| HS Code | 339188 |
| Brand | Fulatex |
| Model | PD0123 |
| Product Type | Natural Latex Pillow |
| Core Material | Natural Rubber Latex |
| Manufacturing Process | Dunlop |
| Cover Material | 100% Cotton |
| Color | White |
| Size | 60 x 40 x 12 cm |
| Weight | 1.3 kg |
| Firmness | Medium |
| Density | 45D |
| Certifications | OEKO-TEX Standard 100, Eco-INSTITUT |
| Care Instructions | Removable washable cover; air dry latex core |
| Warranty | 5 Years |
As an accredited Fulatex PD0123 factory, we enforce strict quality protocols—every batch undergoes rigorous testing to ensure consistent efficacy and safety standards.
| Packing | Fulatex PD0123 is supplied in 25 kg sealed plastic drums with hazard labels and tamper-evident closures. |
| Container Loading (20′ FCL) | 20′ FCL of Fulatex PD0123 loaded on secure pallets, safely braced, labeled, and sealed for efficient chemical transport. |
| Shipping | Fulatex PD0123 is shipped in sealed drums or IBC totes with proper labeling, lot traceability, and accompanying SDS/COA. Transport in dry, ventilated containers, protected from extreme heat and moisture. Use appropriate PPE during handling. Ensure all documentation aligns with local and international chemical transport regulations. |
| Storage | Store Fulatex PD0123 in a cool, dry, well-ventilated area away from direct sunlight, heat sources, and open flames. Keep containers tightly sealed when not in use. Avoid freezing and temperatures above 35°C. Ensure adequate ventilation and use appropriate personal protective equipment when handling. Refer to the SDS for specific incompatibilities. |
| Shelf Life | Store unopened in original container at 5–35°C. Shelf life is 6 months from production date. Avoid freezing. |
Acceptance stock for LWC offset printing, produced in a high-speed off-machine blade coater, is formulated with Fulatex PD0123 added at 8–11 pph dry pigment. The addition point is maintained downstream of the high-shear disperser and upstream of the 80 μm pressure screen because prolonged exposure to a Cowles disperser above 15 m/s tip speed has been observed to cause pre-coagulum formation when calcium stearate is present at 0.8 pph. The coating colour consists of 60–70 parts ground calcium carbonate, 20–30 parts No. 1 kaolin, and 5–10 parts calcined clay, brought to 58–62 wt% solids and adjusted to pH 8.5–9.5 with ammonia or sodium hydroxide. A 2–4 pph oxidized starch co-binder is used for water retention; Fulatex PD0123 alone builds dry pick resistance because the latex film develops sufficient cohesion after hot-air drying at 180–220 °C web surface temperature for 10–15 s. The coated web is finished through a hot soft calender with polymer-covered rolls at 120–140 °C and 120–180 kN/m nip load, then rewound for sheet-fed or web offset printing. Two-side dry coat weight is held at 5–7 g/m² per side to preserve low grammage while maintaining opacity. Compliance of the base stock is tested under ISO 2470-2:2008 for D65 brightness, ISO 8254-1:2009 for 75° gloss, ISO 3783:2006 for IGT dry pick resistance, and ISO 12647-2:2013 for process control on the printed result. Terminal product types include catalogs, retail inserts, magazines, and direct mail pieces where low grammage (45–65 g/m²) and high opacity require a balanced ratio of latex to co-binder. Add-on levels outside the 8–11 pph range are not recommended because lower values produce dusting at the blanket, while higher values increase dryer load and may reduce glueability of the unprinted coated sheet in downstream finishing.
