The Plastics Compounding Market

 Published On: Nov, 2015 |    No of Pages: 182 |  Published By: BCC Research-JT Gabrielsen Consulting LLC Research | Format: PDF
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The North American market for thermoplastic compounds reached 87.33 billion pounds in 2014. This market is expected to grow from 88.78 billion pounds in 2015 to 100.2 billion pounds by 2020, registering a compound annual growth rate (CAGR) of 2.4% over the next five years.

This report provides:

-An overview of the plastics compounding market.
-Analyses of global market trends, with data from 2014, estimates for 2015, and projections of CAGRs through 2020.
-Coverage of the major thermoplastic resins and thermoplastic elastomers (TPEs); the resins include high-density polyethylene (HDPE), low-density polyethylene (LDPE), linear low-density polyethylene (LLDPE), polypropylene, polystyrene, and engineering thermoplastics (ETPs): the major representatives being nylons, polycarbonates, polyacetals, PET, and PBT; the report also includes bio compounds, or plastics that are made from plants instead of hydrocarbons.
-Identifications of major resin producers, key plastics processors, and independent compounders, along with activities, product lines, and estimated sales for the major independent compounders.
-Reviews of key plastics additives used in plastics compounding and advances in plastics compounding machinery/equipment.
-Information on major fillers/reinforcements.
-Developments in carbon fiber and carbon nanotubes, and advances in natural fibers.

INTRODUCTION

BACKGROUND

This report is an update of one published in November 2013 by the same author, a Ph.D. chemical engineer who has written many BCC Research reports on plastics.

The term plastics in this report refers to thermoplastic organic polymers, also commonly called resins. The majority of the plastics discussed in this study are large-volume commodity resins produced from petrochemical feedstocks; they include familiar resins and resin families:
-Polyethylenes (PEs of several types).
-Polypropylene (PP).
-Polystyrene (PS).
-Polyvinyl chloride (PVC) and its copolymers.
-Thermoplastic polyesters (the most common one of which is polyethylene terephthalate or PET).

We also include in this study some more specialty engineering resins such as polyamides (nylons) and polycarbonate. To be thorough, we also include an introduction to some newer biopolymers made from biological instead of petrochemical feedstocks, as well as thermoplastic elastomers.

The subject of this study is plastics compounding. What is compounding? As plastic resins leave the chemical polymerization reactor in which they are formed, they are “neat” polymers; that is, they are essentially pure compounds consisting only of the molecules of the polymer produced. Some of these resins, like PVC, are almost impossible to process as neat polymers; additional chemicals and other materials must be added to make them commercially useful. For other resins, like high-density polyethylene (HDPE) that can be satisfactorily processed in neat form, in virtually all cases some additive or additives are used, such a colorants, to add color to the formed product like an HDPE white milk bottle or a colored motor oil bottle, or a UV absorber to prevent discoloration from exposure to sunlight.

This process of adding other materials is defined as compounding, or, the creation of a compound, a mixture. The additives that are added to neat polymers include colorants, stabilizers, flame retardants, impact modifiers, plasticizers and dozens of others, including a lot of important fillers and reinforcements.

Plastic compounding is a big business that is done by three different kinds of companies. These companies are usually grouped either as resin producers, plastics processors (that is, firms that process and shape resins and compounds by injection or blow molding, thermoforming, and extruding) and independent compounders. Some companies perform more than one of these activities.

SCOPE OF THE REPORT
This report covers the compounding of major thermoplastic resins. The high-volume commodity resins include high-density polyethylene (HDPE), low-density polyethylene (LDPE), linear low-density polyethylene (LLDPE), polypropylene (PP), polystyrene (PS), polyvinyl chloride (PVC) and thermoplastic polyesters (primarily PET). Engineering thermoplastics (ETPs) covered include polybutylene terephthalate (PBT), nylons (polyamides), polycarbonates, acrylonitrile-butadiene-styrene terpolymers (ABS) and some real specialties like polyacetals and polysulfones. This report also includes an introduction to thermoplastic elastomers and some biocompounds—plastics that are made from plants instead of hydrocarbons. It excludes thermosetting resins, since they have different chemistries and are usually processed differently.

The plastics compounding market is segmented by each of the above resins and by each of the three plastics compounding groups. Applications and markets by volume in pounds or value in dollars are estimated for the years 2014, 2015, and a five-year forecast to 2020. Major resin producers, key plastics processors and independent compounders are identified. We discuss the activities, product lines and other information for the major independent compounders.

