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The Definitive Guide to Polypropylene (PP)

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A Definite Guide to Polypropylene (PP)

Polypropylene (PP) is a rigid and crystalline thermoplastic used widely in everyday objects like packaging
trays, household products, battery cases, medical devices, etc. Explore this comprehensive guide and
learn everything you need to know about this widely used thermoplastic.
Quick Links to the Detailed Profile:

» What is Polypropylene and What It's Used for?

» How PP is produced?

» Types of Polypropylene & their Benefits

» Main Differences Between PP Homo and PP Copolymer

» Properties of Polypropylene

» Disadvantages of Polypropylene

» What is PP used for?

» Comparison of Polypropylene with Polyethylene

» Polypropylene Processing - Everything You Need to Know About It!

» 3D Printing with Polypropylene

» Is PP toxic? How to recycle PP?

By SpecialChem

Polypropylene and Its Features

What is Polypropylene and What It's Used for?

Polypropylene is a tough, rigid and crystalline thermoplastic produced from propene (or propylene)
monomer. It is a linear hydrocarbon resin. The chemical formula of polypropylene is (C3H6)n. PP is
among the cheapest plastics available today.

Molecular Structure of Polypropylene

Molecular Structure of Polypropylene

PP belongs to polyolefin family of polymers and is one of the top three widely used polymers today.
Polypropylene has applications both as a plastic and a fiber in:

Automotive Industry

Industrial Applications

Consumer Goods, and

Furniture Market

It has the lowest density among commodity plastics.

Some of the key suppliers of polypropylene are:

A. Schulman - GAPEX®, ACCUTECH™, POLYFORT®, Fiberfil®, FERREX® and more

Borealis - Daplen™, Bormed™, Fibremod™ and more

ExxonMobil Chemical - ExxonMobil™, Achieve™

LyondellBasell - Adstif, Circulen, Hifax, Hostacom, Moplen and more

SABIC - SABIC® PP, SABIC® Vestolen, LNP™ THERMOCOMP™ and more

RTP Company - ESD C, ESD A, RTP 100, RTP 101 to 109 and more

» View >18000 commercially available PP grades and > 350 suppliers in Omnexus Plastics Database
The plastic database allows you to filter your search based on property (mechanical, electrical etc.),
applications, conversion mode and other dimensions for FREE!

How to Produce Polypropylene?

These days, polypropylene is made from polymerization of propene monomer (an unsaturated organic
compound - chemical formula C3H6) by:

Ziegler-Natta polymerization or

Metallocene catalysis polymerization

Structure of PP Monomer

Structure of PP Monomer

C3H6 Ziegler-Natta Polymerization

Arrow

Or Metallocene Catalysis Structure of Polypropylene

Structure of Polypropylene

(C3H6)n

Upon polymerization, PP can form three basic chain structures depending on the position of the methyl
groups:

Atactic (aPP) - Irregular methyl group (CH3) arrangement

Isotactic (iPP) – Methyl groups (CH3) arranged on one side of the carbon chain

Syndiotactic (sPP) - Alternating methyl group (CH3) arrangement

Types of Polypropylene

Facts to Know Polypropylene was first polymerized by German chemist named Karl Rehn and an Italian
chemist named Giulio Natta to a crystalline isotactic polymer in 1954. This discovery soon led to a large-
scale production of polypropylene starting in 1957 by the Italian firm Montecatini.

Syndiotactic polypropylene was also first synthesized by Natta and his coworkers.

Types of Polypropylene & their Benefits

Homopolymers and Copolymers are the two major types of polypropylene available in the market.

Polypropylene Homopolymer is the most widely utilized general-purpose grade. It contains only
propylene monomer in a semi-crystalline solid form. Main applications include packaging, textiles,
healthcare, pipes, automotive and electrical applications.

Polypropylene Copolymer family is further divided into random copolymers and block copolymers
produced by polymerizing of propene and ethane:

Polypropylene Random Copolymer is produced by polymerizing together ethene and propene. It

features Ethene units, usually up to 6% by mass, incorporated randomly in the polypropylene chains.
These polymers are flexible and optically clear making them suitable of applications requiring
transparency and for products requiring an excellent appearance.

