technology of pvc compounding and its applications (hand book)
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technology of pvc compounding and its applications (hand book)
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PART I
INDUSTRY OVERVIEW
Chapter 1
Overview of the PVC Compounding Industry
- Overview of India’s Polymer Growth
- PVC Market Trends
- Growing construction & infra-structure development
- Advancement in PVC Manufacturing Technologies and Product Innovation
- Growth, Opportunities, and Challenges in the India PVC Market
Chapter 2
Major PVC Compound Product Segments.
- Key Market Drivers
- PVC Compound Market Insights .
- Contents-cum-Index Market Drivers
- Rising Demand in Construction Sector
- Expanding Automotive Applications
- Market Challenges
- Volatility in Raw Material Prices
- Other Challenges .
- Environmental Concerns and Regulations
- Market Restraints
- Competition from Alternative Materials
- PVC Compound Product Segments
- Segment Analysis .
Chapter 3
Structure of the PVC Value Chain .
- Polyvinyl Chloride in Chemistry
- Molecular Formula and Composition.
- Preparation and Synthesis Methods
- Physical Properties of Polyvinyl Chloride
- Chemical Properties and Reactions
- Stages of the PVC Value Chain
- Uses of Polyvinyl Chloride in Real Life
- Relation with Other Chemistry Concepts
- Step-by-Step Reaction Example
- Household Products Made of PVC
- PVC Manufacturing Process .
Chapter 4
How to Use This Book
- Use the Book for PVC Compounding
- Key Application Areas Covered
- Key Insights for Usage
- How to Use This Book .
PART I
PVC RESINS, MANUFACTURING AND PROPERTIES
Chapter 5
Introduction to PVC Resins.
- Introduction to PVC Resin and Its Uses .
- Overview of Different Types of PVC Resin
- Properties of High-Performance PVC Resin .
- Applications of Rigid PVC Resin in Industries
- Applications of Flexible PVC Resin in Consumer Products
- Environmental Impact and Recycling of PVC Resin
- Characteristics .
Chapter 6
Manufacture of PVC
- Introduction to Suspension Polymerization .
- Understanding the Suspension Polymerization Process
- Advantages of Suspension Polymerization in PVC Production .
- The suspension polymerisation reaction .
- The suspension polymerisation mechanism
- 1. Initiation .
- 2. Propagation
- 3. Termination
- Clean Reactor
- Technology
- Aspects of the Reactor Process .
- Large Reactor Technology
- Features of Large Reactor Technology
- VCM Containment
- Substance details
- Physical properties
- Chemical properties
- Environmental effects
- Entering the environment
- Where it ends up
- Environmental guidelines
- VCM Production Process
- Direct Chlorination Process for Producing EDC
- VCM Purification
- Process Overview of VCM/PVC Production
- Mass Polymerization Process
- Types of Polymerizations
- 1. Condensation Polymerization
- 2. Addition Polymerization
- Examples of Polymerization
- Aspects of Mass Polymerization
- Emulsion Polymerization Process
- Polymerization Mechanism
- Emulsion Polymerization Process
Chapter 7
PVC Mass Polymerization
- Suspension Grade PVC
- Emulsion Grade PVC
- Bulk Polymerised PVC
- Copolymer PVC
- Characteristics and Process Details
Chapter 8
Comparative Properties of PVC Produced by Different Processes
- Properties of PVC Material
- PVC Performance Parameters:
- Types of PVC
- Typical Properties of PVC Pipe Material
- Physical Properties
- Mechanical Properties
- Electrical Properties
- Thermal Properties
- Fire Performance
- Modified/Derived PVC Processes
- Key Performance Differences
PART II
PVC COPOLYMERS, MODIFIED PVC AND ALLOYS
Chapter 9
Copolymers, Chemical Modification and Blends/Alloys of PVC
- Reactivity Ratios for VCM Copolymerization
- Introduction
- The copolymer equation
- PVC Copolymers
- Understanding Polyvinyl Chloride (PVC)
- The Introduction and Evolution of Polyvinyl Chloride Copolymer
- Understanding Copolymers
- Different Types of Copolymers: Random, Alternating, Block, and Graft
- How PVC Copolymers Differ from Traditional PVC
- Applications of Polyvinyl Chloride Copolymer.
