Next Stage of Polystyrene

TOYO STYRENE Co.,Ltd.

<Lineup of Toyo Styrene's High Functional Polystyrene>

Light Guide Plate
Example of Deep Drawing

Lid for Hot Drink Cup

Good AppearancePS

HMT-PS

ESCR-HIPSLight Guide Plate
LED Lighting（High Melt Tension PS）
Various Food Packages
Foamed Deep Drawing(Environmental Stress CrackingResistance)
Lids for Hot Drink Cup
Food Packages for Oily Food
Improvement of Strength

Excellent
Transparency
Good Moldability
for Foamed PS

Oil Resistance

Conventional
GPPS／HIPS
Minimize Residual
Monomer/Oligomer

Heat Resistance
Flame Retardant

TF-polymer/TFPHigh Purity GP/HI

Microwavable Food Packages

Reduction of Gas evolution at Molding
or Eluted Materials from Packages

Flame Retardant PS
Halogenated/Halogen-free
Flame Retardant Compound PS
Lunch Boxes
Packages of Low Volatile Monomer

Package forToner Container

Distribution Board

Packages of Low Oligomer

High Melt Tension Polystyrene (HMT-PS)
HMT-PS has very high Melt Tension by our own polymerization
technology.
Good material for SHEET/FILM productoin.
Forming productions of HMT-PS have good FORMABILITY, THICKNESSUNIFORMITY.
Low strain-Hardening(Conventional PS)

High strain-Hardening(HMT-PS)

Breakage[Forming test]

HMT-PS

Conventional PS[Food container thickenss uniformity]
Thickness (mm)

2.5
2.0

C-15

A-1

1.5
1.0

A-15

HMT-PS
Conventional PS

0.5

B-1

C-1
B-13

A-1
A-2
A-3
A-4
A-5
A-6
A-7
A-8
A-9
A-10
A-11
A-12
A-13
A-14
A-15
B-1
B-2
B-3
B-4
B-5
B-6
B-7
B-8
B-9
B-10
B-11
B-12
B-13
C-1
C-2
C-3
C-4
C-5
C-6
C-7
C-8
C-9
C-10
C-11
C-12
C-13
C-14
C-150.0[Compression strength of food container]
6Measuring method

Load (N)5HIPS sheet formed package

43HMT-PS

2

Conventional PS

1001020304050

Displacement (mm)[Application]
・Polystyrene Paper (PSP, Foamed expansion sheet for foodcontainer)・Expanded Polystyrene board (XPS, Foamed heat insulationmaterial)
・ Biaxial Oriented Polystyrene(BOPS)

・Injection blow formed productions
・Inflation films
・HIPS sheet formed package

Oil Resistance HI Polystyrene EX7

by Toyo Styrene estimate
Good point of EX7

Merit for Coffe cup lids.

Good oil resistancePreventinon cracking deu tomilk fat

Highly rigid

Fitting compatibilty & Noleakage coffee tilting the cup

Maintaining demensional
stability
Good tear strength

No break easily even if
downguaging lids thickness

Good folding endurance

Coffee Cup lid

Performance comparison for coffee cup lid
Item

EX7

HI-PS+SBR

PP

Excellent

Fair

Excellent

Moldability

GoodGood

Poor

Dimensional stability at the molding

Good

Good or Fair

Poor

Stiffness

Good

Good or Fair

Poor

Thickness

Thin

Thick

Thick

Weight

Light

Heavy

Heavy

Cost

Good

Fair

Fair

Resistance to milk

（Toyo Styrene research）

Sheet properties
Itemunit

Conventional
HI-PS

EX7Folding endurance MDtimes

180＞5000

Folding endurance TDtimes

117

＞5000

Tearing strength MD

N/mm

3.7

5.7(Apprications)・Hot coffee cup lid
・Food packaging that is possiblity of oil adheres.

EX7 prevents cracking.