For folding carton board converted into dry food, personal care, and pharma packaging, the topcoat formulation uses Fulatex PD0123 at 12–15 pph dry pigment. The binder demand is higher than LWC because board-printing offset speeds and die-cutting impose mechanical stress on the topcoat; below 12 pph, IGT dry pick values measured under ISO 3783:2006 approach the specification limit when the topcoat is applied at 10–12 g/m² dry coat weight on recycled board. The colour includes 70–80 parts Brazilian kaolin and 20–30 parts ground calcium carbonate, with 4–6 pph starch or protein co-binder and 0.8–1.2 pph calcium stearate. Application occurs on a two-station blade coater: precoat at 8–10 g/m² and topcoat at 10–12 g/m² per side, blade angle 35–40°, backing roll hardness 85–90 Shore D, and machine speed 700–900 m/min. The board is dried with infrared plus air flotation dryers, then passed through a single-nip soft calender. Food-contact status is governed by FDA 21 CFR 176.170 for paper and paperboard in contact with aqueous and fatty foods; European compliance is based on BfR XXXVI, Regulation (EC) No 1935/2004, and Regulation (EC) No 2023/2006 GMP. The terminal product types are cartons, boxes, and blister cards for dry food, cosmetics, and pharmaceutical inserts, excluding retort or high-fat direct-contact structures unless migration testing under the applicable extraction simulants is completed. pH drift above 10.5 in the topcoat colour should be avoided because prolonged storage under high alkalinity produces viscosity creep that changes blade holdout uniformity.
| Standard/Regulation | Clause/Test designation | Application scope in this section | Verification point |
|---|---|---|---|
| FDA 21 CFR 176.170 | Components of paper and paperboard in contact with aqueous and fatty foods | Coated folding carton topcoat | Master formula certificate and migration data at 12–15 pph binder level |
| BfR XXXVI | Paper and board for food contact | Paper-based packaging | Extraction limits under aqueous and dry food simulants |
| Regulation (EC) No 1935/2004 | Framework migration and traceability | All food-contact grades | Declaration of compliance |
| Regulation (EC) No 2023/2006 | GMP for materials intended for food contact | Converting operations | Process audit and batch lots |
| ISO 2470-2:2008 | D65 brightness | LWC and carton topcoat | Optical target after calendering |
| ISO 8254-1:2009 | 75° specular gloss | Cast-coated and label facestock | Topcoat gloss before printing |
| ISO 8791-2:2013 | Bendtsen roughness | Label and board topcoat | Smoothness after soft calendering |
| ISO 12647-2:2013 | Offset lithography process control | LWC and carton | Print density and dot gain |
Surface sizing of woodfree base stock for dry-toner and inkjet office papers does not use a pigment-rich coating colour; instead Fulatex PD0123 is dosed into a size press solution at 4–8 parts per hundred dry starch. The solution is prepared with oxidized or cationic starch cooked at 8–12 wt% solids and cooled to 55–65 °C; Fulatex PD0123 is injected after the starch cooker to avoid thermal destabilization, then diluted to 6–10 wt% total solids for a metering size press running 800–1200 m/min. Rod pressure is set at 0.8–1.5 kN/m to deposit 1.5–3.0 g/m² dry size per side. The anionic latex raises the elastic modulus of the starch film, reducing dusting on subsequent sheet-fed offset blankets and improving toner anchorage in electrophotographic machines. Over-addition beyond 8 pph on starch increases film-split misting and drying demand without additional surface strength; this is a recognized processing boundary. Compliance is evaluated under ISO 535:2014 for Cobb60 water absorption and ISO 2470-2:2008 for brightness; for inkjet grades, image quality is checked according to ISO 13660:2001. Terminal products are ream-wrapped office papers, preprint base for manuals, and high-speed digital print sheets where dimensional stability and lower linting are mandatory. The use of alum or other cationic fixatives in the wet end must be controlled because excessive cationic charge can destabilize the anionic size press solution when broke recirculates.
A pressure-sensitive label facestock requires a topcoat that balances smoothness, opacity, and silicone holdout before release coating. Fulatex PD0123 is incorporated at 10–14 pph dry pigment in a coating colour made from 60–70 parts kaolin and 30–40 parts ground calcium carbonate, with solids at 55–60 wt%. When the topcoat is applied by an air-knife following a blade precoat, the blade station deposits 6–8 g/m² and the air-knife topcoat deposits 8–10 g/m²; the two-layer structure reduces surface roughness below 0.9 μm Bendtsen while preserving bulk. Higher binder levels above 14 pph produce film splitting at the air-knife tip under 120–160 m/min production speed, causing transverse streaks, while lower levels below 10 pph generate micro-cracking at the die-cut edge. The dried topcoat is supercalendered at 80–100 °C and 150–250 kN/m nip load. Smoothness is measured under ISO 8791-2:2013, gloss under ISO 8254-1:2009, and tensile strength of the facestock under ISO 1924-2:2008. Terminal product types include pressure-sensitive labels for beverage, logistics, and retail packaging, where die-cutting at 80–120 m/min depends on the topcoat’s resistance to edge tearing. Published data for this specific configuration is limited; mill trial records indicate that the blade-to-air-knife transfer point must remain at 60–70% dry solids to avoid binder migration into the base sheet.
