment).
A liquid binder (water or another solvent compatible with the formulation) is slowly added to the dry mixture while the material is continuously stirred or mixed.
2. Agglomeration
As the binder is added, the dry powders begin to agglomerate and form granules. Care is taken to add the binder slowly to avoid overwetting the material.
3. Drying
Once the granules reach the desired size and consistency, the wet granules are dried using methods such as hot air drying in a fluidized bed or tray dryer. This step removes excess moisture from the granules.
4. Screening
The dried granules are passed through a sieve or mesh to achieve uniform particle size. Oversized granules can be crushed and recycled, while fines are reprocessed or discarded.
5. Final Product
The resulting granules should be uniform, free-flowing, and stable, ready for packaging and further use.
Dry Granulation (Roll Compaction)
Dry granulation may be preferred if the materials are sensitive to moisture, which could degrade the antioxidants. This method involves compaction without the use of liquid binders.
1. Pre-mixing
As with wet granulation, the Sodium Benzoate, Antioxidant 1010, and Antioxidant 168 are blended.
2. Roll Compaction
The mixture is then compacted using a roller compactor. The material is fed between two high-pressure rollers that compress it into sheets or ribbons.The pressure from the rollers causes the powders to bond together, forming dense sheets of material.
3. Milling
The compacted material is then broken down into granules using a mill. The size of the granules can be controlled by adjusting the milling parameters.
4. Screening
The granules are passed through a sieve to remove any oversized or undersized particles, ensuring uniformity.
5. Final Product The resulting dry granules are collected, ensuring they are free-flowing and stable for further use.
Benefits
Enhanced Stability The combination of primary and secondary antioxidants helps provide both processing and long-term oxidative stability to polymers.
Ease of Use Preblended granules are easier to handle and incorporate into formulations, reducing the risk of uneven distribution of the additives.
GRANULATION PROCESS
The granulation process for Sodium Benzoate, Antioxidant 1010, and Antioxidant 168 involves creating a homogenous mixture in a granular form. This ensures easy handling, consistent dosing, and improved stability in various industrial applications, especially polymer stabilization and food packaging. Below is a general outline of the granulation process for these compounds:
Step-by-Step Granulation Process
1. Pre-mixing of Ingredients
Sodium Benzoate This is usually the bulk of the mixture. Antioxidant 1010 Acts as a primary antioxidant, added in smaller proportions compared to the sodium benzoate.
Antioxidant 168 A secondary antioxidant added to complement the performance of Antioxidant 1010, typically used in small quantities.
Procedure
All three ingredients are pre-weighed based on the required formulation. These ingredients are thoroughly mixed to ensure an even distribution of antioxidants in the sodium benzoate. This can be done using a low-shear blender to avoid degradation due to heat or friction.
2. Binder Preparation (optional)
Sometimes, a binder is used to help granulation, especially if the powders are very fine or don’t adhere well during processing. Common binders include water, starch solutions, or other polymeric binders compatible with the application.
The binder helps agglomerate the particles together during granulation.
3. Granulation Process
There are two main types of granulation processes that can be applied:
- Wet Granulation
- Dry Granulation.
Wet Granulation Wet granulation is most suitable if you want to form strong granules and have the option of adding a liquid binder. This is typically done in a high-shear mixer or fluidized bed.
4. Quality Control
Granules are tested for particle size distribution, flow properties, moisture content, and stability.
Stability testing may be required to ensure that the antioxidants (Antioxidant 1010 and 168) maintain their efficacy throughout the granulation process.
5. Packaging and Storage
The granulated product is packed in moisture-resistant packaging to prevent degradation due to environmental factors, especially the antioxidants, which can degrade if exposed to oxygen and heat over time.
Proper labeling and storage conditions (cool and dry) should be maintained to preserve the granules’ integrity.
Key Considerations:
Temperature Control Antioxidants, especially Antioxidant 1010, can degrade at high temperatures. Therefore, temperature control during both wet and dry granulation is essential.
Moisture Sensitivity Antioxidant 168 is sensitive to hydrolysis, so the use of excessive water in the granulation process should be avoided, and drying should be efficient in the case of wet granulation.
Particle Size Uniformity Ensuring uniform particle size through proper sieving or milling is important for consistent dosing and performance in the final application.
Advantages of Granulation:
- Improved Handling Granules are easier to handle, transport, and incorporate into formulations than fine powders.
- Enhanced Stability Granulation can improve the stability of the antioxidants, ensuring their effectiveness in the final product.
- Controlled Dosing Granules provide more consistent and controlled dosing in industrial processes compared to raw powders.
This process is widely used in industries such as polymer stabilization, food packaging, and other applications where oxidation resistance is critical.
This preblended mixture would primarily be useful in applications where both preservation and oxidative stability are critical, such as in polymer manufacturing or specific industrial applications requiring thermal and oxidative protection.