Borealis HDPE FS1560
- Product Name: Borealis HDPE FS1560
- Factroy Site: Yinchuan, Ningxia, China
- Price Inquiry: sales8@ascent-chem.com
- Manufacturer: Ascent Petrochem Holdings Co., Limited
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- Borealis HDPE FS1560 is typically used in formulations when melt flow rate and density and processing temperature and pressure must be controlled within specific ranges.
| HS Code | 205978 |
| Product Name | Borealis HDPE FS1560 |
| Manufacturer | Borealis |
| Polymer Type | High Density Polyethylene (HDPE) |
| Density | 0.956 g/cm³ |
| Melt Flow Rate 190 C 2 16 Kg | 0.2 g/10 min |
| Tensile Strength At Yield | 28 MPa |
| Tensile Strength At Break | 40 MPa |
| Elongation At Break | 600% |
| Tensile Modulus | 1200 MPa |
| Flexural Modulus | 1300 MPa |
| Charpy Notched Impact Strength At 23 C | 10 kJ/m² |
| Vicat Softening Temperature | 75°C |
| Melting Temperature | 135°C |
| Shore D Hardness | 60 |
| Water Absorption | <0.01% |
| Processing Method | Film Extrusion |
As an accredited Borealis HDPE FS1560 factory, we enforce strict quality protocols—every batch undergoes rigorous testing to ensure consistent efficacy and safety standards.
| Packing | Borealis HDPE FS1560 is packaged in 25 kg polyethylene bags, 55 bags per 1,375 kg pallet, stretch-wrapped for transport. |
| Container Loading (20′ FCL) | Container Loading (20′ FCL): Borealis HDPE FS1560 supplied in 25 kg bags, palletized, shrink-wrapped, and securely loaded for safe transport. |
| Shipping | Borealis HDPE FS1560 is not classified as dangerous goods for transport. It is shipped as solid polyethylene pellets in 25 kg bags, octabins, or bulk bags/railcars, kept dry and closed. Protect from heat, ignition, and UV; avoid pellet spills to prevent slipping and environmental release. |
| Storage | Borealis HDPE FS1560 should be stored in a cool, dry, well-ventilated warehouse, away from direct sunlight, heat, and ignition sources. Keep original packaging sealed, palletized, and off the floor. Avoid moisture, dust, contamination, and prolonged UV exposure. Do not stack excessively. Ensure good ventilation, protect from physical damage, rotate stock, and follow the supplier’s SDS and local regulations. |
| Shelf Life | Borealis HDPE FS1560 has a shelf life of 2 years when stored unopened, dry, below 50°C, away from direct sunlight. |
Borealis HDPE FS1560 is converted primarily by high-output blown film extrusion for thin-gauge freezer films and mono-material packaging where stiffness, downgauging, and dimensional stability control the final package cost. On single-screw extruders with grooved feed bushings and L/D ratios between 25:1 and 30:1, the melt is processed through a die gap of 0.8 mm to 1.4 mm and a blow-up ratio of 3.5:1 to 5.0:1. Barrel temperatures are set from 180°C in the feed zone to 210°C at the metering section, with the adapter and die held between 205°C and 220°C. The frost line is maintained at 6 to 9 die diameters above the die face, and the bubble neck length is held between 4 and 7 die diameters by adjusting air-ring velocity and internal bubble cooling. Dual-lip air rings and internal bubble cooling are required on lines operating above 150 kg/h, because a single-lip air ring no longer removes sufficient heat to stabilise the bubble diameter within ±2% at high throughput. Tensile properties of the resulting 20 µm film are measured according to ISO 527-3, and downgauging decisions are supported by Elmendorf tear data measured under ASTM D1922-15 because the MD/TD orientation balance changes with frost line height and blow-up ratio.
