At Synthos Dwory 7 spółka z ograniczoną odpowiedzialnością S.K.A. (dawniej Synthos Dwory Sp. z o.o.), we put our ongoing commitment to improving the quality of our products into practice by constantly tracking the market and reacting instantly to our clients’ ever-changing requirements. Our suppliers and our clients are our partners and it is by working in close conjunction with them that the Synthos Group implements its Quality Policy.
One of the ways the Company has turned its Quality Policy into a fact is by introducing cutting edge communications and information systems. On the basis of these systems, systematic analyses of our economic and financial results are carried out, with a view to optimising our product costs. Our quality-related practices also take the form of minimising our consumption of natural resources and energy and running a waste-recycling programme.
Another aspect of our ongoing pursuit of further excellence is the systematic in-house and external specialist training we provide for our employees, in order to improve their qualifications.
Hands-on experience has shown us that the proper implementation and maintenance of a quality management system leads to an increase in management quality, improved product quality and reduced costs.
In order to meet our clients’ expectations, we are constantly working to improve the parameters of our technological processes, with the objective of offering both products and services which will satisfy every demand our customers may make of us. At the Synthos Dwory sp. z o.o. plants, we manufacture synthetic rubbers and latexes, vinyl-acrylic, styrene-acrylic and acrylic dispersions and polyvinyl acetate, styrene and polystyrene materials such as GPPS, HIPS and EPS, as well as XPS plates.
SYNTHETIC RUBBERS AND LATEXES
We manufacture butadiene-styrene, butadiene and butadiene-acrylonitrile latexes intended for the manufacture of solid rubbers, as well as commercial butadiene-styrene and butadiene-styrene-carboxylic latexes.
The manufacture of latex is carried out by the continuous emulsion polymerisation of monomers in an alkaline environment, employing a low-temperature process and using rosin soap and fatty acid derivatives as emulsifiers.
The process is carried out in a reactor battery, equipped with stirrers, coils and cooling jackets. The heat generated by polymerisation is collected by liquid ammonia. The unreacted monomers are degassed in the degassing column system.
Degassed serial latexes are directed to the coagulation process, where coarse-grained rubber is released and the emulsifier is converted into free organic acids by means of the coagulation system. The released rubber is then washed with warm, softened water, followed by mechanical dehydration in the worm extruder and grinding and drying in our cutting edge convection dryers. The dried rubber is formed into cubes and then wrapped with polyethylene film, while high styrene rubbers are formed into granules and packed into polyethylene bags or tank trucks.
Apart from what are generally referred to as rubber latexes, we also manufacture commercial latexes intended for sale, including a range of concentrated latexes.
Application:
The uses to which synthetic rubbers are put include the manufacture of car tyres, conveyor belts, cable insulation. technical goods, seals, rubber hoses, flooring coverings, and shoe soles, etc. The uses of latexes, on the other hand, include the manufacture of sponge-type products and coating the underside of carpets.
POLYACETATE DISPERSIONS (THE WINACET® PRODUCT RANGE) AND VINYL COPOLYMERS (THE OSAKRYL® PRODUCT RANGE)
Polyvinyl acetate is obtained by means of a process entailing the periodic emulsion polymerisation of vinyl acetate. Polymerisation is carried out in an aqueous solution of polyvinyl alcohol, with the addition of an initiator. The polymer is obtained as 50% aqueous dispersion, which is a commercial product. A part of the dispersion is mixed with a plasticiser; two types of plasticised polyvinyl acetate dispersion are obtained as a consequence.
The entire range of specialist wood glues sold under the Woodmax trade name is manufactured on the basis of this polyvinyl acetate.
Apart from the polyacetate dispersions, several variants of vinyl acetate copolymers are produced under the trade name of Osakryl. Obtained by means of periodic copolymerisation, using ionic or nonionic surfactants, with the addition of an inorganic initiator, they include: vinyl acetate copolymers with acrylates, dibutyl maleate, styrene and others.