Cast coating applies a wet coated web directly against a chromium-plated drying drum to transfer a mirror finish to the coating surface. Fulatex PD0123 is used at 12–18 pph dry pigment because the film must remain thermoplastic enough to replicate the drum surface but not adhere so strongly that it fails to release. Below 12 pph, the coating lacks sufficient film continuity and the replicated 75° gloss drops; above 18 pph, tack after drum residence increases and the sheet emits a low-frequency tearing release sound, a production-scale indicator of insufficient release. The colour is prepared at 45–55 wt% solids with a pigment system of 80–100 parts No. 1 kaolin and 0–20 parts ground calcium carbonate, plus 1.0–1.5 pph calcium stearate and 0.5–1.0 pph ammonium oleate release aid. The coating is applied by a roll-coater or a deflecting blade at 18–22 g/m² wet, then pressed against the chrome drum at 105–125 °C and 4–8 kN/m nip load, with dwell time 0.2–0.8 s. Drum surface roughness above 0.02 μm Ra directly degrades the replicated gloss, so drum maintenance is specified as a process parameter. 75° specular gloss is measured under ISO 8254-1:2009, and roughness under ISO 8791-2:2013. Terminal products include high-gloss folding cartons, covers, and decorative wraps where a mirror-like finish is required without film lamination. The latex addition must be rechecked whenever the pH shifts below 8.0 because acidic pigment slurries reduce the release aid efficiency.
Thermal paper pre-coating operates below the dye-developer layer and functions as a thermally insulating and hydrocarbon-smoothing barrier over the raw paper surface. Fulatex PD0123 is incorporated at 10–12 pph dry pigment in a pre-coat colour consisting of 70–100 parts calcined clay or hollow-sphere plastic pigment, with 8–12 wt% solids and blade or four-roll metering to deposit 3–6 g/m² dry coat. The latex is selected for low filming temperature and moderate stiffness so the pre-coat does not form a dense insulating shell that retards heat transfer from the thermal print head; dynamic colour development is retained above 80 mJ/mm² print energy density, while solvent holdout protects the dye layer from migrating into the base sheet. Drying is conducted in air flotation dryers at 110–140 °C web temperature, because residual moisture above 5.5% in the pre-coat causes head-to-head variance during later topcoat application. European compliance is evaluated under REACH Regulation (EC) No 1907/2006 and RoHS Directive 2011/65/EU; end-use paper is validated under ISO 2836:2021 for resistance of printed images to physical agents. Terminal product types are point-of-sale thermal rolls, luggage tags, and pre-printed thermal labels where the pre-coat preserves image density and reduces show-through. Published data for this specific configuration is limited; the operating window is derived from production-scale coating trials rather than independent peer-reviewed studies.
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Fulatex PD0123 is supplied as an aqueous carboxylated acrylonitrile-butadiene (XNBR) latex for dip-moulded protective goods, textile interlining, waterborne barrier coatings, and selected lamination adhesives. The dispersion is delivered within a controlled total-solids range of 43.0–45.0 wt% measured by ISO 3251, with a pH of 8.0–9.0 according to ISO 976 and a Brookfield LV viscosity of 25–80 mPa·s at 25 °C using spindle 2 at 60 rpm. Bound acrylonitrile is controlled between 28 wt% and 32 wt% on dry polymer, a range that provides oil resistance intermediate between general-purpose styrene-butadiene dispersions and high-ACN nitrile latices. The carboxylated structure permits sulfur-free metal oxide crosslinking, while residual free monomers are maintained below 10 mg/kg by headspace gas chromatography. Static storage without agitation shows settling after 72 h, and redispersed material returns to initial viscosity when low-shear agitation at 30 rpm is applied.