The limiting variable on high-output FS1560 lines is not melt plastication but bubble stability under high frost line conditions. At die gaps below 0.8 mm, the increased shear stress at the die lip initiates shark-skin roughness on the outer bubble surface, especially when the die temperature falls below 195°C. At blow-up ratios above 5.0:1, the film develops strong transverse-direction orientation that raises TD tensile modulus but produces a sharp decrease in dart impact and MD tear propagation. Production experience on lines operating at 180 kg/h with a 250 mm die indicates that moving the frost line upward by 2 die diameters can shift the MD/TD tear balance by 15% to 25% without any resin lot change. Processors are therefore required to monitor dart impact per ASTM D1709-16ae1, MD tear per ASTM D1922-15, and transverse-direction tensile strength per ISO 527-3 after each die-gap or bubble-geometry adjustment, because these changes shift fracture behaviour before they are visible as gauge-profile defects.
Coextruded PE/PE Laminate Structures Using FS1560 as High-Stiffness Core
In three-layer and five-layer blown film lines, FS1560 is placed as the high-density polyethylene core between linear low-density polyethylene skins to produce PE/PE laminates that satisfy recyclability design protocols for flexible packaging. Typical layer ratios are 10/80/10 or 15/70/15, with the FS1560 core supplying the flexural stiffness required for stand-up pouch front panels, freezer films, and cereal liner dead-fold, while the LLDPE skins provide dart impact resistance and seal through contamination. Melt flow matching between the HDPE core and the LLDPE skins is maintained at a die temperature of 210°C to 230°C; if the shear viscosity difference between adjacent layers becomes excessive, interfacial shear stress surpasses the melt strength of the lower-viscosity material and produces layer thickness oscillations and wavy interface defects. Because the HDPE core crystallises at a higher temperature than LLDPE, the frost line height is raised by 2 to 3 die diameters relative to an all-LLDPE condition, and the collapsing frame is adjusted to avoid surface blocking caused by the higher modulus of the HDPE layer. Interfacial adhesion in PE/PE structures depends on co-crystallisation and molecular interdiffusion; no tie resin is required when the melt temperature difference at the die is below 15°C.
Adhesion and seal performance of the FS1560-core laminate are verified under ASTM F88/F88M-21 for seal strength and ASTM F904-16 for interlaminar bond strength. On high-speed pouching machines operating at 80 to 120 pouches per minute, the laminate must maintain a seal strength above 10 N/15 mm without delamination under jaw temperatures from 145°C to 170°C. If the FS1560 core fraction exceeds 80% of the total structure, dead-fold property increases, but interlayer adhesion may become insufficient because the crystalline HDPE surface limits the interdiffusion of tie chains across the interface. In such cases, the layer ratio must be corrected or the die lip temperature increased to 230°C to promote interlayer entanglement. Published data for exact adhesion values of FS1560 in PE/PE coextruded structures is limited; pilot-line trials with a 3-layer die are necessary before commercial production.
Dry food packaging lines producing cereal box liners and cracker pouches employ FS1560 at film thicknesses of 20 µm to 35 µm as a moisture barrier layer where product shelf life is controlled by water uptake rather than oxygen ingress. The moisture vapour transmission rate at 38°C and 90% RH, determined under ASTM F1249-20, is governed by film crystallinity, gauge uniformity, and orientation; industrial sources report WVTR values between 4 g/m²·day and 8 g/m²·day for 25 µm HDPE film, though lot-specific FS1560 values must be taken from the supplier technical data sheet. In-line corona treatment raises the wetting tension to 38 mN/m to 42 mN/m, measured per ISO 8296:2003, so that water-based flexographic inks and solventless laminating adhesives wet the non-polar surface. If the treated film is stored in a warehouse at relative humidity above 60% or below the dew point, the surface energy decays to below 36 mN/m within 30 days; lamination or printing should therefore be completed within 72 hours of film conversion to avoid adhesion failure.
The seal initiation temperature of FS1560-based film is higher than that of LLDPE-rich surface layers, and this changes the operating window of vertical and horizontal form-fill-seal machines. Seal jaw temperatures are set between 145°C and 165°C, with dwell times of 0.3 s to 0.6 s, to produce a seal strength above 10 N/15 mm on 30 µm film tested under ASTM F88/F88M-21. HDPE surfaces are not designed for seal through heavy product contamination, and FS1560 should be specified only for applications where the seal area remains free of oil, powder, or fine particulates. If the filling operation generates dust or product mist, a coextruded LLDPE inner skin containing a seal-through-contamination additive package is required over the FS1560 core to maintain seal integrity.
