In 2007, more than 830 million pounds of plastic bags and film were recycled, a 27 percent increase from 2005.

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Case Studies

Our Value / Case Studies

Read below to find out how, through team effort, our customers were able to reduce weight, increase efficiency, and save money.

1:Chemical nucleation in foamed sheet for semi-rigid food packaging results in lower equipment costs, reduced direct gas volume and lower emissions.

Challenge Overview

INDUSTRY : Leading Food Packaging Manufacturer

FINANCIALS : Reducing emissions while retaining properties and low production cost.

CHALLENGE : Understanding performance enhancements with chemical nucleation versus particle nucleation (e.g. talc).


- Reduced amount of butane by 20%

- Maintained 15% weight reduction despite reduction of butane

- Maintained physical properties

- Saved significant resin cost per unit

- Both extruder and thermoforming throughput rates increased by over 20%

2:Foam Pipe company lowers overall costs, improves physical properties and reduces scrap and rework.

Challenge Overview

INDUSTRY : Co-extruded foam pipe

CHALLENGE : To save overall costs and material by-product to meet new governmental regulations for sustainability standards.


- Achieved 6% greater reduction in density over an alternative foaming process

- Achieved a 9% net savings in resin cost

- Increased extrusion rates and lowered direct equipment operating costs per foot by 20%

- Reported an improvement in physical properties

- Consistency of SAFOAM®/SAFTEC® reduced scrap and rework

3:Wood plastic composite compounder with a goal to improve performance of their decking products finds multiple, unexpected benefits.

Challenge Overview

INDUSTRY : Composite decking

QUALIFIER : Looking to increase wood content (MDF) in PVC composite

CHALLENGE : Increasing the percentage of wood increases the water absorption.


- Measured 30-40% less water absorption as measured by 24 and 48 hour water soak standard ASTM tests.

- Increased wood content by 35%

- Increased tensile, flexural and compressive strength by 20-25% according to ASTM standards

- Benefits were achieved with less than 1% of SAFTEC AS applied directly to the wood flour.