Application:
Winacet products are used as a basic component of various types of glue, mainly wood, paper, glass and leather glues, as well as in the manufacture of emulsion paints.
The uses to which Osakryl products may be put include the manufacture of primers for mineral, wooden and other bases, as a binding agent in decorative protective varnishes (dispersion paints) and in the manufacture of emulsion paints.
STYRENE
The method employed by Synthos Dwory in the manufacture of styrene consists of ethylbenzene dehydrogenation at a temperature of 600- 640o C, using an iron catalyst under reduced pressure, in the presence of water vapour and styrene release by distillation from the reaction mixture.
POLYSTYRENE (OWISPOL®)
Polystyrene manufacture consists of a continuous mass polymerisation of styrene. Depending the recipe employed, either general purpose polystyrene (GPPS), popularly referred to as ‘diamond’ polystyrene, or high impact polystyrene (HIPS), is obtained.
The styrene polymerisation process is thermally initiated in the presence of ethylbenzene, with no additional initiators. Heat collection from the polymerisation process is yielded by its exchange in the closed heating oil circulation. The resulting polymer undergoes degassing and granulation. The granulated product is packed into polyethylene bags, cardboard packs (octabins) or tank trucks and then sold.
The basic difference between the manufacture of GPPS and HIPS is that during the manufacture of HIPS, styrene subjected to the polymerisation process contains a suitable amount of the dissolved rubber. Both types may also contain various quantities of mineral oil and both may be produced in several variations, differing in molecular mass, composition and additives, allowing products having differentiated properties and processing parameters to be obtained.
Application:
The Owispole® product range is used in the manufacture of various types of containers, and packaging, fancy goods, household items, toys and office supplies.
POLYSTYRENE FOR FOAMING (OWIPIAN® )
The manufacture of polystyrene for foaming (OWIPIAN®) consists of the suspension polymerisation of styrene with the addition of a pore-making agent. The resulting pearls of OWIPIAN® are centrifuged and then pass on to a pneumatic drier. The dried pearls are separated, on sieves, into specific granulometric fractions.
Once dried and separated into fractions, OWIPIAN® pearls are directed, by means of pneumatic transport, through cyclone separators and intermediate storage bins into mixers for lubrication purposes. The finished product is directed to the storage bins and from there, it is packed, using balances, into cardboard octabins or metal containers. The product contains flame-resistant additives.
Application:
Owipian® foaming polystyrene is used for the manufacture of a foamed material known as Styrofoam, which is used in the form of plates and profiles for cold and heat insulation, as acoustic insulation and for the manufacture of packaging and decorative elements.
EXTRUDED POLYSTYRENE (SYNTHOS XPS)
Synthos Dwory manufactures extruded polystyrene plates with a thickness from 30 to 120 mm.
Extruded polystyrene XPS is an innovative insulating material. It is obtained from general purpose polystyrene, using extrusion technology, with the addition of a foaming agent.
XPS plates take the form of foamed material, i.e. polystyrene foam. Their higher mechanical resistance, better heat insulation properties and low water absorptivity mean that their properties are greatly superior to those of styrofoam plates.
Application:
Given the high measure of hardness of extruded polystyrene plates, they may be used in places exposed to high loads. They are excellent for the insulation of ceilings and flat, or ‘reversed’, roofs. The low water absorptiveness of XPS means that it is suited to use in the external insulation of basement and foundation walls. In addition, the material is used for the insulation of ground-level bases, terraces and pools, as well as in road and rail beds, where the plates are used as a protection against freezing. They are also used to protect airport runways, ice rinks and constructions below ground- level, where the action of frost poses a threat.
XPS is also applied in composite plaster walls and as an intramural laminated insulation, while plates made of this material are also used in the manufacture of cooling-truck bodies and as a thermal insulation for industrial floors, car parks and traffic routes.