| Regulation / Standard | Scope | Application Condition for FS1560-Based Film |
|---|---|---|
| EU 10/2011 | Plastic food contact materials | Overall migration limit 10 mg/dm² using food simulants appropriate to the packaged food; supported by supplier declaration of compliance |
| FDA 21 CFR §177.1520 | Olefin polymers | Permitted for aqueous, acidic, and fatty foods under specified conditions of use; verify FS1560 supplier food-contact statement |
| REACH (EC) No 1907/2006 | SVHC and restrictions | No SVHC above 0.1% w/w in the virgin grade; confirm with Safety Data Sheet Section 15 |
What Mechanical Property Shifts Occur When FS1560 Is Down-Gauged From 25 µm to 12 µm for High-Speed Packaging?
Down-gauging from 25 µm to 12 µm in high-speed packaging lines shifts the limiting failure mode from tensile yield to pinhole formation and impact rupture. At 12 µm, the machine-direction tensile strength may remain within the same orientation range, but the transverse-direction tensile strength and dart impact decrease disproportionately because the orientation balance established by the blow-up ratio is constrained by the thinner melt strand at the die exit. According to ISO 527-3, the apparent secant modulus for a 12 µm film can show higher scatter than for a 20 µm film because gauge variation of ±1 µm corresponds to more than 8% of nominal thickness and is amplified in the strain calculation. Dart impact measured under ASTM D1709-16ae1 and slow puncture resistance measured under ASTM D5748-19 should be combined with a gauge profile scan across the collapsed web, because thin spots below 10 µm become initiation sites for brittle failure. Processors must verify that the extrusion line can maintain a net thickness tolerance of ±3% or better; otherwise downgauging below 15 µm creates fitness-for-use defects that are not detected by average tensile data alone.
The extrusion response must be re-tuned when the target thickness changes from 25 µm to 12 µm. The die gap is moved to the lower end of the 0.8 mm to 1.0 mm range, and the blow-up ratio is increased to 4.5:1 to 5.0:1 to restore transverse-direction strength. At the same time, the frost line height must be shortened by 1 to 2 die diameters relative to the 25 µm window; if the frost line is left too high, the thin film destabilises in the collapsing frame and forms wrinkles that cannot be removed in the downstream dancer system. Published data for FS1560 at 12 µm is limited, and conversion should be validated on the actual line with real-time thickness mapping and continuous bubble diameter monitoring rather than by relying on laboratory-scale cast film results.
When Post-Consumer Recyclate Content Is Encapsulated Beneath Virgin FS1560 Skins
Three-layer lines can use FS1560 as the virgin high-density polyethylene skin layer over a post-consumer recyclate core to maintain surface quality and food-contact status of the outer layers. A typical layer ratio is 15/70/15, with the PCR core produced from clean HDPE bottle flake or film recovery and the FS1560 skins produced from virgin granulate. The FS1560 skin is selected because its stiffness compensates for the modulus loss caused by the lower-viscosity PCR core, and because its film-grade melt stability reduces gel formation at the interface. The melt flow of the PCR core should be matched to the FS1560 skin within 0.2 g/10 min to 0.5 g/10 min when measured at 190°C/2.16 kg under ISO 1133-1:2022; if the mismatch is larger, the interface becomes unstable and the core material migrates toward the surface during bubble expansion.
The main operational boundary in this structure is gel and particulate contamination from the recyclate core. Screen packs with filtration ratings of 120 µm to 200 µm are installed upstream of the die for the core extruder only, because finer filtration on the FS1560 skin extruder increases melt residence time and oxidation risk. At core inclusion rates above 70%, bubble stability decreases because of the higher melt temperature required to homogenise the PCR fraction; the die temperature is raised to 220°C to 230°C, and the frost line height is held at the upper limit of the stable window to prevent bubble sag. Since the FS1560 skins are food-contact compliant under EU 10/2011 and FDA 21 CFR §177.1520, the PCR core must remain fully encapsulated; any surface exposure of the core removes the food-contact status of the outer layer and creates odor transfer pathways.