While in Polypropylene Block Copolymer, ethene content is larger (between 5 and 15%). It has co-
monomer units arranged in regular pattern (or blocks). The regular pattern hence makes thermoplastic
tougher and less brittle than the random co-polymer. These polymers are suitable for applications
requiring high strength, such as industrial usages.
Polypropylene, Impact Copolymer – Propylene Homopolymer containing a co-mixed Propylene Random
Copolymer phase which has an ethylene content of 45-65% is referred to PP impact copolymer. It is
useful in parts which require good impact resistance. Impact copolymers are mainly used in packaging,
houseware, film, and pipe applications, as well as in the automotive and electrical segments.

Expanded Polypropylene - It is a closed-cell bead foam with ultra-low density. EPP is used to produce
three-dimensional polymer foam products. EPP bead foam has higher strength to weight ratio, excellent
impact resistance, thermal insulation, and chemical and water resistance. EPP is used in various
applications ranging from automobiles to packaging, from construction products to consumer goods and
more.

Polypropylene Terpolymer - It is composed by propylene segments joined by monomers ethylene and

butane (co-monomer) which appear randomly throughout the polymer chain. PP terpolymer has better
transparency than PP homo. Also, the incorporation of co-monomers reduces crystalline uniformity in
the polymer making it suitable for sealing film applications.

Polypropylene, High Melt Strength (HMS PP)– It is a long chain branched material, which combines both
high melt strength and extensibility in the melt phase. PP HMS grades have a wide mechanical property
range, high heat stability, good chemical resistance. HMS PP is widely used to produce soft, low density
foams for food packaging applications as well as used in automotive and construction industries.

PP Homopolymer vs. Copolymer – How to decide between the two?

PP Homopolymer PP Copolymer

High strength to weight ratio and stiffer & stronger than copolymer

Good chemical resistance and weldability

Good processability

Good impact resistance

Good stiffness

Food contact acceptable

Suitable for corrosion resistant structures

Bit softer but has better impact strength; tougher and more durable than homopolymer

Better stress crack resistance and low temperature toughness

High processability

High impact resistance

High toughness

Not preferable for food contact applications

The potential applications for PP homopolymer and PP copolymer are nearly identical

This is because of their extensively shared properties. As a result, the choice between these two
materials is often made based on non-technical criteria.

Interesting Material Properties of Polypropylene

Keeping information about the properties of a thermoplastic beforehand is always beneficial. This helps
in selecting the right thermoplastic for an application. It also assists in evaluating if the end use
requirement would be fulfilled or not. Here are some key properties and benefits of polypropylene:

Melting Point of Polypropylene - The melting point of polypropylene occurs at a range.

Homopolymer: 160 - 165°C

Copolymer: 135 - 159°C

Density of Polypropylene - PP is one of the lightest polymers among all commodity plastics. This feature
makes it a suitable option for lightweight\weight saving applications.

Homopolymer: 0.904 – 0.908 g/cm3

Random Copolymer: 0.904 – 0.908 g/cm3

Impact Copolymer: 0.898 – 0.900 g/cm3

Polypropylene Chemical Resistance

Excellent resistance to diluted and concentrated acids, alcohols and bases

Good resistance to aldehydes, esters, aliphatic hydrocarbons, ketones

Limited resistance to aromatic and halogenated hydrocarbons and oxidizing agents

Flammability: Polypropylene is a highly flammable material

PP retains mechanical & electrical properties at elevated temperatures, in humid conditions and when
submersed in water. It is a water-repellent plastic

PP has good resistance to environmental stress cracking

It is sensitive to microbial attacks, such as bacteria and mold

It exhibits good resistance to steam sterilization

Learn more about all polypropylene properties and their values - ranging from mechanical and electrical
to chemical properties; and make the right selection for your application.

How additives help improve PP properties?

Polymer additives like clarifiers, flame retardants, glass fibers, minerals, conductive fillers, lubricants,
pigments and many other additives can further improve PP physical and/or mechanical properties. For
example:
Search PP Grades Based on

Their Reinforcement Method

Search PP Grades Based on Their Reinforcement Method

PP has poor resistance to UV, hence additives like hindered amines provide light stabilization and
enhances the service life as compared to unmodified polypropylene.