- Healthcare Sector: Medical Devices and Equipment
- Construction Industry: Enhanced Building Materials
- Automotive Industry: Durable, Lightweight Components
- Sustainability and Environmental Impact
- Vinyl Acetate Copolymers
- Introduction to Vinyl Acetate
- Understanding Copolymers
- Vinyl Acetate in Copolymer Formation
- Applications of Vinyl Acetate Copolymers
- Environmental and Safety Considerations
- VCM–VAC Copolymerization Recipes
- Suspension Copolymerization Recipe (Typical)
- Emulsion Copolymerization Recipe
- Soap-Free Emulsion Method (VCM/VAc/MAH)
- Key Factors in VCM-VAc Recipes
- Effect of VAC on PVC Properties
- Product Application
- Product Technical Specification
- Mechanical/Structural Effect (Vacuum in PVC Pipes)
- Manufacturing Effect (Vacuum Forming & Pressing)
- Chemical/Thermal Effect (Vacuum on PVC Composition)
- Copolymers with Olefins
- Types and Characteristics
- Production and Technology
- Key Applications
- Copolymers with Vinylidene Chloride
- Key Characteristics and Types
- Common Comonomers
- Applications
- Processing and Stability
- Copolymers with Acrylates
- Key Characteristics & Types
- Common Applications
- Commonly Used Monomers
Chapter 10
Chemically Modified PVC
- Syndiotactic PVC
- Structure and Characteristics
- Advantages and Applications
- Effect of Polymerization Temperature on Crystallinity
- Effects of Temperature on Crystallinity
- Chlorinated PVC (CPVC)
- CPVC Compound
- Strengths of CPVC(chlorinated polyvinyl chloride)
- Heat Resistance .
- Flame Resistance
- Chemical Resistance
- Other Strengths
- Main applications of CPVC
- Comparative Properties of PVC and CPVC
- CPVC vs PVC performance properties
- CPVC and PVC similarities
- CPVC and PVC differences
- CPVC and PVC table comparison .
- Major Differences Summary
Chapter 11
PVC Grafts
- Acrylic Graft PVC
- Characteristics and Benefits
- Main Applications
- Technology & Methods
- EVA Grafted PVC .
- Benefits and Properties
- Common Applications
- Crosslinked PVC
- Aspects of Crosslinked PVC
- Recent Studies and Innovations:
- Properties of PVC Grafts
Chapter 12
PVC Blends and Alloys
- PVC-based blends
- NBR/PVC Blends
- PVC/ABS Blends
- PVC/Polyester Blends
- PVC/ABS Blends
- Polymers Blended with PVC as Processing Aids
- PVC/ENR Blends
- Rheological Properties
- PVC/Acrylic Blends
- Properties of PVC Grafts
- Properties of PVC Grafts
- Specific Grafted PVC Types
PART III
PVC PROCESSING FUNDAMENTALS
Chapter 13
PVC Resins and Processing Behaviour
- Molecular Weight and K-Value
- Calculate the k value
- K-Value: The Molecular Weight Indicator
- PVP K-Value and Molecular Weight (Typical Ranges) 97
- Characteristics and Applications
- Measurement
- Threshold Temperature
- Detailed PVC Temperature Thresholds
- Rheological Properties
- Rheological Characteristics of PVC
- Processing Impact
Chapter 14
Processing Methods
- Extrusion
- Feed Zone
- Transition Zone or Compression Zone
- Mixing Zone
- Metering Zone
- Injection Molding
- Advantages of Injection Molding
- Disadvantages of Injection Molding
- Calendering
- Blow Molding
- Injection Blow Molding
- Extrusion Blow Molding
- Thermoforming
- Reinforcing Process
PART IV
ADDITIVES FOR PVC
Chapter 15
Introduction to PVC Additives
- PVC Additives
- PVC Plasticizers
- Primary Plasticizers
- Secondary Plasticizers
- Plasticizers for Medical Applications
- PVC Stabilizers
- PVC Fillers
- PVC Impact Modifiers
