Modifiers deliver higher performance for virgin and recycled polypropylene

Milliken & Company has introduced what is touts as a radical advancement in additive technology for polypropylene impact copolymers (PP ICPs) and recycled polypropylene. The new masterbatches reportedly maximize the impact strength and melt flow of resins without compromising stiffness performance.

These improved properties allow PP to be used in a wider range of applications in more cost-effective ways. In addition, the new DeltaMax technology is highly effective in modifying post-consumer and post-industrial recycled resins. It elevates impact and melt flow to the same level as – or better than – those of virgin resin. This unique capability allows compounders and converters to incorporate up to 100 percent recycled PP without sacrificing performance or processing.

“DeltaMax solves a long-standing unmet need in the polypropylene industry, where the market has been seeking higher impact PP plastics at higher melt flow rates,” said Patel. “DeltaMax simultaneously improves both impact and melt flow in PP impact copolymers and recycled resins, which now enables converters to make parts stronger, lighter and faster than before. It also improves the sustainability profile of the industry and provides a range of other processing, energy reduction and system cost benefits. The net effect is that converters, brand owners and OEMs can now meet market needs for higher impact driven by e-commerce shipments and increasing automotive safety standards, while keeping a keen eye on improving sustainability and costs.”

Milliken’s new DeltaMax Performance Modifiers offer customers the ability to increase impact performance, maximize melt flow or achieve a precise balance of these properties. The DeltaMax melt flow modifier can raise melt flow by as much as five times while maintaining impact and stiffness. This improvement allows converters to increase operating efficiencies and create more innovative part design with easier flow through molds. The DeltaMax impact modifier increases impact strength by as much as three times by optimizing rubber dispersion and domain size. This higher impact performance allows compounders to decrease rubber content to reduce weight and costs.

Another important benefit of the DeltaMax technology is its ability to optimize recycled PP. Until now, the limited availability of high-performance recycled streams and their variability from month to month have inhibited adoption of recycled PP. DeltaMax Performance Modifiers remove this roadblock by restoring impact and melt flow properties, enabling recycled resin to mirror or even surpass the properties of virgin PP. DeltaMax offers Milliken customers an opportunity to significantly increase recycled PP content to reduce costs and answer demands for more-sustainable materials.

Target applications for PP copolymers and compounds enhanced with DeltaMax masterbatches include housewares such as totes and hampers, lawn and garden products such as outdoor furniture and flowerpots, and industrial crates, battery cases and pails. These PP materials can also be used in appliance components such as washer drums, refrigerator trays and motor housings, and in automotive bumpers and interior parts.

At NPE 2018, Milliken exhibited applications that showcase the benefits of DeltaMax Performance Modifiers, including a paint tray made with 100 percent recycled PP, and other products made with virgin PP. The DeltaMax family of masterbatches is currently available in North America, with global distribution planned for the coming year.