High Performance ESCR-HIPS for Refrigerator liners
・Superior Strength・Stand up to foods and foaming agents・Potential to downgauge of liner thickness
Physical Properties
Unit

EX7

Competitive A Competitive B
Other Company

Other Company

g/10min

3.2

2.3

3.7℃

88

9388

Charpy Impact StrengthkJ/m2

171011

Flexural Modulus

MPa

1770

1750

1680

Melt Mass Flow Rate(MFR)
Vicat Softening Temperature(VST)Measured by Toyo Styrene

Chemical resistance performance
Vegetable Oil

Critical Strain %

0.80

ESCR

(Critical Strain(%))

0.70

>0.6

Few possibilities of generating cracks

0.3～0.6

Possibilities of generating cracks

0.60
0.50
0.40
0.30
0.20
0.10
Cracked Point

0.00
Conventional
PS

EX7

Competitive A Competitive B

Heat Resistance Polystyrene(TF & TFP)
125

VST (℃)

120
115
110
105
100

Application: Microwavable Food Package, etc.

95
90
ConventionalPS
PS
Conventional

TF-Polymer
TF-polymer

TFP
TFP

Good Appearance Polystyrene : GA

Combines Good appearance close to PMMAand benefits of PS
GoodAppearance

Light Weight
Hard towarp

Low CostPSGAPMMAPCSpecific gravity

Excellent

Excellent

Fair

Fair

Moisture absorption

Excellent

Excellent

Poor

Good

Price per volume

Excellent

Excellent

Fair

Fair

Formability & Workability

Excellent

Excellent

Good

Fair

Transparency

Good

Excellent

Excellent

Good

Yellowish

Fair

Excellent

Excellent

Fair

Aging Yellowing

Good

Excellent

Excellent

Good

Strength

Good

Good

Good

Excellent

Transparancy

at 100mm
at 300mm

Transmittance (%)(

Internal loss (%)◆ Property Comparison

Yellowish

at 280mm

PSPS∆ Yellow index (－)

Aging test at 80℃

at 115mm

PSGA60
PMMA

Aging time (hr)< Applications >・Light guide plates
・Lightings
・Optical Components etc.

TOYO STYRENE Flame Retardant PS Resin Genealogy
Toyo Styrene Flame Retardant PS is a polystyrene resin with a certain flame-retardant.
By the flame-retardant class, we have not only V-2/V-0 series but also 5VA that is usually difficult in PS systems.
It has been adopted in response to needs such as consumer electronics, OA equipments and housing equipments.

◆ Representative grade
Heat Stability and Super Light Resistance
Halogen type：LH30 (V-2)：ES150 (5VA)

Copying Machine

LCD TV‐B/CHigh Flow and Good Light Resistance
Halogen type ：J2 (V-2)

High Flow and Good Heat Resistance
Halogen type ：FS100S (V-0)

Flame-Retardant Compound Resin・Halogen type・Non-Halogen type

Distribution Board

High Strength and Heat Stability
Non-Halogen ：NR5 (5VB)

High Cycle Molding andHigh Heat Creep Endurance
Halogen type ：LH30 (V-2)
Non-Halogen ：LX20 (V-2)

Toner Container

LCD Monitor Housing‐B/C◆ FR-PS Masterbatch
NameDirection

Flame-retardant MB (V-0) ：Halogen type
Flame-retardant MB (V-2) ：Halogen type

Good control for combination ratio between MB &Resin: Enable customer to design FR-HIPS which issuitable for anticipated Flame Retardance by mixed
with optional resins. (compatibility is needed)－Options by Customers－

FR‐MB（Bromine contents ： x％）＋※ Color : All color and Black color

Thinner Base Resin( PS )

Plasticization( Extrusion、Processing )Finished FR‐HIPS
V‐0 or V‐2

Ratio between MB & Resin mast be controled.