Further, fillers (clays, talc, calcium carbonate…) and reinforcements (glass fiber, carbon fiber…) are added
to achieve significant properties related to processing and end use application.

Development & the use of new additives, latest polymerization processes as well as blending solutions
significantly increase polypropylene performance. Hence, today PP is less seen as a low cost solution, but
much more as a high performance material competing with traditional engineering plastics and
sometime event metal (e.g. long glass fiber reinforced PP grades).

Disadvantages of Polypropylene

Poor resistance to UV, impact and scratches

Embrittles below -20°C

Low upper service temperature, 90-120°C

Attacked by highly oxidizing acids, swell rapidly in chlorinated solvents and aromatics

Heat-aging stability is adversely affected by contact with metals

Post molding dimensional changes due to crystallinity effects – this can be solved with nucleating agents
» Watch video

Poor paint adhesion

Key Areas of Applications of Polypropylene

Polypropylene is widely used in various applications due to its good chemical resistance and weldability.
Some common uses of polypropylene include:

Packaging Applications: Good barrier properties, high strength, good surface finish and low cost make
Polypropylene ideal for several packaging applications.

Flexible Packaging: PP films’ excellent optical clarity and low moisture-vapor transmission make it
suitable for use in food packaging. Other markets shrink-film overwrap, electronic industry films, graphic
arts applications, disposable diaper tabs and closures, etc. PP Film is available either as Cast Film or bi-
axially orientated PP (BOPP).

Rigid Packaging: PP is blow molded to produce crates, bottles, and pots. PP thin walled containers are
commonly used for food packaging.

Packaging Applications - Packaging & Consumer Goods Applications

Consumer Goods: Polypropylene is used in several household products and consumer goods applications
including translucent parts, housewares, furniture, appliances, luggage, toys etc.

Automotive Applications: Due to its low cost, outstanding mechanical properties and moldability,
polypropylene is widely used in automotive parts. Main applications include battery cases and trays,
bumpers, fender liners, interior trim, instrumental panels and door trims. Other key features of
automotive applications of PP include low coefficient of linear thermal expansion and specific gravity,
high chemical resistance and good weatherability, processability and impact/stiffness balance.

Automotive Applications of Polypropylene

» Follow all that Happens in Automotive Market

Fibers and Fabrics: A large volume of PP utilized in the market segment known as fibers and fabrics. PP
fiber is utilized in a host of applications including raffia/slit-film, tape, strapping, bulk continuous
filament, staple fibers, spun bond and continuous filament. PP rope and twine are very strong and
moisture resistant very suitable for marine applications.

Medical Applications: Polypropylene is used in various medical applications due to high chemical and
bacterial resistance. Also, the medical grade PP exhibits good resistance to steam sterilization.
Disposable syringes is the most common medical application of polypropylene. Other applications
include medical vials, diagnostic devices, petri dishes, intravenous bottles, specimen bottles, food trays,
pans, pill containers, etc.

Medical Applications of Polypropylene

» Follow Latest Medical Industry Updates

Industrial Applications: Polypropylene sheets are widely used in industrial sector to produce acid and
chemical tanks, sheets, pipes, Returnable Transport Packaging (RTP), etc. because of its properties like
high tensile strength, resistance to high temperatures and corrosion resistance.

Polypropylene Sheets

Usefulness of Polypropylene Films

PP film is among the leading materials today used for flexible packaging as well as industrial applications.
Two important forms of polypropylene films include:

Cast Polypropylene Film

Cast polypropylene commonly known as CPP and widely known for its versatility.

Super resistance to tears & puncture

Greater transparency and better heat resistance at high temperatures.

Excellent moisture and atmospheric barriers

High permeability to water vapor

Biaxially Oriented Polypropylene Film

Biaxially oriented polypropylene film (BOPP) is stretched in both transversal and longitudinal directions,
producing molecular chain orientation in two directions.