- PVC Pigments
Chapter 16
Plasticizers
- Introduction
- Types and Properties
- Types
- Phthalate Plasticizers
- Non-Phthalate Plasticizers
- Properties of Plasticizers
- Effect on PVC Properties
- Effects of Plasticizers on PVC Properties
- Factors Affecting Performance
- Migration and Gelation
Chapter 17
Impact Modifiers and Processing Aids
- Usage
- Light Stabilizers
- Flame Retardants
- Foaming Agents
- Processing Aids
- Flow Promoters
- Flow Promoters & Functions for PVC
- Benefits of Using Flow Promoters
- Impact Resistance Mechanisms
- Rubber-Toughening Mechanisms (Core-Shell Particles)
- Molecular Orientation (PVC-O )
- Interfacial Interaction and Compatibility
- Impact Modifiers for PVC
Chapter 18
Heat Stabilizers
- Heat Stabilizers
- Lead Stabilizers
- Types of Lead Stabilisers
- Properties and Applications
- Lead Stabilizers Manufacturing Process
- Production techniques
- Essential Quality control
- Applications of Lead Stabilizers
- Tin Stabilizers
- Types of Tin Stabilizers
- Applications
- Advantages
- Calcium-Zinc Stabilizers
- Applications in the PVC Industry
- PVC Pipes and Fittings
- Window Profiles and Construction Materials
- Healthcare and Food Packaging
- Innovation and Future Trends
- Advancements in PVC Stabilization
- Organic and Epoxy Stabilizers
- Organic Stabilizers
- Economic Impact Of Transitioning From Lead Stabilizers To Safer Alternatives
- Conversion Costs
- Impact on Production Costs
- Adapting to Environmental Regulations
- Supply Chain Impact
- Manufacturing Process
- Raw Material Sourcing
- Mixing and Blending
- Compounding
- Pelletizing
- Quality Control
Chapter 19
Lubricants
- External PVC lubricants
- Internal PVC lubricants
- The Importance of Lubricants in PVC Processing
- The Role of PVC Lubricants
- Consequences of Improper Lubricant Use
- Over-lubrication
- Under-lubrication
- Excessive Lubricants
- Common Types of Lubricants in PVC Formulations
- Metallic Stearates
- Wax-Based Lubricants
- Specialty Lubricants
- Effects of Lubricants on Processing Efficiency
- Improving Melt Flow and Energy Consumption
- Enhancing Surface Quality and Dimensional Control
- Preventing Equipment Damage
Chapter 20
Fillers and Reinforcements.
- Fillers
- Calcium Carbonate
- Enhanced Stiffness and Strength
- Improved Impact Resistance
- Enhanced Thermal Stability
- Increasing The Opacity And Surface Gloss
- Increasing Flexibility Of The Pipe
- Cost-Effectiveness
- Environmental Benefits
- Talc, Clay, Silica
- How Talc Powder is used for PVC Sheets:
- Clay
- Silica
- Viscosity Control
- Processing Enhancements
- Performance Boosts
- Effects of Fumed Silica Nanoparticles on PVC
- Enhanced Thermal Stability
- Improved Mechanical Properties
- Improved Surface Finish
- Reinforcements
- Short-fiber Reinforcement
- Long-fiber Reinforcements
- Woven Cloth Reinforcement
- Glass fibers
Chapter 21
Flame Retardants, Colourants and Special Additives
- Flame Retardants
- Key Additives
- Common Uses
- Benefits in the Field of PVC and Additives
- Applications of Flame Retardants in PVC Products
- Automotive and Electronics
- Types of Flame Retardant Additives for PVC
- How Formulations Affect the Performance of PVC Compounds
- Colourants
- Role and function of colorants
- Type of colorant
- Masterbatches
- Colored pellets/colored compounds
- Dry color .
- Paste color liquid masterbatches
- Masterbatches manufacturing process .
