Polythene Pollution

History of Polyethylene

Other plastics emerged in the prewar period, though some wouldn't come into widespread use
until after the war.

By 1936, American, British, and German companies were producing "polymethyl

methacrylate" (PMMA), better known as "acrylic." Although acrylics are now well-known
for the use in paints and synthetic fibers, such as "fake furs," in their bulk form they are
actually very hard and more transparent than glass, and are sold as glass replacements under
trade names such as "plexiglas" and "lucite." Plexiglas was used to build aircraft canopies
during the war, and it is also now used as a marble replacement for countertops.

Another important plastic, polyethylene (sometimes known as "polythene") was discovered

in 1933 by Reginald Gibson and Eric Fawcett at the British industrial giant Imperial
Chemical Industries (ICI). This material evolved into two forms, low density polyethylene
(LDPE) and high density polyethylene (HDPE).

Polyethylene is cheap, flexible, durable, and chemically resistant. LDPE is used to make
films and packaging materials, including plastic bags, while HDPE is used more often to
make containers, plumbing, and automotive fittings. While PE has low resistance to
chemical attack, it was found later that a PE container could be made much more robust by
exposing it to fluorine gas, which modified the surface layer of the container into the much
tougher "polyfluoroethylene."

Polyethylene would lead, after the war, to another material, "polypropylene" (PP), which
was discovered in the early 1950s. It is common in modern science and technology that the
growth of the general body of knowledge can lead to the same inventions in different places
at about the same time, but polypropylene was an extreme case of this phenomenon, being
separately invented about nine times. It was a patent attorney's dream scenario, and litigation
wasn't resolved until 1989.

Polypropylene managed to survive the legal process, and two American chemists working for
Phillips Petroleum of the Netherlands, Paul Hogan and Robert Banks, are now generally
credited as the "official" inventors of the material. Polypropylene is similar to its ancestor,
polyethylene, and shares polyethylene's low cost, but it is much more robust. It is used in
everything from plastic bottles to carpets to plastic furniture, and is very heavily used in
automobiles.

Polyurethane was invented by Friedrich Bayer & Company of Germany in 1937. It would
come into use, after the war, in blown form for mattresses, furniture padding, and thermal
insulation. It is also used in non-blown form for sports wear such as "lycra."

In 1939, I.G. Farben Industrie of Germany filed a patent for "polyepoxide" or "epoxy."
Epoxies are a class of thermoset plastics that form cross-links and "cure" when a catalyzing
agent, or "hardener," is added. After the war, they would come into wide use for coatings,
"super glues," and composite materials.

Composites using epoxy as a matrix include "fiberglass," where the structural element is
glass fiber, and "carbon-epoxy composites," in which the structural element is carbon fiber.
Fiberglass is now often used to build sport boats, and carbon-epoxy composites are an
increasingly important structural element in aircraft, as they are lightweight, strong, and heat-
resistant.

Two chemists named Rex Whinfield and James Dickson, working at a small English
company with the quaint name of the "Calico Printer's Association" in Manchester,
developed "polyethylene terephthalate" (PET or PETE) in 1941. It would be used for
synthetic fibers in the postwar era, with names such as "polyester," "dacron," and "terylene."

PET is more impermeable than other low-cost plastics and so is a popular material for
making bottles for Coke and other "fizzy drinks," since carbonation tends to attack other
plastics, and for acidic drinks such as fruit or vegetable juices. PET is also strong and
abrasion resistant, and is used for making mechanical parts, food trays, and other items that
have to endure abuse. PET films, trade-named "mylar," are used to make recording tape.

One of the most impressive plastics used in the war, and a top secret, was
"polytetrafluoroethylene" (PTFE), better known as "teflon," which could be deposited on
metal surfaces as a scratchproof and corrosion-resistant, low-friction protective coating. The
polyfluoroethylene surface layer created by exposing a polyethylene container to fluorine gas
is very similar to teflon.

A Du Pont chemist name Roy Plunkett discovered teflon by accident in 1938. During the
war, it was used in gaseous-diffusion processes to refine uranium for the atomic bomb, as the
process was highly corrosive. By the early 1960s, teflon "non-stick" frying pans were a hot
consumer item.

