HMEL PP Polysure E35RR1

Polysure E35RR1 is a top-tier Controlled Rheology Polypropylene Homopolymer from HPCL-Mittal Energy Ltd (HMEL), manufactured using advanced Spheripol-II technology. E35RR1 is engineered for high-speed extrusion coating and lamination lines, delivering ultra-low neck-in, robust substrate adhesion, and a glossy, uniform surface finish. Produced at HMEL’s Bathinda Spheripol-II unit, E35RR1 is trusted by converters for food packaging, industrial, and medical applications across North India. The grade is fully compliant with IS 10910, FDA 21 CFR 177.1520, and IS 16738:2018, meeting the strictest standards for food and pharma contact.

Technical Insights & Specifications

• Melt Flow Index (ASTM D1238, 230°C/2.16 kg): 35 g/10 min, supporting stable melt flow and efficient processing in extrusion and coating operations.
• Tensile Strength at Yield (ASTM D638): 35 MPa, providing strong mechanical integrity and durability in finished applications.
• Tensile Elongation at Yield (ASTM D638): 9%, offering controlled flexibility while maintaining structural strength.
• Flexural Modulus – 1% Secant (ASTM D790A): 1500 MPa, indicating high stiffness and excellent dimensional stability for coated structures.
• Notched Izod Impact Strength at 23°C (ASTM D256A): 25 J/m, delivering moderate impact resistance under standard conditions.
• Vicat Softening Temperature (ASTM D1525, 10N): 150°C, demonstrating good thermal resistance for applications exposed to elevated processing temperatures.
• Heat Deflection Temperature (ASTM D648, 0.455 MPa): 95°C, ensuring the material maintains shape and performance under moderate thermal loads.

Processing Guidelines

Barrel: 180–250°C | Adapter: 240–260°C | Die: 250–270°C | Air Gap: 150–250 mm | Chill Roll: 20–40°C | Line Speed: >600 m/min | Coating Weight: 15–50 gsm

Technical Strength

E35RR1’s Spheripol-II CR formulation ensures ultra-low neck-in at high speeds, a high flexural modulus (1500 MPa) for stiffness, and exceptional substrate adhesion for defect-free lamination. The grade’s process stability and low gel count enable consistent, glossy coatings even at 600+ m/min, outperforming reactor-based and gas-phase alternatives.

Applications & Industry Use Cases

Liquid Packaging Cartons

E35RR1 delivers uniform, defect-free coatings for milk, juice, and aseptic beverage cartons. The ultra-low neck-in ensures full web coverage at 20–30 gsm, preventing edge defects and ensuring high barrier performance. Full IS 10910 and FDA compliance secures its use in direct food contact packaging.

Flexible Packaging Laminates

Converters rely on E35RR1 for foil-paper laminates, snack packaging, coffee and tea pouches, and metallized film structures. The grade’s high-speed lamination capability (>800 m/min) and superior adhesion prevent delamination and ensure optimal print quality.

Woven Sack Lamination

For 50kg cement and feed bags, E35RR1 provides 18–25 gsm lamination with outstanding stiffness and moisture protection. The CR design prevents web distortion and edge build-up, maximizing yield and sack strength.

Medical & Hygiene Lamination

E35RR1 is widely used for nonwoven and surgical pack lamination, offering a breathable, waterproof barrier with medical-grade compliance. Its process stability ensures consistent coating for hygiene and healthcare applications.

Industrial Coating

Ideal for tarpaulins, geotextiles, and technical coatings, E35RR1 offers high adhesion and durability in demanding industrial environments

Alternatives & Comparative Overview

Several polypropylene grades offer performance comparable to E35RR1, particularly for extrusion coating and lamination processes. Key alternatives include:

• E35RR – MFI 35, produced using Spheripol-II Controlled Rheology (CR) technology with a flexural modulus of ~1500 MPa. Used in coating and lamination applications and considered an identical twin grade with nearly the same processing and performance profile.
• 1350EG – MFI 35, manufactured with IOCL Spheripol-II technology and a flexural modulus of ~1200 MPa. Primarily applied in extrusion coating. Being reactor-based, it may show higher neck-in during coating compared to CR-modified grades like E35RR1.
• P1350EG – MFI 35, also produced using IOCL Spheripol-II technology with a flexural modulus around ~1200 MPa. Suitable for coating and nonwoven applications. Produced at Paradip, it typically offers less controlled rheology compared to CR-based grades.
• RH35 – MFI 35, produced using OPaL Ineos gas-phase technology, with a flexural modulus near ~1200 MPa. Used in coating and nonwoven applications. Its gas-phase polymerization provides a different flow profile during processing.
• F135 – MFI 35, manufactured using HPL Spheripol technology with a flexural modulus of ~1200 MPa. Applied in spunbond and coating segments, with strong supply availability in the East coast market.

These alternatives enable manufacturers to evaluate options based on processing technology, stiffness requirements, coating behavior, and regional supply availability, supporting efficient and reliable production planning.

E35RR1 Advantage: Spheripol-II CR design enables ultra-low neck-in and high-speed coating, outperforming reactor and gas-phase grades (1350EG, RH35) in process stability and substrate adhesion. E35RR1’s 1500 MPa flexural modulus ensures maximum stiffness for packaging and industrial applications. Identical technical performance to E35RR, with process optimization for next-gen lines.