Orientation increases tensile strength and stiffness

Good puncture and flex crack resistance over wide range of temperatures

Have excellent gloss and high transparency can be glossy, clear, opaque, matte or metalized

Efficient barrier against oxygen and moisture

PP vs. PE – Selecting the Suitable Polymer

Though Polyethylene and Polypropylene are similar in physical properties but here are key points to
consider to select the polymer suitable to your needs.

Polypropylene Polyethylene
Monomer of polypropylene is propylene

It can be produced optically clear

It is lighter in weight

PP exhibits a high resistance to cracking, acids, organic solvents and electrolytes

It has high melting point and good dielectric properties

PP is non-toxic

It is stiffer and resistant to chemicals and organic solvents compared to polyethylene

PP is more rigid than polyethylene

Monomer of polyethylene is ethylene

Polyethylene can only be made translucent like a milk jug

Its physical properties allow it to stand up better in cold temperatures, particularly when using it as signs

It is a good electrical insulator

PE offers good tracking resistance

Polyethylene is sturdy as compared to Polypropylene

» View all PP Commercial Grades » View all PE Commercial Grades

Polypropylene Processing Conditions

Polypropylene can be processed virtually by all processing methods. The most typical processing
methods include: Injection Molding, Extrusion, Blow Molding and General-Purpose Extrusion.

Injection Molding

Melt temperature: 200-300°C

Mold temperature: 10-80°C

Drying is not necessary if stored properly

High mold temperature will improve brilliance and appearance of the part

Mold shrinkage lies between 1.5 and 3%, depending on processing conditions, rheology of the polymer
and thickness of the final piece

Watch free video tutorial to improve PP cycle time and limit part shrinkage

How to Reduce PP Cycle Time (+ Avoid Shrinkage & Warpage)

Extrusion (tubes, blow and cast films, cables, etc.)

Melt temperature: 200-300°C

Compression Ratio: 3:1

Cylinder Temperatures: 180-205°C

Pre-Drying: No, 3 hours at 105-110°C (221-230°F) for regrind

Blow molding

Compression molding

Rotational molding

Injection blow molding

Extrusion Blow Molding

Injection stretch blow molding

General-Purpose Extrusion

Expanded Polypropylene (EPP) may be molded in a specialized process. Being an ideal material for
injection molding process, it is majorly used for batch and continuous production.
3D Printing with Polypropylene

As a tough, fatigue resistant and durable polymer, PP is ideal for low strength applications. Due to its
semi-crystalline structure and heavy warping, it is currently difficult to use polypropylene for 3D Printing
processes.

Today, several manufacturers have optimized PP properties or even created blends with improved
toughness making it suitable for 3D Printing applications. Hence, it is recommended to thoroughly refer
to documentation provided by supplier for printing temperature, printing bed, etc., while 3D Printing
with polypropylene...View all PP Grades Suitable for 3D Printing

Polypropylene is suitable for:

Complex models

Prototypes

Small series of components, and

Functional models

(Credit: FormFutura)

Is PP toxic? How to recycle PP?

All plastics have a ‘Resin Identification Code/ Plastic Recycling Code’ based on the type of resin used. PP’s
resin identification code is 5.

PP is 100% recyclable
PP is 100% recyclable. Automobile battery cases, signal lights, battery cables, brooms, brushes, ice
scrapers, etc., are few examples which can be made from recycled polypropylene (rPP).

The PP recycling process mainly includes melting of waste plastic to 250°C to get rid of contaminants
followed by removal of residual molecules under vacuum and solidification at nearly 140°C. This recycled
PP can be blended with virgin PP at a rate upto 50%. The main challenge in PP recycling is related to its
amount consumed – currently nearly 1% PP bottles are recycled as compared to 98% recycling rate of
PET & HDPE bottles together.

The use of PP is considered safe because it does not have any remarkable effect from an occupational
health and safety point of view, in terms of chemical toxicity.

