1. New developments in Polypropylene grades
Polypropylen Innovativ
Würzburg
Ben Raven
SABIC EuroPetrochemicals
Technical Marketing PP Moulding & Extrusion

2. Contents Basic facts SABIC Developments in polypropylene grades
Evolution of MFR
Application of nucleators
Multi-functional PP grades
Conclusions

3. SABIC: Saudi Arabian Basic Industries Corporation
Started from scratch in 1976, produced first tons in 1983
World wide employees in 22 countries
Turn-over of € 11,4 bln in 2002
Is 70% owned by Saudi government and 30% by private sector
100% owner of SABIC EuroPetrochemicals
Basic Chemicals
Intermediates
Polymers
Fertilizers
Metals

4. SABIC EuroPetrochemicals
Geleen site
Gelsenkirchen site
SABIC’s first major acquisition outside Saudi Arabia

5. West-Europe PP/PE Supply 2003

6. Developments in polypropylene grades
Increasing MFR
shorter cycle times
thinner wall thicknesses
Nucleation
Multi functional PP grades

7. Increasing MFR - evolution of grade portfolio block-copolymers
100
1980
Notched Izod impact (kJ/m²) 10
Sheet 18
If we translate these customer needs into a general direction of wanted development of PP properties, the following picture emerges.
Here the dependency of the IZOD impact strength and the melt flow rate of PP is shown: it is clear that if the melt flow rate of the material improves, the IZOD impact strengths deteriorates. The preferred development direction is indicated by the red arrow: more impact strength at higher melt flow rates. Over time we see a gradual improvement of the balance of these properties.
In the next few slides I will show you some recent Stamylan P developments that support this preferred development direction and add to improve the property balance of the Stamylan P portfolio. 1
0,1 1 10
100
Melt flow rate (g/10 min)

8. Increasing MFR - evolution of grade portfolio block-copolymers
100
1980
1990
Notched Izod impact (kJ/m²) 10
Sheet 18
If we translate these customer needs into a general direction of wanted development of PP properties, the following picture emerges.
Here the dependency of the IZOD impact strength and the melt flow rate of PP is shown: it is clear that if the melt flow rate of the material improves, the IZOD impact strengths deteriorates. The preferred development direction is indicated by the red arrow: more impact strength at higher melt flow rates. Over time we see a gradual improvement of the balance of these properties.
In the next few slides I will show you some recent Stamylan P developments that support this preferred development direction and add to improve the property balance of the Stamylan P portfolio. 1
0,1 1 10
100
Melt flow rate (g/10 min)

9. Increasing MFR - evolution of grade portfolio block-copolymers
100
1980
1990
2000
Notched Izod impact (kJ/m²) 10
Sheet 18
If we translate these customer needs into a general direction of wanted development of PP properties, the following picture emerges.
Here the dependency of the IZOD impact strength and the melt flow rate of PP is shown: it is clear that if the melt flow rate of the material improves, the IZOD impact strengths deteriorates. The preferred development direction is indicated by the red arrow: more impact strength at higher melt flow rates. Over time we see a gradual improvement of the balance of these properties.
In the next few slides I will show you some recent Stamylan P developments that support this preferred development direction and add to improve the property balance of the Stamylan P portfolio. 1
0,1 1 10
100
Melt flow rate (g/10 min)

10. Increasing MFR - evolution of grade portfolio block-copolymers
100
1980
1990
2000
2010 ?
SABIC® PP
Notched Izod impact (kJ/m²) 10
Sheet 18
If we translate these customer needs into a general direction of wanted development of PP properties, the following picture emerges.
Here the dependency of the IZOD impact strength and the melt flow rate of PP is shown: it is clear that if the melt flow rate of the material improves, the IZOD impact strengths deteriorates. The preferred development direction is indicated by the red arrow: more impact strength at higher melt flow rates. Over time we see a gradual improvement of the balance of these properties.
In the next few slides I will show you some recent Stamylan P developments that support this preferred development direction and add to improve the property balance of the Stamylan P portfolio. 1
0,1 1 10
100
Melt flow rate (g/10 min)

11. Increasing MFR - processing advantages (example MFI 15 vs
Increasing MFR - processing advantages (example MFI 15 vs. MFI 35 grade)
140
120
100 80
Traditional grade
Index figure 60
High MFR grade 40 20
Flow
Mould
Cycle time
Output
pressure
rate

12. Increasing MFR – reduced wall thicknesses (example MFI 15 vs
Increasing MFR – reduced wall thicknesses (example MFI 15 vs. MFI 35 grade)
800
700
600
500
Traditional grade
Flow length (mm)
400
High MFR grade
300
200
100
0,5
1,0
1,5
2,0
Wall thickness (mm)

13. Improved pail grade: SABIC PP 612MK10
New Grade
Old Grade
100
Notched izod impact (KJ/m²) 10
SABIC® PP
612MK10
MFR 15
MFR 35 1
0,1 1 10
100
Melt flow rate (g/10 min)

