Blown film lines processing Borealis Borcycle™ NAV101L as a secondary feedstock for non-food heavy-duty packaging require differentiated barrel profiling and screen-pack monitoring because recyclate gel bodies and low-molecular-weight fractions alter bubble stability at low frost-line settings. The material is let down at 20–40 wt% into virgin LDPE with an ISO 1133-1:2022 melt flow rate of 0.7–1.0 g/10 min at 190°C/2.16 kg. Extrusion is carried out on a single-screw blown film line with a barrier screw of 25:1–30:1 L/D, a Maddock mixing section, feed throat temperature 35–45°C, barrel zones from 150°C to 175°C, and melt temperature 160–185°C. Die diameter is held at 250–350 mm, die gap at 1.0–1.5 mm, blow-up ratio at 2.0:1–2.5:1, and frost line height at 350–500 mm. Screen-pack differential pressure is recorded at start-up and after 4 h; a delta P rise above 2.0 MPa indicates gel accumulation requiring screen change. Compliance for non-food packaging requires EU 94/62/EC Annex II heavy-metal sum limits of 100 mg/kg and REACH Article 33 candidate list screening below 0.1% w/w per article. Tensile properties are tested under ASTM D882-12, dart impact under ASTM D1709-16a Method A, and gel dispersion under ISO 18553:2002. Terminal products include refuse sacks, industrial liners, pallet shrouds, and heavy-duty shipping sacks.

Why Does Gel Dispersion Control Extrusion Coating More Than Melt Temperature?

In extrusion coating of non-food paper and board, Borealis Borcycle™ NAV101L is introduced at 10–30 wt% into virgin LDPE to limit draw-down and neck-in defects. The coating line operates with a coat-hanger slot die, air gap 150–250 mm, chill roll temperature 12–18°C, die melt temperature 260–300°C, and line speed 80–150 m/min. Because gel particles from recycled LDPE disrupt the adhesion interface at low melt temperature and preferentially oxidize at extended air gaps, the air gap is not increased beyond 250 mm without trial confirmation. Adhesion to kraft paper is evaluated under ASTM D903-98(2017), coating weight is controlled gravimetrically under ISO 536:2019, and neck-in is measured at the die edge with a tolerance of 25–60 mm. Compliance for imported non-food laminates requires EU 94/62/EC Annex II heavy-metal limits of 100 mg/kg and REACH Article 33 screening below 0.1% w/w. Published data for this specific configuration is limited above 300°C; oxidative surface degradation may reduce peel strength before visible melt fracture appears. Terminal products include industrial paper sacks, protective interleaving, non-food pouch laminates, and release paper coatings.

Injection Moulding of Non-Food Handling Components from Recycled LDPE

Blending Borealis Borcycle™ NAV101L into injection moulding compounds at 15–50 wt% is constrained by thin-wall flow-length reduction and short-shot variability caused by the higher melt elasticity of post-consumer LDPE. The moulding cell is configured with a general-purpose screw of 20:1–22:1 L/D, clamp force 800–1,600 kN, melt temperature 160–200°C, mould temperature 15–30°C, injection pressure 50–80 MPa, and holding pressure 30–50 MPa. When ambient relative humidity exceeds 60%, the recyclate is pre-dried at 60–70°C for 2 h to limit surface splay. Shot weight variation is monitored within ±0.5% on production-scale machines to detect fill instability. Compliance for industrial non-food articles is verified under REACH Annex XVII restricted substances and RoHS Directive 2011/65/EU Annex II when overmoulded electrical or electronic accessories are produced: lead threshold 1,000 mg/kg, cadmium threshold 100 mg/kg, mercury threshold 1,000 mg/kg, hexavalent chromium threshold 1,000 mg/kg in homogeneous materials. Tensile properties are determined under ASTM D638-14, and notched Izod impact under ASTM D256-10. Terminal products include storage totes, edge protectors, damping pads, material-handling trays, and snap-fit industrial housings.

The following compliance matrix consolidates the regulatory standard designations applicable to each downstream conversion route.

When Borcycle™ NAV101L Replaces Virgin Resin in Rotational Moulding of Secondary Containment Tanks

Rotational moulding conversions of Borealis Borcycle™ NAV101L are restricted to 10–25 wt% let-down into virgin LDPE rotational moulding grades because higher recycled content reduces environmental stress crack resistance and low-temperature impact performance. The biaxial rotational moulding machine is operated at primary-to-secondary axis speed ratios between 4:1 and 6:1, oven temperature 250–280°C, total cycle time 20–30 min, and wall thickness 4–8 mm. Cooling is controlled at 2–3°C/min through forced air before water mist to prevent warpage and internal porosity. Oversized recyclate particles above 1,000 µm increase pinhole risk in thin-wall sections and are screened prior to powder blending. Compliance for non-food storage tanks is evaluated under REACH and ASTM D1998-15, with environmental stress crack resistance tested per ASTM D1693-15 Condition B and low-temperature impact under ASTM D1998-15 referenced methods. Published data for this specific grade in rotational moulding is limited; a full ESCR regression should be generated on the production tool before fixed formulation release. Terminal products include secondary containment basins, agricultural sprayer tanks, non-potable water storage tanks, and chemical dosing day tanks.

Drip Irrigation Pipe Extrusion Demands a Narrow Melt Viscosity Window

In low-pressure agricultural drip laterals, Borealis Borcycle™ NAV101L is let down at 15–30 wt% with virgin LDPE or LLDPE; above this range the hoop strength of the lateral and the dimensional accuracy of emitter orifices show unacceptable batch-to-batch variance. The pipe extrusion line uses a grooved-feed extruder of 25:1–28:1 L/D, a die and sizing mandrel for 12–20 mm outer diameter, vacuum calibration at -0.02 MPa to -0.05 MPa, melt temperature 170–190°C, and line speed 10–30 m/min. Die-entry melt pressure is monitored at 10–18 MPa to ensure dimensional consistency, and emitter orifice diameter variance is maintained below 2% coefficient of variation. Compliance for agricultural micro-irrigation components is assessed against ISO 9261:2004 for emitters and emitting pipe and REACH Title VIII restrictions. Hydrostatic pressure resistance is measured per ISO 1167-1:2006, and tensile properties per ISO 527-2:2012. Terminal products include drip irrigation laterals, micro-tubing, soaker hose, and low-pressure agricultural distribution tubing.

Extrusion blow moulding of non-food technical containers from Borealis Borcycle™ NAV101L is run at 25–50 wt% let-down into virgin LDPE blow moulding grades; the upper limit is set by parison melt strength and bottle wall thickness distribution rather than melt index alone. Single-station accumulator blow moulding equipment with clamp force 150–300 kN, die head 40–80 mm, and parison swell ratio 1.4:1–1.7:1 operates at melt temperature 165–185°C, mould temperature 5–20°C, and cycle time 35–60 s. Parison pinch weld and tail flash regrind can be reintroduced at 10–15 wt% as an internal reclaim stream, provided the combined recycled stream does not exceed the specified NAV101L let-down. Compliance for non-food technical containers requires EU 94/62/EC Annex II heavy-metal limits of 100 mg/kg and REACH Article 33 screening below 0.1% w/w. Environmental stress crack resistance is determined per ASTM D1693-15 Condition B, and drop impact for filled containers per ASTM D2463-15. Terminal products include non-food jerrycans, dosing tanks, technical hollow parts, and industrial fluid reservoirs. Hazardous goods certification is not claimed without additional UN packaging approvals.