Our market estimates are mostly for markets for the United States or North America. Other features in this report include the following:
-Review of key plastics additives used in plastics compounding.
-Important information on major fillers/reinforcements.
-Developments in carbon fiber and carbon nanotubes for reinforcement of thermoplastics.
-Advances in natural fiber reinforcements.
-Regulatory and environmental developments shaping compounds, ranging from phthalate plasticizers to halogenated flame retardants.
-Key suppliers of plastics additives and fillers/reinforcements.
-Notes of some recent advances in plastics compounding and machinery.

REASONS FOR DOING STUDY
Plastics compounding is a big business (or group of businesses) that is of interest to a wide group of organizations and individuals involved in the design, development, manufacture, sale and use of plastics and plastics compounds and products made from them.

BCC Research updates this study to provide a new and comprehensive reference for those involved in and interested in plastics and plastics compounds. We have sorted through, organized and condensed information from a number of sources and reference materials to compile this report. We have tried to cover the overall market, and in doing so have included several critical issues that should shape plastics compounding for the next five years. These include biocompounds, carbon fiber, carbon nanotubes, natural fiber reinforcements and environmental regulations.

METHODOLOGY AND INFORMATION SOURCES
Extensive searches were made of the literature and the Internet, including leading trade journals, technical papers, company literature, government information, pertinent trade associations, etc. Much product and market information was obtained from the industry principals involved. The information in our company profiles was obtained primarily from the companies themselves, especially the larger publicly owned firms. Other sources include directories, articles and Internet sites.
Chapter- 1: INTRODUCTION - Complimentary 4     $0
BACKGROUND
SCOPE OF THE REPORT
REASONS FOR DOING STUDY
METHODOLOGY AND INFORMATION SOURCES
ABOUT THE AUTHOR
RELATED BCC RESEARCH REPORTS
BCC RESEARCH WEBSITE
DISCLAIMER

Chapter- 2: SUMMARY 2 $250
Table Summary : NORTH AMERICAN MARKET VOLUME FOR THERMOPLASTIC COMPOUNDS BY TYPE OF COMPOUNDER, THROUGH 2020
Figure Summary : NORTH AMERICAN MARKET VOLUME FOR THERMOPLASTIC COMPOUNDS BY TYPE OF COMPOUNDER, 2014-2020

Chapter- 3: OVERVIEW 4     $198
INTRODUCTION AND DEFINITIONS
BACKGROUND
ADDITIVES
TYPES OF COMPOUNDERS

Chapter- 4: RESINS 42 $2075
OVERVIEW
POLYETHYLENE
POLYPROPYLENE
POLYVINYL CHLORIDE
POLYSTYRENE
THERMOPLASTIC POLYESTERS
ENGINEERING THERMOPLASTICS
THERMOPLASTIC ELASTOMERS

Chapter- 5: BIOCOMPOUNDS 12 $593
STARCH-BASED PLASTICS
POLYHYDROXYALKANOATE (PHA)
POLYHYDROXYBUTYRATE (PHB)
POLYLACTIDE (POLYLACTIC ACID, OR PLA) PLASTICS
CASTOR OIL POLYMERS
CELLULOSE
SOYBEAN OILS
BIO-DERIVED POLYETHYLENE
1,3-PROPANEDIOL (PDO)
NEW DEVELOPMENTS IN BIOPLASTICS
Table 13 : EXAMPLES OF BIOPLASTICS

Chapter- 6: PLASTICS ADDITIVES 28     $1383
MARKET ESTIMATES AND FORECASTS
ADDITIVE USAGE IN THERMOPLASTICS
ANTISTATIC AGENTS
ANTIOXIDANTS
BIOCIDES
BLOWING AGENTS
COLORANTS
COUPLING AGENTS
DEFOAMING AGENTS
EMULSIFIERS
FLAME/FIRE RETARDANTS
HEAT STABILIZERS
IMPACT MODIFIERS
LUBRICANTS
PLASTICIZERS
PVC PROCESSING AIDS
SLIP AGENTS
SURFACTANTS
THICKENERS
THIXOTROPES
UV STABILIZERS
OXYGEN DEGRADATION INITIATORS

Chapter- 7: FILLERS AND REINFORCEMENTS     31 $1532
PROPERTY PROFILES
CHARACTERISTICS OF FILLERS/REINFORCEMENTS
FILLER/REINFORCEMENT USAGE WITH SPECIFIC RESINS
REINFORCEMENTS
INORGANIC FILLERS

Chapter- 8: MASTERBATCHES 4 $198
OVERVIEW
DEFINITION
INDUSTRY STRUCTURE
MARKET ESTIMATE AND FORECAST
SOME NEW DEVELOPMENTS