◆ Corresponding to the EPEAT (the United States)
For electronics-related customers, we have developed a product that can correspond to the EPEAT *1
registration. It is a V-2（registration in preparation） compatible products using post-consumer recycledmaterials and non-halogenated flame retardants.
*1："Electronic Products Environmental Assessment Tool"
It is a system to evaluated according to certain criteria whether the product has been designed andmanufactured taking into account the environmental impact.The materials for the products are required
to be some of the matters such as the use of post-consumer recycled materials, the content less thanhalogen-based retardant content standards, compliance with the RoHS Directive, etc.
It is one of a procurement requirement for electronic products by federal govermment institutions in theU.S.

Flame Retardant PS (5VA)

The world’s-first performance1)
1) except for SPS（syndiotactic polystyrene）「ES150」 UL standard“1.5㎜／5VA”
FRPS of the TOYO STYRENE confidence having highest flame retardant performance and superior
lightfastness.

【Physical properties】
Property

unit

ES150

g/10min

7Vicat softening temperature (VST)℃

88Heat deflection temperature℃

Melt mass flow rate (MFR)

70210Tensile elongation at breakkJ/m%

Flexural strength

MPa

45

Charpy impact strength50

Flexural modulus

MPa

2250

Density

Kg/m

31185

Burning behaviouｒ(UL94)-1.5mm/5VA
1.5~3.0mm/V-0【UL Certification】【example:1】Electrical box for air conditioner【example:2】Wattmeter box【other examples】
・Electrical box（Refrigerator・Laundry machine・Air cleaner）

・OA equipment exterior

Toyo Styrene suggests solution to the problems of waste
Ways of Plastic Recycle (In General)
Method of Recycling

Type (Called In Japan)

by Materialization
by Productization
Raw Materialization/ Monomerization

Material Recycle

Reuse

Chemical RecycleMechanical Recycle

Blast Furnace Deoxidation
Chemical Raw Materialization by Coke Oven
Gasification/Oiled

Thermal Recycle

ISO 15270

Feedstock Recycle

Chemical Materialization
Conversion to fuelRaw Fuel for Cement Production

Energy Recovery

Waste Power Generation
RPF, RDF
RPF: Refuse Paper and Plastic FuelRDF: Refuse Drived Fuel

Plastic Recycle by Coke Oven Chemical Materialization Method
ConsumerContainer/Package Converter
Manufacturing of Container & Package

Containers, Package
Plastic Products

Toyo Styrene
Production of Polystyrene

Classified Discharge

Pellets of Resin
Container / Package

Nippon Steel & Sumikin Chemical

MunicipalitiesStyrene Monomer

Collect/Sort/Compaction/Strage
Collected Plastics

Nippon Steel &Sumitomo Metal

BenzeneTolueneXylene etc.

Carbon Black
Pitch Coke
Naphtalene etc.

Light OilTar

210,000t/ｙ（2014）
Processed 1/3 of Collection by
Japanese Municipalities

Styrene Plant

Thermal Decomposition at Coke Ovens(Plastics are heated by the heating chamber
to about 1200ﾟC in the absense of oxygen)

Utilize for Chemical Raw Materials
Coke Ovens

Coke (20%)

Coke Oven Gas (40%)

Blast Furnace

Power Plant

Steel ProductsElectricity

Hydrocarbon Oil (40%)※The contents and numbers of Thermal
Decomposition are based on the information atWebsite of Nippon Steel & Sumitomo Metal.

Final-enApril,2014

POLYSTYRENE IS A SAFE FOOD PACKAGING MATERIAL
Polystyrene is made from styrene, listing
as “ possibly cause cancer to human”.
Is polystyrene food packaging safe ?

Styrene: a natural ingredient in various foodYes. PS is safe.

1010.1

100

1000

wheat

・Minor residual revel of styrene is remainin polystyrene and may migrate to food.

peanuts
strawberries
beef

But there is no data suggesting that theCoffee beanslevel of styrene migrating to food causecinnamonbeer

any harmful effect to animals and humans.
The listing as carcinogen for styrene is

Natural Presence of Styrene (ppb)

based on studies of workers and animals
Steel et.al (1994) & Maarse (1992)

exposed by inhalation to very high levelsof styrene .