Commercially Available Polypropylene (PP) Grades

Polypropylene Properties and Their Values

Property Value

Dimensional Stability

Coefficient of Linear Thermal Expansion 6 - 17 x 10-5 /°C

Shrinkage 1 - 3%

Water Absorption 24 hours 0.01 - 0.1%

Electrical Performances

Arc Resistance 135 - 180 sec

Dielectric Constant 2.3

Dielectric Strength 20 - 28 kV/mm

Dissipation Factor 3 - 5 x 10-4

Volume Resistivity 16 - 18 x 1015 Ohm.cm

Fire Performances

Fire Resistance (LOI) 17 - 18%

Flammability UL94 HB

Mechanical Properties

Elongation at Break 150 - 600%

Flexibility (Flexural Modulus) 1.2 - 1.6 GPa

Hardness Rockwell M 1 - 30

Hardness Shore D 70 - 83

Stiffness (Flexural Modulus) 1.2 - 1.6 GPa

Strength at Break (Tensile) 20 - 40 MPa

Strength at Yield (Tensile) 35 - 40 MPa

Toughness (Notched Izod Impact at Room Temperature) 20 - 60 J/m

Toughness at Low Temperature (Notched Izod Impact at Low Temperature) 27 - 107 J/m

Young Modulus 1.1 - 1.6 GPa

Optical Properties

Gloss 75 - 90%

Haze 11%

Transparency (% Visible Light Transmission) 85 - 90%

Physical Properties

Density 0.9 - 0.91 g/cm3

Glass Transition Temperature -10°C

Radiation Resistance
Gamma Radiation Resistance Poor

UV Light Resistance Fair

Service Temperature

Ductile / Brittle Transition Temperature -20 to -10°C

HDT @0.46 Mpa (67 psi) 100 - 120°C

HDT @1.8 Mpa (264 psi) 50 - 60°C

Max Continuous Service Temperature 100 - 130°C

Min Continuous Service Temperature -20 to -10°C

Others

Sterilization Resistance (Repeated) Poor

Thermal Insulation (Thermal Conductivity) 0.15 - 0.21 W/m.K

Chemical Resistance

Acetone @ 100%, 20°C Satisfactory

Ammonium hydroxide, 30% @ 20°C

Ammonium hydroxide, diluted @ 20°C Satisfactory

Aromatic hydrocarbons @ 20°C Non Satisfactory

Aromatic hydrocarbons @ hot conditions

Benzene, 100% @ 20°C Limited

Butylacetate, 100% @ 20°C

Butylacetate, 100% @ 60°C Non Satisfactory

Chlorinated solvents @ 20°C

Chloroform @ 20°C Limited

Dioctylphtalate, 100% @ 20°C Satisfactory

Dioctylphtalate, 100% @ 60°C Limited

Ethanol, 96% @ 20°C Satisfactory

Ethyleneglycol (Ethane diol), 100% @ 100°C

Ethyleneglycol (Ethane diol), 100% @ 20°C

Ethyleneglycol (Ethane diol), 100% @ 50°C

Glycerol, 100% @ 20°C

Hydrogen peroxide @ 30%, 60°C Limited

Kerosene @ 20°C

Methanol, 100% @ 20°C Satisfactory

Methylethyl ketone, 100% @ 20°C

Mineral oil @ 20°C Satisfactory

Phenol @ 20°C

Silicone oil @ 20°C Satisfactory

Sodium hydroxide, 40%

Sodium hydroxide, 10% @ 20°C Satisfactory

Sodium hydroxide, 10% @ 60°C Satisfactory

Sodium hypochlorite, 20% @ 20°C

Strong acids, concentrated @ 20°C Satisfactory

Toluene @ 20°C Limited

Toluene @ 60°C Non Satisfactory

Xylene @ 20°C

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3 Comments on "The Definitive Guide to Polypropylene (PP) "

Melissa B Oct 23, 2018

looking for the softening temperature of Polypropylene when used during manufacturing. I have an
application in which the material is under a prepregnated carbon in a female tool. I would like to know at
what temperature it begins to soften to allow the material enough time to sink into the female mold
shape of the bond tool.

Jeff E Sep 3, 2017

Great explanation and detail. Can be used for both engineers and sales knowledge - one of the best we
have seen

deepak b Aug 24, 2017

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excellent article and video

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