14. Improved high MFR multipurpose grade: SABIC PP 513MNK40
New Grade
Old Grade
100
SABIC® PP
513MNK40
Notched izod impact (KJ/m²) 10
MFR 70
MFR 40 1
0,1 1 10
100
Melt flow rate (g/10 min)

15. Improved beaker grade: SABIC PP 313MNK40
New Grade
Old Grade
100
Notched izod impact (KJ/m²) 10
SABIC® PP
313MNK40
MFI 90
grade 1
0,1 1 10
100
Melt flow rate (g/10 min)

16. Improved high impact grade: SABIC PP PHC26
100
SABIC® PP
PHC26
75MR10
New Grade
Old Grades
Notched Izod impact (kJ/m²) 10
66MNK10
Sheet 22
The last example I would like to give you is that of the introduction of an improved multi-purpose high impact grade for crates, boxes and suitcases: Stamylan P PHC26, that is building on the very successful current PHC27 grade. The combination of flow properties and impact level is at a very high level and sets new standard in the Stamylan P portfolio.
Moreover, these values were achieved without any compromise on surface properties and elastic recovery.
Stamylan P PHC26 is excellently positioned for parts in which surface appearance, low temperature impact strength and sturdiness are of utmost importance. It also provides improved cycle time within manufacturing.
Suitcases
Crates & Boxes 1
0,1 1 10
100
Melt flow rate (g/10 min)

17. Developments in polypropylene grades
Increasing MFR
Nucleation
increased stiffness
better transparency
higher crystallisation temperatures
Multi functional PP grades

18. The influence of nucleation
non-nucleated
nucleated

19. Nucleation - increased stiffness
Non-nucleated
Nucleated
2000
Flexural
modulus
[MPa]
1500
1000
PP homopolymer
PP copolymer

20. Nucleation - increased transparency

21. Nucleation - increased transparency
Cross-section

22. Spherulitic growth in praxis
In-line thermoforming
Sheet thickness = 2 mm
PP grade non-nucleated

23. New SABIC® PP grade for thermoformingPS
Clarity
clarified
nucleated PP
Stiffness
possibility of down gauging

24. New SABIC® PP grade for thermoforming
Clarity
clarified
SABIC® PP 523K
nucleated PP
Stiffness
possibility of down gauging

25. Nucleation - higher crystallisation temperatures (Tc)
Addition of nucleating agent

26. Nucleation - influence nucleation agent (DSC test)Tc

27. Nucleation - higher crystallisation temperatures; faster cycle times
Required cooling time
T crystallisation

28. Nucleation - influence Tc on cooling time; indentation test
Indentation pin
Mold plates
Hydraulic
cylinder
Pressurized oil
Ejection pins
Injection
sprue
Cavity
Runner (5 mm)
Injection point
Indentation point
Crystallisation speed can be measured by the so called “indentation test”. Depth of indentation (mm) is measured during subsequent injection moulding cooling times. At longer cooling time, the indentation becomes less. Nucleated grade shows faster solidification than non-nucleated grades.

29. Indentation test Non nucleated PP Nucleated PP
Crystallisation speed can be measured by the so called “indentation test”. Depth of indentation (mm) is measured during subsequent injection moulding cooling times. At longer cooling time, the indentation becomes less. Nucleated grade shows faster solidification than non-nucleated grades.

30. Developments in polypropylene grades
Increasing MFR
Nucleation
Multi functional PP grades
reduction in number of PP grades
broader application range

31. Decreasing number of W.European COPOL PP grades
200
nr of COPOL PP grades
1997
1999
2001
2003
SABIC EPC
Comp 1
Comp 2
Comp 3

32. Decreasing number of W.European HOPOL PP grades
300
nr of HOPOL PP grades
1997
1999
2001
2003
SABIC EPC
Comp 1
Comp 2
Comp 3

33. Reduction in number of PP grades
SABIC EuroPetrochemical’s answer:
Multi-functional PP grades
Broad application area
Ultimate product consistency

34. The multi-functional block copolymer grades for injection moulding offer:
Shot to shot consistency
Short cycle times
Acceptable stiffness / impact balance
Dimensional stability
Good surface appearance
Low blushing performance
Good organoleptics

35. Multi-functional block copolymers (1)
Cycle time
SABIC® PP 412MN40
Dimensional Stability
Organoleptic
Tamper evidence
Impact/stiffness Balance
Surface Appearance

36. Multi-functional block copolymers (2)
SABIC® PP PHC31
Surface Appearance
Impact
Impact/stiffness Balance
Dimensional stability
Cycle time

37. Conclusions Increasing MFR shorter cycle times
reduced wall thicknesses
Nucleation
increased stiffness
better transparency
higher crystallisation temperatures
Multi functional PP grades
reduction in number of PP grades
broader application range