| HS Code | 486066 |
| Density | 0.958 g/cm³ |
| Melt Flow Rate 190 C 2 16 Kg | 0.25 g/10 min |
| Tensile Modulus | 1300 MPa |
| Tensile Stress At Yield | 28 MPa |
| Tensile Strain At Break | >600 % |
| Charpy Notched Impact Strength 23 C | 10 kJ/m² |
| Charpy Notched Impact Strength 30 C | 4 kJ/m² |
| Ball Indentation Hardness | 55 MPa |
| Vicat Softening Temperature A50 | 126 °C |
| Thermal Conductivity | 0.4 W/m·K |
| Water Absorption | <0.01 % |
| Dielectric Constant | 2.3 |
| Volume Resistivity | >1E15 Ω·cm |
| Melting Temperature | 130 °C |
| Environmental Stress Cracking Resistance 10 Igepal F50 | >1000 h |
As an accredited Borealis HDPE HE2558 factory, we enforce strict quality protocols—every batch undergoes rigorous testing to ensure consistent efficacy and safety standards.
| Packing | Borealis HDPE HE2558 is packaged in 25 kg polyethylene bags, stacked on pallets and shrink-wrapped for secure delivery. |
| Container Loading (20′ FCL) | 20′ FCL loaded with 25 kg bags of Borealis HDPE HE2558 polyethylene pellets, palletized, shrink-wrapped, and securely stowed for transport. |
| Shipping | Borealis HDPE HE2558 is a non-hazardous high-density polyethylene resin. It is typically shipped in 25 kg bags, octabins, or bulk containers. Keep dry, clean, and protected from direct sunlight and heat. Not regulated for transport; no UN number, hazard class, labels, or placards required. |
| Storage | Borealis HDPE HE2558 should be stored in a cool, dry, well-ventilated warehouse, away from direct sunlight, heat, sparks, flames, and strong oxidizers. Keep original bags or containers closed to prevent moisture, dust, and contamination. Avoid prolonged UV exposure and excessive temperatures. Store separately from incompatible materials. Use first-in, first-out stock rotation and grounding/bonding where dust may form. |
| Shelf Life | Borealis HDPE HE2558 has an indefinite shelf life when stored in original packaging, cool, dry, away from sunlight and contamination. |
In high-cavitation carbonated soft drink closure production, Borealis HE2558 is typically processed at melt temperatures of 230–250 °C in tools with 48 to 96 valve-gated cavities. The grade’s melt mass-flow rate, measured according to ISO 1133-1:2022 at 190 °C/2.16 kg, is commonly reported as 1.8–2.1 g/10 min, and this flow length permits filling of 0.85–1.10 mm sidewall sections without excessive injection pressure. On production machines with clamp force between 1800 kN and 3500 kN, injection velocities of 80–130 mm/s, fill times of 0.12–0.30 s, and holding pressures of 600–900 bar are used. Mould temperature is kept at 10–20 °C because rapid gate freeze-off minimises gate vestige length and reduces cycle time. The density of 0.958 g/cm³ determined by ISO 1183-1:2019 corresponds to a tensile modulus in the range of 1000–1200 MPa at 1 mm/min under ISO 527-2:2012, providing cap top-load resistance. Mould shrinkage measured by ISO 294-4:2018 is typically 0.018–0.024 mm/mm for an end-gated plaque, and core/cavity dimensions must compensate for anisotropic shrinkage in the threaded region.
Closure shells from HE2558 are commonly combined with EVA or polyolefin plastomer liners, and the shell must not alter the organoleptic profile of the beverage. Odour and taste conformity is assessed following EN 1622:2006 and EN 1420-1:2006, while food-contact compliance for the polyolefin shell is covered by FDA 21 CFR 177.1520 and EU Regulation (EU) No 10/2011 together with its amendments. Carbonated beverage closures sustain internal CO₂ headspace pressures of 3.0–4.5 bar at 20 °C; torque-retention testing after 24 h and 72 h at 40 °C is therefore used to evaluate creep under capping stress. Environmental stress crack resistance determined by ASTM D1693-15b, Condition B, 100 % Igepal CO-630, remains relevant when the threaded zone carries residual hoop stress. Melt temperature should not exceed 260 °C because prolonged residence at higher temperatures reduces molecular weight and degrades ESCR; screw speed is normally kept below 120 min⁻¹ to limit shear heating.