Teflon was later used to synthesize the miracle fabric "GoreTex," which can be used to build
raingear that in principle "breathes" to keep the wearer's moisture from building up. GoreTex
is also used for surgical implants; teflon strand is used to make dental floss; and teflon mixed
with fluorine compounds is used to make "decoy" flares dropped by aircraft to distract heat-
seeking missiles.

After the war, the new plastics that had been developed entered the consumer mainstream in a
flood. New manufacturing was developed, using various forming, molding, casting, and
extrusion processes, to churn out plastic products in vast quantities. American consumers
enthusiastically adopted the endless range of colorful, cheap, and durable plastic gimmicks
being produced for new suburban home life.

One of the most visible parts of this plastics invasion was Earl Tupper's "tupperware," a
complete line of sealable polyethylene food containers that Tupper cleverly promoted
through a network of housewives who sold Tupperware as a means of bringing in some
money. The Tupperware line of products was well thought out and highly effective, greatly
reducing spoilage of foods in storage. Thin-film "plastic wrap" that could be purchased in
rolls also helped keep food fresh.

Another prominent element in 1950s homes was "formica," a plastic laminate that was used
to surface furniture and cabinetry. Formica was durable and attractive. It was particularly
useful in kitchens, as it did not absorb, and could be easily cleaned of stains from food
preparation, such as blood or grease. With formica, a very attractive and well-built table
could be built using low-cost and lightweight plywood with formica covering, rather than
expensive and heavy hardwoods like oak or mahogany.

Composite materials like fiberglass came into use for building boats and, in some cases, cars.
Polyurethane foam was used to fill mattresses, and styrofoam was used to line ice coolers and
make float toys.

Plastics continue to be improved. General Electric introduced "lexan," a high-impact

"polycarbonate" plastic, in the 1970s. Du Pont developed "kevlar," an extremely strong
synthetic fiber that was best-known for its use in bullet-proof vests and combat helmets.
Kevlar was so remarkable that Du Pont officials actually had to release statements to deny
rumors that the company had received the recipe for it from space aliens.

One of the most potentially important new developments in plastics is circuits made out of
plastics called conductive polymers. Electronic circuitry fabricated using plastics or other
materials that could be simply printed on a substrate could be incredibly cheap, opening the
door to throwaway electronic devices that would cost pennies, or to applications hardly
dreamed of now.

So far, electronic devices made with such materials have not been acceptable for production
but, in 2001, prototypes of flat-panel displays based on such technologies were being publicly
demonstrated, with predictions of commercial introduction in two or three years.

THE 4 STAGES OF MAKING A POLYTHENE BAG

Manufacturing polythene bags can be split into 4 stages -

Raw Material
Film
Printing
Final Product
Please use the glossary table table to look up any words or phrases contained within this
text. A list of technical abbreviations can be found here

RAW MATERIAL
Polyethylene (PE) - the correct name for 'polythene', which is the trade name given to the
material first commercially produced by ICI in the 1930s, is a member of a family of
materials called POLYMERS (from the Greek meaning many parts). Unlike most naturally
occurring substances, these have long chains of repeating molecular units (known as
monomers), which give them strength and other properties

The main ingredient in most plastics is polyolefins hydrocarbons, mainly crude oil or natural
gas, which have one or more double bonds (ethylene [CH2=CH2] being the one). To simplify
a complicated process: crude oil or natural gas is CRACKED into several useful components
(including petrol and ethylene), ethlene ( a monomer) is then POLYMERISED using heat,
pressure and catalysts, into polyethylene in large chemical plants, using a variety of processes
developed by individuals and corporations over the years

POLYMERISATION
The original polyethylene - low density PE (LDPE) is produced by a high pressure process,
the newer types of polyethylene - starting with high density PE (HDPE) in the 1950s, are
produced with lower pressures. The difference in density between the two is not great - LDPE
having a density of approx. 0.92 (8% less than water) and HDPE 0.95 (5% less than water)
To make it suitable for processing into something useful, the molten material is forced
(extruded) through a plate containing many small holes (the die), so that it forms continuous
strands like spaghetti, which are then cooled and chopped into small pieces, known as
granules, which are then conveyed into silos for subsequent transport to the processing
factories in bulk tankers or sacks