Heavy-Duty Sack Film and Industrial Liner Extrusion with High Puncture and Tear Requirements
For heavy-duty sacks and industrial liners, FS1560 is processed at film thicknesses of 50 µm to 80 µm, using blow-up ratios of 4:1 to 5:1 and a die gap of 1.2 mm to 1.6 mm to preserve impact and slow-puncture properties. In these gauges, the output rate is limited by the cooling capacity of the air ring rather than by melt strength; high-density polyethylene films of this thickness require internal bubble cooling and elevated frost line temperatures to prevent the outer surface from blocking at the collapsing frame. Tear resistance measured under ASTM D1922-15 and puncture resistance measured under ASTM D5748-19 are the critical specifications, because sack failure during filling occurs by impact or puncture rather than by tensile yield. The high stiffness of FS1560 reduces sack elongation under load, but the material is less tolerant of sharp objects and rough handling than LLDPE-based heavy-duty sack films, and converters should not use the HDPE grade where multi-axial tear propagation resistance is the sole acceptance criterion.
The industrial liner application requires a stabilisation package that withstands moderate heat exposure during filling of granular chemicals and resins. If the sack is stored at continuous temperatures above 60°C, the film should be tested for oxidative induction time under ISO 11357-6 or ASTM D3895-19, because HDPE packaging exposed to warm fill conditions can lose elongation and suffer cracking along the seams. For sacks intended for outdoor storage, the film formulation must include a UV stabilisation package; unmodified FS1560 is not rated for long-term ultraviolet exposure and loses tensile strength rapidly under direct sunlight unless pigmented with carbon black at 2% to 3% loading. At these high loadings, the tensile modulus increases further, but the addition of carbon black masterbatch reduces the melt flow and requires the extruder barrel temperature to be increased by 10°C to 15°C relative to natural film production.
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- Borealis HDPE FS1560 is manufactured under an ISO 9001 quality system and complies with relevant regulatory requirements.
- COA, SDS/MSDS, and related certificates are available upon request. For certificate requests or inquiries, contact: sales8@ascent-chem.com.
Borealis HDPE FS1560 is a high-density polyethylene extrusion grade engineered for blown film conversion. The product is manufactured on a multimodal Borstar process train, which produces a bimodal molecular weight distribution rather than the unimodal distribution typical of conventional chromium or Ziegler HDPE film resins. Nominal density is 0.956 g/cm³ when measured according to ISO 1183-1, and melt flow rate is 0.60 g/10 min at 190°C under 2.16 kg load according to ISO 1133-1. The grade is intended for thin-gauge blown film applications where higher stiffness and downgauging potential are required, including freezer films, carrier bags, lamination films, bin liners, and heavy-duty sacks. Film-specific mechanical values depend on processing history, film thickness, blow-up ratio, and frost line height; therefore, converter trials are required to establish final specification limits. The resin is not designed for cast film, injection moulding, or pipe extrusion, and use outside this envelope can produce property anisotropy that is not captured by standard datasheet values.
What distinguishes the bimodal molecular architecture of FS1560 from conventional unimodal HDPE?
The Borstar multimodal process produces a low-molecular-weight fraction and a high-molecular-weight fraction within the same reactor sequence. The low-molecular-weight component lowers high-shear viscosity and improves extruder throughput, while the high-molecular-weight component contributes to melt strength and strain hardening during bubble expansion. Conventional unimodal HDPE film grades lack this controlled bimodality; their molecular weight distribution is narrower, so equivalent melt flow rate resins may exhibit higher melt pressure at the die or reduced bubble stability at low gauges. Gel permeation chromatography of multimodal HDPE shows a characteristic shoulder in the high-molecular-weight region, which corresponds to improved orientation-induced mechanical properties. The bimodal distribution also shifts the shear-thinning response: under film extrusion shear rates, FS1560 typically enters a more pronounced shear-thinning regime than unimodal HDPE of similar density. This does not eliminate the need for machine-specific validation, because die geometry, melt temperature, and cooling air capacity control the final balance between output and bubble stability. Lot-to-lot variance in melt flow rate is controlled within the supplier certificate of analysis, but converters should monitor melt pressure and screw speed during grade changes because grooved-feed extruder response can differ from smooth-bore equipment. In-line rheometers or capillary rheometry at 190°C are used to compare shear viscosity curves; such measurements are more informative than single-point MFR data for high-speed film extrusion.