Chapter- 9: MACHINERY AND EQUIPMENT 7 $346
SELECTION CRITERIA
TYPES OF MATERIALS
TYPES OF COMPOUNDING EQUIPMENT
MAJOR COMPOUNDING EQUIPMENT MANUFACTURERS

Chapter- 10: TYPES OF COMPOUNDERS 2 $99
TOLL COMPOUNDING
CUSTOM COMPOUNDING
PROPRIETARY COMPOUNDING
CONCENTRATE COMPOUNDING
AFFILIATED COMPOUNDING AND COMPOUNDERS

Chapter- 11: INDUSTRY STRUCTURE 9 $445
RESIN PRODUCERS
PROCESSORS
INDEPENDENT COMPOUNDERS

Chapter- 12: COMPOUNDING COMPANY PROFILES 34     $1680
AARON INDUSTRIES CORP.
ACLO COMPOUNDERS
ACTON TECHNOLOGIES INC.
ADELL PLASTICS INC.
ADDIVANT
ADVANCED COMPOSITES INC.
AGC CHEMICALS AMERICAS INC.
AKCROS CHEMICALS INC.
ALPHAGARY CORP.
AM STABILIZERS CORP.
AMCO POLYMERS
AMERICAN COMPOUNDING SPECIALTIES LLC
AMERICHEM INC.
AMETEK WESTCHESTER PLASTICS
AMPACET CORP.
AMPLAS COMPOUNDING INC.
AMTOPP DIVISION
ASAHI KASEI PLASTICS NORTH AMERICA
ASCEND PERFORMANCE MATERIALS LLC
AXIALL CORP.
BASF CORP.
BAY POLYMER CORP.
BAYER MATERIALSCIENCE/COVESTRO
BAYSHORE VINYL COMPOUNDS
BIRCH PLASTICS INC.
CHROMA CORP.
CLARIANT INTERNATIONAL LTD., MASTERBATCHES DIVISION
COLORTECH INC.
DECEUNINCK NORTH AMERICA LLC
THE DOW CHEMICAL CO.
DSM ENGINEERING PLASTICS INC.
E.I. DUPONT DE NEMOURS AND CO.
DYNEON LLC
EMERALD PERFORMANCE MATERIALS LLC
EMS-CHEMIE (NORTH AMERICA) INC.
EXXONMOBIL CHEMICAL CO.
FERRO CORP.
FOSTER CORP.
HERITAGE PLASTICS INC.
INFINITY LTL ENGINEERED COMPOUNDS
INVISTA
KRATON PERFORMANCE POLYMERS INC.
THE LUBRIZOL CORP.
LYONDELLBASELL ADVANCED POLYOLEFINS
MILLIKEN & CO./MILLIKEN CHEMICAL
MRC POLYMERS INC.
MUEHLSTEIN NORTH AMERICA
MULTIBASE INC.
NOVA POLYMERS INC.
O'NEIL COLOR AND COMPOUNDING
OXFORD POLYMERS
PERFORMANCE COMPOUNDING LLC
PLASTIC RECYCLING TECHNOLOGY INC.
PLASTICOMP INC.
THE PLASTICS GROUP OF AMERICA
PLASTICS PLUS INC.
POLYFIL CORP.
POLYFUSION LLC
POLYMER RESOURCES LTD.
POLYONE CORP.
POLYRAM U.S.A. AND CANADA
RHEIN CHEMIE ADDITIVES
RIVERDALE GLOBAL
ROSCOM INC.
RTP COMPANY
SABIC INNOVATIVE PLASTICS/LNP
A. SCHULMAN INC.
SO.F.TER. USA USA
STANDRIDGE COLOR CORP.
TECHMER PM LLC/TECHMER ES
TECHNICAL POLYMERS LLC
TEKNI-PLEX INC.
TEKNOR APEX CO.
THEMIX PLASTICS INC.
WELLMAN ENGINEERING RESINS