- Preparation/stirring
- Extrusion
- Cooling
- Cutting
- Filling/packing
- Special Additives
- PVC Additives
- Plasticizers
- Primary Plasticizers
- Secondary Plasticizers
- PVC Compounding additives
PART V
COMPOUNDING THEORY AND TECHNOLOGY
Chapter 22
Compounding Principles and Mixing Theory
- Compounding Principles
- Mixing Raw Materials
- Melting and Mixing
- Shaping
- Cooling
- Pelletizing
- Principles of PVC Com-
- pounding
- Components in a Formulation
- Common Compounding Techniques
- Considerations for Success
- The Mixing theory
- Basic Principles of PVC Mixing
- The Two-Stage Process
- Key Formulation and Mixing Considerations
Chapter 23
Methods of Compounding
- Basic Processing Techniques
- Injection Molding
- Intensive Dry Mixers
- The Role of Invoitplast Machinery in Modern Compounding
- The Working Principle
- Industrial Applications
- Internal Batch Mixers
- The Mixing Process
- Main Types of Internal PVC Mixers
- Benefits in PVC Production
- Continuous Mixers
- Types of PVC Mixing Equipment
- Advantages Over Batch Mixing
- Two-Roll Mills
- Roll Mill Work for PVC Material
Chapter 24
Compounding Equipment
- Single screw extruder
- Twin screw Extruder
- Farrel continuous mixers
- Pelletiser
- A twin screw extruder
PART VI
COMPOUNDING OF PVC BY PRODUCT TYPE
Chapter 25
Selection and Character-ization of PVC Resins.
- Selection of PVC Resins
- K-Value Considerations for Material Strength
- K-Value (Molecular Weight)
- Impact of Additives on Final Product Performance
- Thermal Stability Requirements for Processing .
- Common Selection Mistakes .
- Characterization of PVC Resins
- The main characteristics of PVC resin
Chapter 26
Rigid PVC Compounds
- Composition and Key Properties
- Pipes Compounds
- Types of Pipe Compounds
- Features and Applications
- How to Use Pipe Joint Compound
- Alternatives
- Profile Compounds
- Aspects of Compound Profiling
- Tools and Resources
- Sheet and Film Compounds
- Types and Applications
- Common Material Components
- Production Processes
Chapter 27
Flexible PVC Compounds
- Applications of Flexible PVC Compound
- Electrical and Electronics Cables
- Medical and Consumer Devices
- Automotive Interior Components
- Flexible Tubing and Technical Products
- Footwear and Fashion Industry
- PVC in Automotive Industry
- Coated Fabrics
Chapter 28
PVC Paste, Plastisols and Latices.
- Plastisols
- Ingredients Used to Formulate PVC Plastisols
- PVC resin as base polymer
- Details About PVC Plastisol
- Usage Examples of PVC Plastisol
- Synonyms of PVC Plastisol
- Organosols
- Aspects of Organosols
- Latex Compounding
- Chemical Ingredients in the Latex Compounding Process
- What Happens at Each Stage of Latex Compounding
Chapter 29
PVC Solutions and Adhesives.
- Main Usage Examples
- Synonyms and Related Terms
- Advantages of PVC a dhesives
- Typical applications for industrial PVC adhesives .
- Plumbing and drainage networks
- Building and construction industry
- Pool equipment and outdoor applications
- The different types of PVC adhesive
- PVC pressure adhesive
- Soft PVC glue
- Waterproof PVC adhesive
- Best Adhesives for PVC
- Infinity Bond Awesome Acrylic Hot Glue Sticks
- Infinity Bond Instant Bond Super Glue
- Infinity Bond MMA 420 Glue
- ASI 5900 Quick Grab Adhesive .
- PVC Polymer
- Homopolymers
- Copolymers
PART VII
TESTING, QUALITY CONTROL AND TROUBLESHOOTING
Chapter 30
Testing of PVC Resins
- PVC Resin Testing Parameters
- Standard Test Organizations
- Testing Methods
Chapter 31
Testing of PVC Compounds.
- PVC Test Methods
- Chemical Testing
- Hardness Testing
- Plastic Pipe Testing
- Phthalates Analysis
- Physical Testing .
- Thermal Analysis .
- Tensile Testing
Chapter 32
Testing of PVC End Products
- PVC End Product Testing Areas
- Common Standards and Techniques
- Essential Quality Control Tests
- Dimensional Inspection
- Hydrostatic Pressure Test
- Tensile Strength & Elongation Test
- Impact Resistance / Notch
- Test
- Chemical & Thermal Resistance Test
Chapter 33
Problem Solving in PVC Compounding and Processing
- Introduction
- The main problems reported in acetylene-based PVC
- Effect of K Value variation on processing and how to correct recipe:
- Air Bubble Problem
- Rough Surface
- Poor Insulation .
- Moisture Absorption
- Brittleness Issue
- “Oil Leakage” Phenomenon
- Common PVC Processing Problems .