Mean hydrodynamic particle diameter by dynamic light scattering is 0.14–0.18 µm with a polydispersity index below 0.08. Surface tension of the raw dispersion is 38–42 mN/m under ISO 1409. A film cast at 23 °C and dried to constant mass shows a glass transition temperature of −20 °C to −17 °C by ISO 11357-2. Mechanical testing at 0.5 mm thickness prepared with a 4 mm drawdown bar on glass gives tensile strength of 18–24 MPa and elongation at break of 550–650% using ISO 37 Type 2 dumbbells. After hot-air ageing for 70 h at 100 °C per ISO 188, tensile retention is >80% and elongation retention is >70%. The tetrahydrofuran gel content after 24 h extraction at 23 °C is 40–50%, indicating a pre-crosslinked fraction that limits polymer flow on vertical formers during drying.
Compounding-scale dispersion of zinc oxide, sulfur, and dithiocarbamate accelerator is performed with a Cowles blade at peripheral speeds below 12 m/s to avoid shear-induced coagulation. A typical sulfur loading of 1.5 phr and zinc oxide loading of 3.0 phr increases room-temperature tensile strength by 15–20% while reducing elongation at break to 450–500%. In a 500 L jacketed compounding vessel fitted with a slow sweep anchor at 20–30 rpm, batch temperature during accelerator addition is maintained at or below 28 °C; above 30 °C the pre-crosslinked latex shows measurable viscosity rise. The compounded lot remains pumpable for 48 h at 20 °C when the pH is held at 8.5–9.0 with potassium hydroxide, but pH falls below specification within 6 h if ammonia is the sole alkali source.
On nonwoven interlining lines, the latex is applied to polyester webs at a wet add-on of 18–22% through a padder with horizontal pad pressure of 3–5 bar. Drying at 90–110 °C for 3–5 min produces a dry add-on of 8–10 g/m². The cured interlining withstands 5 perchloroethylene dry-cleaning cycles without visible delamination. Compared with self-crosslinking vinyl acetate-ethylene dispersions, PD0123 film retains a higher modulus at 40 °C, but it develops more yellowness after hot-air ageing at 150 °C. Published data for this specific interlining configuration is limited.
At shear rates relevant to transfer-pump recirculation and roller coating, Fulatex PD0123 is slightly pseudoplastic. Cone-and-plate data at 25 °C show 40 mPa·s at 100 s−1 and 28 mPa·s at 1000 s−1. Mechanical stability tested by ISO 2006 for 30 min yields coagulum below 0.05 wt% on a 200 mesh screen, provided that zinc ammonium carbonate is not used below pH 8.0. On a dip-line recirculation loop driven by a 1.5 kW progressive-cavity pump at 300 rpm for 8 h, Brookfield viscosity shifts by +8 mPa·s to +15 mPa·s. This drift is reversible after 12 h quiescent standing and is attributed to temporary association of the carboxylated surface layer rather than irreversible destabilisation. Dip-tank viscosity is checked at 2 h intervals and adjusted by controlled water addition to a solids target of 44 wt%.
| Property | Test method | Fulatex PD0123 | Non-carboxylated NBR latex | High-ACN XNBR latex |
|---|---|---|---|---|
| Total solids | ISO 3251 | 43.0–45.0 wt% | 41.0–43.0 wt% | 44.0–46.0 wt% |
| pH | ISO 976 | 8.0–9.0 | 10.0–11.0 | 8.0–9.0 |
| Brookfield viscosity at 25 °C, spindle 2, 60 rpm | ISO 2555 | 25–80 mPa·s | 15–40 mPa·s | 60–120 mPa·s |
| Mean particle diameter | ISO 22412 | 0.14–0.18 µm | 0.18–0.24 µm | 0.10–0.14 µm |
| Glass transition temperature | ISO 11357-2 | −20 °C to −17 °C | −28 °C to −22 °C | −12 °C to −8 °C |
| Tensile strength | ISO 37 | 18–24 MPa | 10–14 MPa | 25–30 MPa |
| Elongation at break | ISO 37 | 550–650% | 600–700% | 420–500% |
| Volume swell in IRM 903 oil, 70 h at 100 °C | ASTM D471 | 10–12% | 22–28% | 5–8% |
The greatest departure from a non-carboxylated NBR latex is seen in tensile development and hot-oil swelling. Carboxylation introduces ionic crosslink sites that consume zinc oxide during cure, but it also raises sensitivity to acidic coagulants and to polar solvents. The high-ACN grade shows lower equilibrium swelling in non-polar hydrocarbons but requires more coalescing agent unless the latex is heated during film formation; PD0123 can be film-formed without coalescent at 23 °C.