Chapter- 13: APPENDIX COMMON ACRONYMS     3 $148
 
List of Tables

Summary Table : NORTH AMERICAN MARKET VOLUME FOR THERMOPLASTIC COMPOUNDS BY TYPE OF COMPOUNDER, THROUGH 2020
Table 1 : NORTH AMERICAN MARKET VOLUME FOR COMMODITY THERMOPLASTIC RESIN BY PLASTIC TYPE, THROUGH 2020
Table 2 : NORTH AMERICAN MARKET VOLUME FOR COMMODITY THERMOPLASTIC RESIN FOR LDPE BY TYPE OF COMPOUNDER, THROUGH 2020
Table 3 : NORTH AMERICAN MARKET VOLUME FOR COMMODITY THERMOPLASTIC RESIN FOR HDPE BY TYPE OF COMPOUNDER, THROUGH 2020
Table 4 : NORTH AMERICAN MARKET VOLUME FOR COMMODITY THERMOPLASTIC RESIN FOR LLDPE BY TYPE OF COMPOUNDER, THROUGH 2020
Table 5 : NORTH AMERICAN MARKET VOLUME FOR COMMODITY THERMOPLASTIC RESIN FOR POLYPROPYLENE BY TYPE OF COMPOUNDER, THROUGH 2020
Table 6 : SOME TYPICAL RIGID PVC APPLICATIONS
Table 7 : SOME TYPICAL FLEXIBLE PVC APPLICATIONS
Table 8 : NORTH AMERICAN MARKET VOLUME FOR COMMODITY THERMOPLASTIC RESIN FOR PVC BY TYPE OF COMPOUNDER, THROUGH 2020
Table 9 : FABRICATION METHODS AND SOME USES FOR POLYSTYRENE
Table 10 : NORTH AMERICAN MARKET VOLUME FOR COMMODITY THERMOPLASTIC RESIN FOR POLYSTYRENE BY TYPE OF COMPOUNDER, THROUGH 2020
Table 11 : NORTH AMERICAN MARKET VOLUME FOR COMMODITY THERMOPLASTIC RESIN FOR THERMOPLASTIC POLYESTER (PET) BY TYPE OF COMPOUNDER, THROUGH 2020
Table 12 : NORTH AMERICAN MARKET VOLUME FOR COMMODITY THERMOPLASTIC RESIN FOR ENGINEERING THERMOPLASTICS BY TYPE OF COMPOUNDER, THROUGH 2020
Table 13 : EXAMPLES OF BIOPLASTICS
Table 14 : NORTH AMERICAN MARKET VOLUME FOR PLASTICS ADDITIVES BY MAJOR TYPES, THROUGH 2020
Table 15 : SELECTED ADDITIVE USAGE IN THERMOPLASTICS
Table 16 : NORTH AMERICAN MARKET VOLUME FOR PLASTIC BLOWING AGENTS BY TYPE, THROUGH 2020
Table 17 : NORTH AMERICAN MARKET VOLUME FOR PLASTIC FLAME RETARDANTS BY TYPE, THROUGH 2020
Table 18 : NORTH AMERICAN MARKET VOLUME FOR HEAT STABILIZERS BY CHEMISTRY, THROUGH 2020
Table 19 : PROFILES OF FILLER/REINFORCEMENT CHARACTERISTICS
Table 20 : OVERVIEW OF CHARACTERISTICS AND APPLICATIONS OF FILLERS/REINFORCEMENTS
Table 21 : OVERVIEW OF FILLER/REINFORCEMENT USAGE WITH DIFFERENT THERMOPLASTICS
Table 22 : NORTH AMERICAN MARKET VOLUME FOR REINFORCED PLASTICS GLASS FIBER*, THROUGH 2020
Table 23 : GLOBAL CARBON FIBER SUPPLIERS AND ESTIMATED CAPACITY, 2020
Table 24 : GLOBAL MARKET VOLUME FOR PAN-BASED CARBON FIBERS BY KEY MARKETS, THROUGH 2020
Table 25 : GLOBAL MARKET FOR CARBON NANOTUBE-REINFORCED POLYMERS, THROUGH 2020
Table 26 : GLOBAL MARKET FOR NATURAL FIBER-PLASTIC COMPOSITES, THROUGH 2020
Table 27 : NORTH AMERICAN MARKET VOLUME FOR PLASTIC FILLERS BY TYPE, THROUGH 2020
Table 28 : NORTH AMERICAN MARKET VOLUME FOR PLASTIC MASTERBATCHES, THROUGH 2020
Table 29 : BATCH COMPOUNDING EQUIPMENT
Table 30 : MAJOR COMPOUNDING EQUIPMENT MANUFACTURERS
Table 31 : LEADING BLOW MOLDERS
Table 32 : LEADING INJECTION MOLDERS
Table 33 : LEADING PIPE, PROFILE AND TUBING EXTRUDERS
Table 34 : LEADING FILM/SHEET PRODUCERS
Table 35 : LEADING THERMOFORMERS
Table 36 : LEADING ROTATIONAL MOLDERS
Table 37 : LEADING NORTH AMERICAN THERMOPLASTIC COMPOUNDERS AND CONCENTRATE PRODUCERS

List of Figures

Summary Figure : NORTH AMERICAN MARKET VOLUME FOR THERMOPLASTIC COMPOUNDS BY TYPE OF COMPOUNDER, 2014-2020
Figure 1 :

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