- Problem Solving Strategies
- Common Compounding Solutions
- Processing Control Points
PART VIII
SPECIALITY COMPOUNDS AND PROJECT PROFILES
Chapter 34
Speciality Plastic Compounds and Masterbatches
- Speciality Plastic Compounds
- Types and Applications
- Major Manufacturers and Brands .
- Characteristics .
- Masterbatches .
- Major Steps and Process in Masterbatch Manufacturing
- Formulating and Compounding for Masterbatch Manufacturing
- Homogenization
- Extrusion
- Pelletization
- Types of Masterbatch .
- Additive Masterbatch
- White Masterbatches
- Black Masterbatch
- Mineral Masterbatches
- Recyclable Masterbatches
- Advantages of Using Masterbatch
- Masterbatch vs. Pigments: Clear Advantages in Plastic Manufacturing
Chapter 35
PVC Compounds -Project Profiles.
- Rigid PVC Pipe Manufacturing Plant Project Report.
- Introduction to Rigid PVC Pipes
- Investment Highlights
- Rigid PVC Pipe Plant Capacity
- Rigid PVC Pipe Plant Profit Margins .
- Rigid PVC Pipe Plant Cost Analysis
- Financial Projection
- Major Applications
- Why Rigid PVC Pipe Manufacturing?
- Transforming Vision into Reality
- How to Setup a Rigid PVC Pipe Manufacturing Plant? .
- Project Economics:
- Capital Expenditure (CapEx) and Operational Expenditure (OpEx) Analysis:
- Power Requirement
- Manpower Requirement
- Approvals & Registration Requirement
- Bottles
- PET Bottle Plant Capacity
- PET Bottle Plant Profit Margins
- Financial Projection .
- Major Applications .
- Why PET Bottle Manufacturing? .
- How to Setup a PET Bottle Manufacturing Plant?
- Project Economics
- Manufacturing Process :
- Quality Control and S tandards
- Garden Hose.
- Key Investment Highlights
- Garden Hose Plant Capacity .
- Garden Hose Plant Profit Margins .
- Garden Hose Plant Cost Analysis
- Financial Projection .
- Why Garden Hose Manufacturing?
- Transforming Vision into Reality
- How to Setup a Garden Hose Manufacturing Plant?
- Project Economics .
Chapter 36
XLPE Cable Compounds, FRLS and Sheathing Compounds.
- XLPE cable material
- Advantages of XLPE over Non-Cross-Linked Materials
- Advantages of XLPE in Cable Manufacturing
- Key Benefits of XLPE
- Performance and Durability of XLPE Cables
- Applications of XLPE Cables
- Key Takeaways
- FRLS and Sheathing Compounds
- Significant FR and FRLS Cable Difference .
- Fire Resistance vs Fire Prevention .
- Dense Smoke Vs Low Smoke .
- Temperature-Based Performance Differences
- FRLS Cable Properties
- Supreme Insulation
- Reliable Under Pressure
- Certified to the Highest Standards .
- Relatively Lower Smoke Emission
- Features and Benefits of FRLS Cables
- FRLS vs. Other Types .
- Sheathing Compounds
- Types and Characteristics .
- Superiority of Sheathing PVC Compound
- Strong Mechanical Durability: The Armor Plate .
- Excellent Adhesion with Insulation Layers: A Unified Defense
- UV and Weather Resistance: Battling the Elements
- Fire Safety Characteristics: A Crucial Safety Feature
Chapter 37
Plastic Granules from Fresh Resin .
- Use and applications .
- Plastic Granule Types .
- LDPE (Low-Density Polyethylene)
- High-Density Polyethylene (HDPE)
- LLDPE (Linear Low-Density Polyethylene) .
- PP (Polypropylene)
- PVC (Polyvinyl Chloride) .
- PET (Polyethylene Terephthalate) .
- Plastic Granules Manufacturing Process .Collection of Raw Material
- Cleaning and Washing
- Shredding or Grinding
- Separation and Drying .
- Extrusion and Pelletizing
- Cooling and Drying .
- Packaging and Distribution
- Part IX
- PVC Applications
Chapter 38
Review of Major PVC Applications
- Construction .
- Domestic
- Packaging .
- Automotive .
- Medical .
- Clothing
- Electrical
- Others
Chapter 39
Pipes, Profiles and Structural Applica- tions.