(2) FILM

For us, the first stage is to make polythene film. We take the granules, blend them with
colouring agents (known as Masterbatch) and other additives if required. This mixture of cold
granules is then conveyed to a film extruding machine, in which the granules are heated
until they are molten and again forced through a die - but in this case, of an annular shape
(circular) with about a 1mm gap between the inner and outer parts of die, so a molten tube of
polyethylene emerges vertically with a wall thickness of 1mm and a diameter the same as that
of the die (typically 60-300mm)

extruding machine
This molten tube has air pumped into it, so that it inflates like an elongated balloon. This
stretches the tube outwards, whilst at the same time the tube is being pulled by a pair of nip
rollers, which stretch it the other direction. This process is known as biaxial orientation, as
it causes the molecular chains to orientate both crossways and lengthways, thus giving it
strength
The tube is cooled by cold air blowing onto it; it emerges beyond the nip rollers, still as a
flattened tube, but now of a much larger diameter and with a wall thickness of typically 10-
100 micron (Mu = 1/1000th mm). this flattened tube (known as layflat tubing LFT) is then
wound on to a cardboard or plastic tube (known as a core)

The finished rolls of film, typically 100kg each and of up to 10,000 metres (10km) in length
of tube depending on its thickness, are removed for the next stage

(3) PRINTING

If the bags are to be printed, the roll of film is taken to the printing machine known as a
'press'. This is usually aflexographic printer, which means that it uses flexible printing plates
which are mounted on to a steel cylinder of the correct diameter to give the repeat
length required - the repeat length will subsequently determine the size of bag made
2 Colour Flexographic Printer
There are 2 main types of flexographic press - (a) stack type and (b) central impression.
To ensure the ink sticks to the film, which is, unlike paper, non-absorbent and smooth, the
film is Corona Dischargetreated. This device essentially bombards the surface of the film
with high voltage sparks which indiscernibly roughen the film's surface

Our 8 Colour Printing Press

The level of treatment is critical and should normally be between 38-44 dynes (measure of
surface resistivity). Once the rolls of film are printed, they are ready for the final stage in the
bag making process

(4) PRODUCT
All standard bags and carriers have one side open and three sides closed. There are 2 main
methods of making bags - sideways or lengthways
Sideways - with this method, the bags are produced sideways-on by a machine using a hot
knife to simultaneously cut and seal the tubular film to form the sides of the bag, the bottom
being the fold in the tubular film. These are known as side-weld bags
One of our side weld machines
(b) Lengthways - using this method, the layflat tube is pulled through the machine and a hot
wire makes a seal across the tube while a flying knife (a sharp blade traveling at great speed),
cuts the film below the seal whilst the film is motionless for the sealing process. Thus the seal
forms the bottom of the bag and the folds of the layflat tubing, the sides. These are known as
bottom-weld (or end-seal) bags
There is a third method commonly used, usually for vest-carriers and heavy duty pouches,
this is where the bags have a bottom-weld type seal at both ends, or both sides. This is known
as mixed or skirt-weld (because it leaves a skirt below the seal). On vest carriers, a portion
of the bag is then punched out to form the handles and opening section

ADVANTAGES

Polythene film is one of the most lightweight and durable packaging mediums available.

Plastic packaging makes an important contribution to reducing food spoilage rates.

Polythene ducting is compatible with most fans, heaters, air conditioners, air handling
units,etc

Polythene Bags use less energy and resources to create than glass or paper.

Clear polythene allows recipients to view the contents (such as a magazine cover) prompting
them to open immediately if the item is of interest or expected

Polythene has one of the advantages of lightweight material, which is mainly used for the
packaging purposes.
Polythene also finds an important component in the spoilage of food. In reduces the food
wastage.
The Polythene ducting is very much suitable for the air coolers, fans, heater equipment, and
air handling units.
By the usage of polythene bags it is very much compatible for the consumers. It is useful than
the glass or paper.
Polythene has also finds the advantage of transparency. One can easily view the materials
inside the polythene bags.