On a 65 mm grooved-feed single-screw extruder with 30:1 L/D, blown film extrusion of FS1560 commonly uses a flat or slightly reverse temperature profile with barrel zone set points from 180°C to 210°C. Melt temperature at the die is held between 190°C and 220°C; temperatures above 230°C during extended residence time can initiate thermo-oxidative degradation and gel formation. Die gaps from 0.8 mm to 1.4 mm and blow-up ratios between 3:1 and 5:1 are typical for high-density polyethylene blown film lines. The high-molecular-weight fraction supports bubble stability at low gauge, but frost line height should be controlled with infrared or contact thermometry to prevent blocking and film wrinkling. Granules stored at relative humidity above 60% may carry surface moisture; if condensation is visible, drying at 60°C for 2 h is recommended before extrusion. Contamination with polypropylene above approximately 2 wt% can create dispersed domains that appear as gels in thin film. Silos, hoppers, and conveying lines should be purged and dedusted during grade changes from polypropylene or mineral-filled compounds. Screen packs with mesh sizes from 40 to 80 are commonly installed before the die to remove incidental contaminants and to build the required head pressure; pressure drop across the screen should be monitored because blinded screens raise melt temperature and reduce output.
Differential scanning calorimetry to ISO 11357-3 provides the melting temperature; the crystallisation temperature and degree of crystallinity are also useful for estimating stiffness and barrier behaviour. Oxidative induction time measured by ISO 11357-6 is a stabiliser performance indicator, not a long-term ageing prediction. Shear viscosity curves obtained by capillary rheometry at 190°C are more informative than single-point MFR for predicting die pressure and bubble stability. The flow rate ratio between 21.6 kg and 2.16 kg loads is a conventional indicator of shear sensitivity; the exact value for FS1560 should be obtained from the certificate of analysis or supplier technical service. In production-scale trials, the main failure modes observed are not catastrophic product deformation but cumulative defects such as gel streaks, gauge bands, and blocking at the collapsing frame. These defects are caused by melt temperature drift, uneven cooling air distribution, and poor frost line control. No single laboratory test captures these interactions, so line trials remain mandatory.
When thin-gauge freezer film replaces LDPE in vertical form-fill-seal operations
In vertical form-fill-seal packaging, FS1560 is evaluated when stiffness, puncture resistance, and seal integrity are controlling requirements. Because the density of 0.956 g/cm³ increases film modulus relative to low-density polyethylene at equal thickness, downgauging trials are common in non-clarity-critical freezer packaging. Specific gauge reduction cannot be stated as a universal value; it must be established on the target VFFS equipment because drawing geometry, seal jaw pressure, and film tension differ among machines. Heat seal performance of FS1560 should be qualified with a seal curve generated on the production line. Typical seal bar set points for HDPE films fall between 130°C and 150°C with dwell times of 0.5 s to 1.0 s, but these values are machine-specific and should not be used as product specifications. Seal strength is measured according to ASTM F88/F88M; because HDPE seal curves are narrower than LDPE, seal jaw temperature should be controlled within ±5°C of the established set point. Published data for FS1560-specific heat seal initiation temperatures is limited; therefore, converter trials must define the operating window. The grade is also used in carrier bags, bin liners, lamination films, and heavy-duty sacks. For food-contact applications, compliance must be confirmed through supplier documentation referencing EU 10/2011 and FDA 21 CFR 177.1520 for the specific grade and conversion conditions.
Compared with low-density polyethylene film grades, FS1560 provides higher density, higher tensile modulus, and lower water vapour transmission at equivalent film thickness. It is not a clarity film: haze and gloss are closer to opaque HDPE than to LDPE or metallocene LLDPE. Compared with linear low-density polyethylene, FS1560 exhibits higher stiffness and lower dart impact at equal gauge in many formulations; resin selection therefore depends on the balance between puncture resistance and stiffness. In tensile terms, HDPE blown film shows yield stress values that are typically higher than LDPE and LLDPE at comparable thickness, while elongation at break is usually lower. These differences are amplified by molecular orientation introduced by the blow-up ratio and frost line height. Compared with conventional unimodal HDPE film resins of similar density, the bimodal molecular weight distribution of FS1560 typically allows a wider blow-up ratio range and lower melt pressure at equivalent output. The difference is best measured through capillary rheometry at 190°C followed by extrusion trials on the target die; published data for this specific comparison is limited. When replacing another HDPE film grade, converters should compare melt flow rate, density, and film tensile properties using identical processing parameters, because blow-up ratio and frost line height interact with molecular orientation. A change in die gap from 1.0 mm to 1.4 mm can shift tear strength in machine and transverse directions, so the die should not be changed without re-qualifying film property balance.