In lamination adhesives for flexible packaging, PD0123 is compounded with rosin ester tackifier dispersions at 10–15 wt% on dry polymer. The compounded adhesive develops peel strength of 1.5–2.5 N/15 mm on corona-treated polyethylene terephthalate at a coating weight of 3–4 g/m² after 24 h at 23 °C. The bond retains 60–70% of initial peel strength after 5 thermal cycles between −20 °C and 60 °C. Under high humidity at 90% RH, the nitrile latex exhibits lower wet creep than vinyl acetate-ethylene adhesives, but plasticiser migration from PVC films can soften the adhesive layer within 4 weeks.
Immersion in Reference Fuel C under ASTM D471 for 70 h at 23 °C produces a mass change of 15–18%. Grade-specific behaviour is apparent in IRM 903 oil at 100 °C for 70 h, where PD0123 shows 10–12% mass change against 8–10% for a high-ACN XNBR and 25–30% for a non-carboxylated NBR latex. Acetone immersion swells the cured film by 35–40% at 23 °C, confirming that the product is not intended for sustained ketone exposure. Water absorption after 48 h at 23 °C is 5–8%. Aqueous extractables from a cured film post-leached for 24 h in warm water remain below 1.2 mg/dm² after 10 days at 40 °C.
At 120 °C oven cure, a compounded film containing 1.5 phr sulfur and 0.8 phr zinc dibutyldithiocarbamate reaches 90% of maximum torque on a moving-die rheometer in 6–8 min. At 110 °C, the same conversion requires 12–14 min. This narrows effective oven residence to 14–18 min when the hot-air temperature along the curing tunnel varies by ±5 °C. Thick sections above 1.5 mm exhibit under-cure in the core unless the post-cure leach and drying sequence is extended; production trials on 1.8 mm glove samples showed surface cracking when the leach temperature exceeded 70 °C before complete cure. Therefore, the post-cure leach tank is set at 50–60 °C and the final drying stage at 70–80 °C for 25–35 min.
Solvent-free sealant compounds formulated with 35–45 wt% PD0123 on total compound show VOC below 5 g/L under ISO 11890-2. Coalescing-agent demand is low because the minimum film-forming temperature of PD0123 is below −5 °C. Joint movement capability after cure is ±7.5% by ISO 9046 when the compound contains 40 wt% latex solids and 35 wt% fine calcium carbonate. The uncured compound uses a hydrophobically modified alkali-swellable thickener at 0.4 wt% to control pseudoplasticity. Because the polymer is nitrile-functional, outdoor UV resistance is inferior to acrylic sealants; the grade is therefore specified for indoor or sheltered joints unless a UV-resistant topcoat is applied. Published data for continuous outdoor exposure of this specific carboxylated nitrile grade is limited.
| Assessment | Standard or regulation | Typical result for cured film |
|---|---|---|
| REACH SVHC, intentionally added substances | (EC) No 1907/2006 | No intentionally added SVHC above 0.1 wt% |
| REACH Annex XVII PAH restrictions | Annex XVII entry 50 | Each PAH below 1 mg/kg |
| RoHS restricted heavy metals and brominated flame retardants | Directive 2011/65/EU | Cd, Pb, Hg, Cr(VI), PBB, PBDE each below 1000 ppm |
| Nitrile examination glove tensile requirements | ASTM D6319 | Tensile strength above 14 MPa before ageing and above 14 MPa after accelerated ageing |
| Medical glove freedom from holes | EN 455-2 | AQL below 1.5 |
| Cytotoxicity of leachates prepared at 37 °C for 24 h | ISO 10993-5 | No cytotoxic response observed |
For production environments where relative humidity exceeds 60%, pre-drying tunnels at 60–80 °C with air velocity of 2–3 m/s are required to avoid surface tack and non-uniform wet-film build. Residual chlorinated solvents from former-release operations must not enter the recirculated dip tank; even 0.1 wt% dichloromethane residue can initiate local gelation at the air–liquid interface. Amine-based defoamers should be avoided because they can drive pH above 9.5 and produce premature thickening. Acid-amphoteric defoamers are preferred when foam suppression is required in continuous dip tanks.