| Property | Standard | Typical range |
|---|---|---|
| Density | ISO 1183-1:2019 | 0.957–0.959 g/cm³ |
| Melt mass-flow rate 190 °C/2.16 kg | ISO 1133-1:2022 | 1.8–2.1 g/10 min |
| Tensile modulus 1 mm/min | ISO 527-2:2012 | 1000–1200 MPa |
| Tensile yield stress | ISO 527-2:2012 | 26–28 MPa |
| Charpy notched impact 23 °C | ISO 179-1/1eA:2010 | 5–8 kJ/m² |
| Vicat softening temperature A50 | ISO 306:2022 | 126–131 °C |
| Mould shrinkage | ISO 294-4:2018 | 0.018–0.024 mm/mm |
Design of the tamper-evident band on a HE2558 closure shell starts from the minimum wall thickness that can be reproducibly filled in high-cavitation tooling. The grade can fill band sections of 0.35–0.40 mm when the valve gate diameter is 0.6–0.9 mm and the hot runner manifold maintains a cavity-to-cavity melt temperature spread of ±5 °C. Reducing the main panel wall below 0.60 mm increases sidewall flexure, and top-load retention after pasteurisation at 75–85 °C for 15–20 min often becomes insufficient. The tensile yield stress of 26–28 MPa under ISO 527-2:2012 supports the use of vertical anti-ovalisation ribs instead of thicker wall sections. Slit bridges with a cross-section of 0.30 mm × 0.60 mm show lower drop-impact failure when the injection unit is operated with 20–40 bar back pressure and a screw speed below 120 min⁻¹. Production failures observed in multi-cavity tools include asymmetric band stretching caused by cavity-to-cavity core temperature differences; validation therefore requires thermal imaging and a measured cavity temperature spread no greater than ±5 °C.
Bridge strength after slitting is also influenced by the direction of melt filling. Radial flow from a central gate produces high circumferential orientation in the band, improving elongation at break in the hoop direction; however, excessive orientation raises shrinkage anisotropy and can cause band diameter undersizing after 48 h of ageing. Cap dimension checks after 24 h and 48 h following moulding are performed with calibrated plug gauges. When colour masterbatch is used, loading above 2 wt% of a non-PE carrier can localise stress near the slit bridges and should be avoided unless the carrier is a compatible high-density polyethylene with a melt index within ±20 % of the base resin.
Flip-top dispensing closures used in haircare and household cleaner packaging require hinge performance that depends on molecular orientation across the hinge axis and on flexural fatigue generated during repeated open-close cycles. HE2558 is processed in single-gate cold-runner tools and in multi-cavity hot-runner tools with melt temperatures of 220–240 °C; the lower melt temperature reduces odour and limits degradation when organic pigment masterbatches are present. Hinge thickness is typically designed at 0.25–0.45 mm, and the gate is positioned to deliver melt across the hinge rather than parallel to it, because parallel flow creates a weak knit line at the thinnest section. The tensile modulus of 1000–1200 MPa under ISO 527-2:2012 provides snap-back stiffness, while the notched Charpy impact at 23 °C of 5–8 kJ/m² under ISO 179-1/1eA:2010 reduces brittle failure if the closure is dropped before assembly. Surfactant exposure from shampoo and liquid detergent can accelerate environmental stress cracking in the hinge root; resistance is assessed by stress crack testing following ASTM D1693-15b after immersion in 10 % nonylphenol ethoxylate solution at 50 °C for 72 h. Unlike beverage closures, household chemical caps are not always labelled for food contact, but finished articles must meet REACH Article 33 candidate list requirements and, where applicable, EN 71-3 for heavy metal migration if the closure is used on packaging perceived as child-accessible.
On high-output assembly lines, the hinge is flexed at 90° immediately after ejection to induce stress whitening in any defective part; components showing visible whitening at the hinge root are rejected because localised yielding reduces fracture resistance. Mould release is restricted to external non-silicone release because silicone-based sprays transfer to the hinge and may interfere with pad printing or labelling. Shrinkage variation across the hinge axis must be accounted for in tooling; cavity dimensions are typically adjusted to allow 0.018–0.024 mm/mm linear shrinkage in the body and 0.010–0.015 mm/mm in the thinner hinge because the faster-cooling hinge freezes before full packing.
During hydrogen peroxide cap sterilisation in aseptic dairy filling, closure shells made from HE2558 are exposed to 30–35 % hydrogen peroxide at 60–70 °C for 2–5 s, followed by hot air drying. Residual peroxide on the cap is controlled below 0.5 mg/unit as part of the filling line’s microbiological validation. The grade’s Vicat softening temperature of 126–131 °C under ISO 306:2022 allows brief exposure to sterilisation temperatures without thread distortion. Organoleptic testing against EN 1622:2006 and EN 1420-1:2006 is more critical in milk-based beverages because fat absorption into the polyolefin surface can carry off-flavours from the processing environment. Overall migration for food contact is tested under EU Regulation (EU) No 10/2011 using simulant D1 for milk and cream, and the supplier’s Declaration of Compliance must be confirmed for the specific converter’s masterbatch and liner system.