Compliance checklist and material specification matrix
The nominal property values in the table below are extracted from standard polyethylene specification methods. Actual lot values are reported on the certificate of analysis and may vary within supplier tolerance. The melting temperature is determined by differential scanning calorimetry at a heating rate of 10°C/min under inert atmosphere; the value is the peak melting endotherm, not the onset. Density is measured after conditioning according to the standard method; values obtained by other methods may differ. The MFR measurement is conducted at 190°C with a 2.16 kg load, which characterises low-shear melt flow and correlates with extruder throughput only when combined with shear viscosity data.
| Property | Test method | Typical value | Unit |
|---|---|---|---|
| Density | ISO 1183-1 | 0.956 | g/cm³ |
| Melt flow rate (190°C, 2.16 kg) | ISO 1133-1 | 0.60 | g/10 min |
| Melting temperature | ISO 11357-3 | 132 | °C |
Food-contact compliance for FS1560 is established through manufacturer documentation referencing EU 10/2011 and FDA 21 CFR 177.1520 for olefin polymers. REACH registration is maintained by the supplier. Users should verify the specific additive package and organoleptic suitability for the intended food simulant, because overall migration values depend on film thickness, contact surface area, and conversion conditions. The grade is not intended for medical device implants, prolonged hot-water pressure pipe service, or injection-moulded articles.
Mechanical testing of FS1560 film should follow ISO 527-3 for tensile modulus, tensile stress at yield, and elongation at break. Dart impact resistance is commonly measured by ASTM D1709 or ISO 7765-1. Elmendorf tear resistance is measured by ISO 6383-2 or ASTM D1922. These tests do not directly predict field performance because orientation, seal geometry, and loading rate differ from laboratory conditions. For freezer applications, low-temperature impact testing at -20°C is advised; published data for FS1560 at sub-zero temperatures is limited, and converter validation is required. Water vapour transmission rate is measured by ISO 15106-1 or ASTM F1249; FS1560 is expected to provide lower WVTR than LDPE at equal thickness because of its higher density and crystalline fraction. Permeability coefficients should be obtained from material certificates for the actual film gauge and conditioning history. Film thickness should be measured by ISO 4593 to ensure that reported mechanical properties are normalised to actual gauge rather than nominal gauge. Pinhole counts and gel counts are not standardised in the same way; optical inspection systems with camera-based defect classification are used on production lines to control film quality.
Operational boundaries govern high-speed blown film conversion
FS1560 is designed for blown film extrusion; cast film, injection moulding, and pipe extrusion are outside the documented processing envelope. On high-speed lines, the limiting factors are melt temperature control, bubble cooling capacity, and die lip cleanliness. Sustained melt temperatures above 230°C increase the risk of gel formation and oxidative embrittlement; start-up and shutdown sequences should be short and purged with polyethylene of similar melt flow rate. In humid environments with relative humidity above 60%, surface moisture on granules can produce surface defects in thin film; pre-drying at 60°C for 2 h is recommended if condensation is visible. The resin should not be blended with amine-based processing additives or unsaturated esters because such additives can alter stabiliser performance and reduce oxidative induction time. Post-industrial scrap can be added at levels determined by target film properties and relevant food-contact regulations; the user must verify that recycled content does not violate EU 10/2011 or FDA 21 CFR 177.1520 if food contact is claimed. For converters using internal regrind from edge trim and start-up film, the fraction of regrind should be kept constant to avoid shifts in melt viscosity and film gauge. Die lip fouling from stabiliser migration can occur after long campaigns; periodic die cleaning is required, and the cleaning interval should be recorded as part of the machine log to identify grade-specific build-up rates.
