The production of LVT flooring places specific demands on the stabilizer and lubricant system. SPC substrates contain a high level of calcium carbonate, so even a small change in the stabilizer package can affect plasticization, equipment load, sheet surface quality, and production campaign duration.
Reapak 9916 has been developed for highly filled rigid PVC compounds and is suitable for SPC substrates used in LVT flooring.
Key Functions of Reapak 9916
- protection of PVC against thermal degradation;
- maintenance of stable plasticization;
- reduction of deposits on processing equipment;
- production of a uniform SPC sheet surface;
- longer operating time between cleaning cycles;
- support for consistent line throughput.
Why Stabilizers for LVT Must Account for High Filler Loading
An SPC substrate is a highly filled rigid PVC compound. Calcium carbonate accounts for a significant share of its mass, and its properties directly affect mixing and processing.
The following factors are important:
- filler particle size and particle-size distribution;
- surface treatment;
- moisture content;
- quality of hot and cold mixing;
- the balance of internal and external lubricants;
- processing temperature and intensity.
In this type of formulation, the stabilizer system does not work in isolation. Its lubricant balance must be compatible with the filler, modifiers, and operating conditions of the specific line.
Reapak 9916 combines thermal stabilization with the processing properties of the compound in one system designed for a high mineral filler content.
Reducing Plate-Out in SPC Production
One of the common issues in LVT production is plate-out: the build-up of formulation components on the die, rolls, and other equipment contact surfaces.
Deposits can lead to:
- streaks and an uneven surface;
- changes in gloss;
- unstable sheet thickness;
- equipment contamination;
- downtime for cleaning;
- increased process scrap.
Reapak 9916 reduces the tendency of highly filled compounds to form plate-out. This helps keep equipment clean for longer, maintain a consistent flooring surface, and support stable line parameters. The result depends on the entire formulation, so when switching to Reapak 9916, individual lubricants, calcium carbonate properties, and the actual temperature profile should be considered.
Stable Plasticization Without Excessive Load
For SPC, both insufficient and excessively intensive plasticization are undesirable.
Insufficient plasticization can result in a non-uniform substrate structure, surface defects, and lower machining quality. Excessive thermal and shear load increases motor current, melt pressure, and melt temperature, reducing the available thermal stability margin.
Reapak 9916 helps keep the compound within its operating window. With a correctly adjusted formulation, this provides:
- stable compound feeding;
- predictable extruder load;
- uniform forming of the SPC substrate;
- consistent thickness;
- high surface quality;
- stable throughput.
The stabilizer does not replace proper equipment setup, but it helps make the behaviour of a highly filled compound more stable and controllable.
What to Check When Testing Reapak 9916
The product should be evaluated in the current LVT formulation. At the initial stage, PVC, calcium carbonate, modifiers, and the other main components should remain unchanged.
On the Production Line
Compare the following:
- mixing time and temperature;
- dry-blend flowability;
- extruder motor current or torque;
- melt pressure and temperature;
- line throughput;
- surface quality;
- thickness consistency;
- time before deposits appear;
- operating time between cleaning cycles;
- scrap volume.
After the first trial, individual lubricants and process settings can be adjusted if necessary.
For Finished Flooring
Check the following:
- SPC substrate thickness and density;
- flatness and warpage;
- dimensional stability after heating;
- structure uniformity;
- surface quality;
- milling quality;
- edge quality;
- click-lock joint performance;
- reject rate.
The stabilizer does not determine all of these properties on its own, but changing the stabilizer package should not impair the performance of the finished flooring.
Calculate the Cost per Square Metre of Saleable Flooring
It is not sufficient to compare stabilizers only by price per kilogram. For an LVT producer, the important measure is the cost per square metre of flooring that meets the required specifications.
The calculation includes:
- stabilizer dosage;
- line throughput;
- weight per square metre;
- scrap volume;
- time between equipment cleaning cycles;
- downtime duration;
- milling losses;
- thickness and surface consistency.
Reducing plate-out and extending the production campaign can have a greater economic impact than a small difference in the purchase price of a stabilizer package.
Reapak 9916 for LVT Production
Reapak 9916 is a calcium-zinc stabilizer system for highly filled rigid PVC compounds.
The product helps SPC flooring manufacturers address several related tasks at once:
- provide the required thermal stability;
- adjust plasticization;
- reduce deposit formation;
- maintain surface consistency;
- reduce downtime and scrap;
- manage the cost per square metre of saleable flooring.
To prepare a comparative trial, Revada Plastic specialists require the current formulation, the stabilizer in use and its dosage, calcium carbonate characteristics, lubricant system composition, mixing and extrusion parameters, throughput, and a description of current production issues.
Based on these data, an initial Reapak 9916 dosage is selected and the formulation is adjusted if necessary.
For flexible LVT flooring, Revada Plastic offers separate stabilizer solutions that account for the plasticizer system and finished-material requirements.