DISADVANTAGES

Polythene is not biodegradable, and if dumped in the soil causes harm to the plant life, as the
toxic substances of polythene get blocked among the soil particles.

Polythene threatens the life in the water bodies. The chemicals in polythene affects the
survival of flora and fauna of the aquatic and marine eco systems.

Polythene is also likele to clog the drains causing problems in the water flow of the pipes.
The pipe blockages would cause flooding and the free flow of water is disturbed.

Polythene is harmful for animals if swallowed. It solidifies inside the abdominal cavity which
ultimately becomes lethal to the animal.

In most households poly bags are used to preserve food items. It has been found out, the
colourful poly bags contains lead and cadmium which are toxic and cause adverse effects to
human health.

If polythene is burnt in open air Hydrogen cyanide which is carcinogenic (cancer causing) is
released.

Hydrogen cyanide causes environmental pollution and health hazards

Polythene is defined as one of the harmful substances, when we throw it in the soil it will
easily damage the plant life. The soil particles are also damaged.
Polythene is also having the disadvantages of damaging the water particles. The toxic
chemicals present in the making of polythene will damage the plants and animals easily. It
also damages the ecosystems of aquatic and marine.
Polythene gas one of the disadvantages in the pipe blocking. If we use the [polythene in the
pipe blocking it will leads to free flow of the water particles.
If the polythene chemicals are inhaled by the animal’s means, it damages the abdominal
cavity of the animal.
If we preserve food items in the colorful polythene bag, it also harmful because the color of
the bag contains the chemicals like lead and the cadmium. It will damage the human health.
If we burn the polythene in the presence of air means, it will release the gas which will cause
the cancer disease.
One of the other disadvantages is, it causes the atmospheric pollution.

Can a polythene product ever be classed as environmentally friendly?

The facts are as follows:
Polythene is, obviously, an oil-based product, so does that mean it can never be
environmentally friendly? Before you judge, you should know that the manufacture of this
material uses a relatively small amount of additional carbon based energy as it is easily
melted and formed and cooled with no major mechanical function involved.
Polythene is completely recyclable and can be recycled many times over; more times than
paper in which the fibres degrade and become weaker – no such problems for plastic
products. Even if the first use has been printed, it can be re-formed into granules, dyed and
made into dark colour or black plastic products such as bin liners. Clear film can be re-
formed back into more clear film, although it is slightly cloudier than a virgin product – who
cares when you are saving valuable resources?
The manufacture of paper takes enormous energy resource. The virgin material is made from
chipping the bark off a tree, then turning the tree trunk into wood chips and then pulping
down into a fibre soup for use in paper making. Even when making recycled paper, (which
takes much less energy than making virgin fibre) a modern 5 metre wide paper machine uses
the equivalent energy of 50,000 domestic homes during the manufacture and drying process.
In the paper versus plastic debate, it must be pointed out that the relative weight of paper
required to contain and protect an item, particularly through the mailing system, is much
greater than required if polythene is used. This means greater transport costs and another
negative for carbon product use.
If polythene and other plastic products were collected in greater quantity from the domestic
waste stream, they would be ideal materials for many second uses when recycled; from new
polythene through to plastic walkways and clothes hangers. The recycling capacity is
currently insufficient in the UK to make this waste stream effective, but it could be and
should be put right.
Companies, like ours, that are at the forefront of developing and producing environmentally
friendly polythene products, find it difficult to source sufficient recycled film for our
customers – a situation we would like to see changing! We recycle all our process waste and
would like to see more polythene being returned into the system.
In addition to recycled products, we also make photo-degradable items; although these
clearly won’t degrade once in landfill, they will break down in light conditions if they are
littered. We also sell the ultimate environmental product; an envelope or bag that is made
from potato starch which is fully compostable in 8 weeks – I know!
Conclusion

Plastic is harm not only to us its harm to small birds, animals, nature. Now a days
Polythene pollution is a big monster to the world. Be cool and make the earth cool.I am sure
from today I am going to avoid using plastics what about you??? Think !!!