- Applications Of PVC Pipes
- Plumbing Sector .
- Drainage systems
- Electrical conduits
- Irrigation systems
- Ventilation systems
- Water supply systems
- Chemical Handling
- Gas distribution systems
- Fire Sprinklers .
- PVC Pipes for Rainwater Management
- PVC Extrusion Profiles
- Applications of PVC Profiles
- Windows and Doors
- Roofing Systems
- Fencing and Railings
- Wall Cladding
- Structural Construction Components .
- Industrial and Commercial Applications
Chapter 40
PVC Sheets, Films and Packaging Applica- tions.
- Applications of PVC Sheets
- Construction Industry .
- Furniture Industry
- Advertising Industry .
- Industrial Applications
- Interior and Construction Uses
- PVC Film Applications Across Industries .
- Medical and Healthcare .
- Stationery
- Construction and Architecture
- Graphics and Advertise- ment
- Packaging Applications
- Primary PVC Packaging Applications .
- Blister Packs and Clamshells .
- Food Packaging
- Cosmetic Packaging.
- Innovative PVC Packaging Solutions .
- Sustainable PVC Formula- tions .
- Smart Packaging Features
- The Future of PVC Packaging .
Chapter 41
Flooring, Coated Fabrics and Tarpaulins
- PVC Flooring .
- Types of PVC Flooring
- Ideal Applications
- PVC Flooring is best used in these areas.
- Modern Interiors and Design Flexibility.
- PVC Flooring Room-Specific Advice.
- PVC flooring is simple to maintain and has the following tips.
- Durability and Longevity .
- PVC Coated Fabric Applications of PVC Coated Fabric
- Industrial Storage & Covers
- Biogas Plant Domes .
- Agriculture & Aquaculture .
- Transportation & Logistics
- PVC Tarpaulin
- Applications of PVC Tarpaulin
- Industrial Uses
- Commercial Uses
- Residential Uses
- Transportation (Truck Covers, Boat Covers) ..
- Construction and Agriculture .
- Awnings and Tents .
Chapter 42
Medical, Footwear and Specialty Applica- tions.
- Medical
- Flexible Containers
- Medical Tubing
- Medical Gloves
- Face Masks and Respiratory Equipment
- Diagnostic Equipment
- Surgical Drapes and Gowns
- Footwear applications
- Formulation and Mixing .
- Molding
- Heating and Cooling.
- Demolding
- Assembly
- Quality Control .
- Finishing Touches
- Packaging and Distribution
- Shoe sole
- Sandal
- General boots .
- PVC Straps
- Specialty Applications
- Healthcare and Medical Applications
- Industrial and Engineering Solutions
- Electronics and Specialty Electrical
- Construction and Advanced Materials
Chapter 43
Fabrication, Welding and Post-Processing
- Plastic Fabrication: Processes and Applications .
- Compounding Plastic Fabrication
- Plastic Lamination Fabrication .
- Plastic Molding Fabrication
- Injection Molding Fabrication
- Compression Molding Fabrication
- Rotational Molding Fabrication
- Blow Molding Fabrication
- Plastic Extrusion Fabrication
- Thermoforming Fabrication
- Die Cutting Fabrication
- Pultrusion Fabrication
- Forging Fabrication
- Vacuum Casting Fabrication
- Understanding PVC Welding
- Types of PVC Welding Techniques .
- Hot Gas Welding..
- High-Frequency Welding .
- Solvent Welding
- Ultrasonic Welding
- Essential Tools and Equipment .
- Welding Gun or Heat Gun
- · Welding Rods
- Clamps and Fixtures
- Safety Gear (Gloves, Goggles, etc.)
- Step-by-Step PVC Welding Process
- Surface Preparation
- Heating and Welding
- Cooling and Finishing
- Appli.cations of PVC Welding
- Plumbing and Piping Systems
- Fabrication of Tanks and Containers
- Automotive and Construction Uses
- Bortte PVC Welding Gun
- Post-processing
- Main Post-Processing Methods
PART X
RECYCLING & SUSTAINABILITY
Chapter 44
Recycling of PVC
- PVC Recycling Process
- Collection and Sorting
- Cleaning ..
- Shredding and Granulation
- Melting and Reprocessing .
- PVC
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