Migration of styrene from PS package

・Styrene occurs naturally in some foods(e.g., strawberries, peanuts, beef, beer,coffee and spices). Styrene concentrationof these natural diet and migration fromPS food packaging into food are similarrange.

0.1101100ppb

Naturallyoccurring styrene

Dairy products*Soup(instant noodle)*

TypicalMaxima*Fried food・ Acceptable Daily Intake (ADI) andSimilar range of styrene concentration as natural ingredient in foodTolerable Daily Intake (TDI) for styrene
based on animal studies(* :Hirahara et.al, 2010 ),0.46 ～ 12.0

mg/person/day, are published by several
authorities.

Estimated styrene daily

Estimated styrene daily intake

intake in EU and U.S. are in the range of 1
～10μg/person/day. Styrene intake is 40～
1000 times below safe intake level.
・Polystyrene is authorized for food contact
materials in U.S.A, EU , Japan and China

1101001000μg/person/day

UK (1999)
Germany(2000)

U.S. (1995)

etc.

US EPA

TDI, ADI
WHOHealthCanada

Margin is order of magnitude

Final-en

Styrene(SM): Is there any concern about
cancer risk to human ?
No. There is not. Styrene is not a humancarcinogen.
・The results of extensive health studies ofworkers in styrene-related industries anda two-year styrene inhalation study inrats exposed to high concentrations ofstyrene show that exposure to styrene
does not increase the risk of developingcancer.
・The International Agency for Research
on Cancer (IARC) has classified forstyrene asa "possible" humancarcinogen. Many scientists have disputed
this action because it was not based onnew studies. Competent authorities of EU
decided notto classify styrene for
carcinogenicity taking into account allavailable scientific information in 2007.
Styrene dimers and trimmers (SDT) :What are SDT ?
・ Residual amount( ～ １ %)of SDT
present in polystyrene resin as reaction
byproducts and degradation products.
Very low migration ( less than 50 ppb ) ofSDT from PS food container into food werereported.
・SDT was suspected of having estrogenic
activity in the Wingspread Declaration[Our Stolen Futures, 1996] despite thelack of scientific analysis.
Are there any risk for human health ?
No. There is no risk.
・Endocrine disruption activity:
Competent authorities in Japan concluded
no specific actions are judged to be necessary
for the time being, since no evidence
indicating the endocrine disrupting activity ofSDT has been found from the test results on
purely synthesized SDT and extracts frompolystyrene, then Japanese EPA deleted SDTApril,2014

from suspected materials list (2000).
・Other health effects_a) General toxicity
A mixture of styrene dimers and trimers
extracted from polystyrene was orally
administered to pregnant rats at up to 1
mg/kg/day. There were no test compound-related
clinical signs or effects in dams and offspring.
The highest dosage of 1.0 mg/kg・bw/day is1000 times of the maximum estimated daily
intake of SDT assuming that a man of 60 kg
takes 1 liter of instant noodle and soup a day(Nagao,2000) .
b) Genotoxicity
A mixture of SDT extracted from polystyrene
was examined conformed to the FDA test guideline for food contact materials. Point mutation
using bacteria (Ames test ) and Chromosomal
aberration using mammalian cell were negative(unpublished, 2013).
Ethylbenzene (EB):Can EB migrate into food from PS
packaging ? If so, are the migration of EB
of concern to consumers?
No. it is of no concern.
It is unlikely to cause any health risks tohumans due to EB migrated from PS
packaging.
・In the production of PS, they primarily use
EB as a solvent . Small amount of EB may
remain in PS as a residual volatile
substance.
・The migration concentration level of EB
into foods are extremely low. Migration levelof EB is similar as of styrene monomer.
・Estimated maximum daily intake for EB
migrated from PS packaging is 6μg/person.
This value is about 2 order lower than theTDI established by WHO (580 μg/person).
Japan Styrene Industrial Association
3-5-2, Nihonbashi-Kayabacho, Chuo-ku
Tokyo, 103-0025, Japan
Tel: +81-3-5649-8261