HMEL PP Polysure E35RR

Polysure E35RR is a premium Controlled Rheology Polypropylene Homopolymer engineered by HPCL-Mittal Energy Ltd (HMEL) using advanced Spheripol-II technology. Specifically formulated for extrusion coating and lamination, E35RR delivers exceptional processability with minimal neck-in, outstanding bonding strength to diverse substrates, and superior surface finish. Manufactured at HMEL’s Bathinda refinery complex, Polysure E35RR is the trusted choice for liquid packaging cartons, woven sack lamination, flexible packaging, and industrial coating applications across North India. The grade combines regulatory compliance (IS 10910, FDA 21 CFR 177.1520) with proven field performance in high-speed production environments.

Technical Insights & Specifications – E35RR

E35RR Technical Properties (ASTM Tested):

• Melt Flow Index (ASTM D1238, 230°C/2.16 kg): 35 g/10 min, supporting smooth flow and efficient processing in extrusion and coating applications.
• Tensile Strength at Yield (ASTM D638): 35 MPa, delivering strong mechanical performance and reliable structural stability in finished products.
• Tensile Elongation at Yield (ASTM D638): 9%, providing balanced rigidity with controlled deformation under stress.
• Flexural Modulus – 1% Secant (ASTM D790A): 1500 MPa, indicating high stiffness and excellent dimensional stability.
• Notched Izod Impact Strength at 23°C (ASTM D256A): 25 J/m, offering moderate resistance to sudden impact.
• Vicat Softening Temperature (ASTM D1525, 10N): 150°C, reflecting strong thermal resistance suitable for heat-exposed applications.
• Heat Deflection Temperature (ASTM D648, 0.455 MPa): 95°C, enabling the material to maintain shape and mechanical performance under elevated temperatures.

Processing Guidelines for Extrusion Coating:Barrel Temperature: 180–250°C | Die Temperature: 250–270°C | Air Gap: 150–250 mm | Line Speed Capability: >600 m/min

Technical Strength & Differentiators:E35RR’s Spheripol-II controlled rheology design delivers a narrow molecular weight distribution, enabling superior low neck-in performance—a critical advantage for high-speed coating lines operating above 600 m/min. The 1500 MPa flexural modulus (highest in its MFI class) ensures rigid, durable coated products. Superior adhesion to paper, foil, and woven substrates is achieved through optimized surface chemistry, eliminating delamination issues common with reactor-based alternatives. The 150°C Vicat softening point allows processing at elevated temperatures without degradation, enabling faster cycle times and higher throughput.

Applications & Industry Use Cases

Liquid Packaging Carton Coating

E35RR is the preferred grade for coating paperboard used in milk, juice, and beverage cartons. The low neck-in characteristic ensures uniform coating thickness across the entire web width, preventing edge defects that compromise package integrity. At 20–30 gsm coating weight, E35RR provides excellent moisture barriers while maintaining FDA compliance for food contact. The superior bonding to paperboard eliminates delamination during filling and transport, critical for aseptic packaging lines operating at high speeds.

Woven Sack Lamination

For 50 kg cement, fertilizer, and feed bags, E35RR delivers robust lamination at 15–25 gsm coating weight. The controlled rheology enables high-speed lamination (>800 m/min) without edge buildup, reducing material waste and increasing production efficiency. The 1500 MPa flexural modulus provides excellent sack stiffness and handle, improving consumer perception and reducing damage during storage and transport.

Flexible Packaging Foil Lamination

E35RR excels in flexible packaging applications, bonding strongly to aluminum foil for snack packaging, coffee pouches, and pharmaceutical laminates. The low neck-in ensures consistent coating across narrow web widths, while superior adhesion prevents foil delamination during filling and sealing operations. Processing at 250–270°C die temperature enables rapid quenching and high-speed production without compromising coating quality.

Industrial & Technical Coating

E35RR is used for tarpaulin coating on woven fabrics, geotextile lamination for civil engineering applications, and breathable waterproof barriers in medical nonwovens. The grade’s excellent bonding to diverse substrates and high heat resistance (95°C HDT) make it suitable for demanding industrial environments where coating durability is paramount.

Alternatives & Comparative Overview

Several polypropylene grades provide comparable performance to E35RR, particularly for extrusion coating and lamination applications. The following alternatives differ in processing technology, stiffness, and coating behavior:

• E35RR1 – MFI 35, produced using Spheripol-II Controlled Rheology (CR) technology with a flexural modulus of ~1500 MPa. Primarily used in coating and lamination applications. It offers nearly identical specifications to E35RR, typically representing a variant production grade.
• P1350EG – MFI 35, manufactured using IOCL Spheripol-II technology with a flexural modulus of ~1200 MPa. Suitable for coating and nonwoven applications. Being reactor-based, it generally provides less controlled rheology and may exhibit slightly higher neck-in during coating compared to E35RR.
• 1350EG – MFI 35, also produced via IOCL Spheripol-II technology with a flexural modulus around ~1200 MPa. Used in extrusion coating applications, with production typically from Gujarat and Panipat facilities, offering performance similar to P1350EG.
• RH35 – MFI 35, manufactured using OPaL Ineos gas-phase technology, with a flexural modulus near ~1200 MPa. Applied in coating and nonwoven sectors. Its gas-phase polymerization results in different flow and processing characteristics compared to Spheripol-based grades.
• E07RR – MFI 7, produced using HMEL Spheripol-II CR technology, with a flexural modulus of ~1600 MPa. Designed for heavy extrusion coating applications, where lower MFI supports thicker coatings and higher melt strength.

These alternatives allow processors to select grades based on coating thickness requirements, melt flow behavior, stiffness, and processing technology, helping optimize production efficiency and end-product performance.

E35RR Competitive Advantages

E35RR’s Spheripol-II controlled rheology delivers superior low neck-in compared to reactor-based alternatives (P1350EG, 1350EG), enabling consistent coating at line speeds exceeding 600 m/min. The 1500 MPa flexural modulus—highest in the 35 MFI coating category—ensures superior product stiffness and durability. Unlike gas phase grades (RH35), Spheripol-II CR provides optimized adhesion chemistry specifically tuned for paper, foil, and woven substrates. For heavy coating applications requiring lower flow, E07RR (7 MFI) is available; for lighter coating or multi-purpose use, E25RR (25 MFI) offers alternative throughput options.

Please note: E35RR has been superseded by E35RR1 – superior alternative with improved performance metrics and cost efficiency. Explore full specifications, applications, and advantages to see how it delivers better value for your manufacturing needs.