Dairy closures are often assembled with aluminium foil induction seals or polyolefin foam liners, and the cap shell must provide a flat sealing rim within ±0.1 mm flatness to avoid seal voids. Tooling for dairy caps uses lower mould temperatures of 10–15 °C to control shrinkage in the rim area; the resulting post-mould shrinkage is typically 0.018–0.024 mm/mm under ISO 294-4:2018. Flash in the sealing rim cannot be tolerated because loose flash may transfer to the container seal area. Multi-cavity tools running dairy closures in 32 or 48 cavities require hot runner balance verified by short-shot weight variation below 1.5 % across all cavities.
To avoid silicone migration in child-resistant pharmaceutical closures, converter practice with HE2558 centres on internal lubrication control and precise core cooling. The closure body is usually injection moulded with melt temperatures of 220–240 °C and a mould temperature of 10–20 °C; core cooling must maintain the internal lugs within ±0.05 mm of the specified diameter. Tensile modulus of 1000–1200 MPa under ISO 527-2:2012 gives the lug stiffness needed for child resistance, but excessive packing pressure above 900 bar can create high hoop stress that relaxes after 24 h and changes the torque profile. Pharmaceutical packaging line qualification often includes torque testing according to ASTM D3475-18 and extraction/migration assessment under USP <661.1> for plastic components. Published data for this specific closure configuration is limited, so converter validation is required for each geometry.
The resin’s stress crack resistance under ASTM D1693-15b Condition B, 100 % Igepal CO-630, influences field performance when closures are exposed to liquid formulations with alcohols and surfactants. In push-and-turn designs, the lower skirt is often designed with a thickness of 0.70–1.00 mm to balance compliance for the child-resistant lugs against top-load strength. Computer-aided flow simulation using Moldflow or Moldex3D is normally employed to position weld lines away from the lugs, because a weld line at a lug root reduces load-bearing cross-section and lowers the maximum torque before shear failure. Ageing of assembled child-resistant closures is evaluated after 14 days at 40 °C to detect torque drift before stability testing of the packaged formulation.
Large-diameter industrial lids moulded from HE2558 are evaluated for stack loading, chemical resistance, and dimensional stability in logistics. The material’s density of 0.958 g/cm³ and tensile modulus of 1000–1200 MPa give lid panels sufficient stiffness, but large-diameter lids require ribbing to prevent panel oil-canning under stacked loads of 200–400 kg per pallet position. Moulding of a 2.0–2.5 mm lid panel is performed with melt temperatures of 220–250 °C and a mould temperature of 15–25 °C; the lower cooling rate relative to thin-wall caps produces a flatter sealing rim when post-mould shrinkage of 0.018–0.024 mm/mm is anticipated. Chemical compatibility for industrial contents is checked by immersion testing at 40 °C for 14 days in representative solvents or aggressive media, and the weight change after immersion is compared with the limits of ISO 175:2010. For UN-certified dangerous goods packaging, the closure is tested as part of a package under UN 6.1.3 leakproofness and internal pressure procedures.
Because industrial pail lids are often assembled with tamper-evident tear bands, the tearing notch is produced by a shear edge in the mould; notch sharpness is maintained by using a tool steel hardness of 50–52 HRC and by avoiding abrasive regrind levels above 20 %. Regrind inclusion changes the melt index and can affect tear propagation; converters using post-industrial regrind should verify that the blend’s MFR remains within ±0.3 g/10 min of the virgin HE2558 value under ISO 1133-1:2022. Heat cycling between −20 °C and 40 °C is used to evaluate stress cracking in lid living hinges and tear bands; failure modes observed on production lines include circumferential cracking at the lid edge when the mould temperature is too low and the rim is overpacked.
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Borealis HDPE HE2558 is a bimodal high-density polyethylene resin produced through the Borealis Borstar PE process. The product is delivered as natural pellets and is specified for extrusion blow moulding of rigid containers used in household chemical, liquid detergent, and industrial packaging applications. Manufacturer-published typical values for this grade include a density of 0.958 g/cm³ (ISO 1183-1), a melt flow rate of 0.25 g/10 min at 190 °C and 2.16 kg load (ISO 1133-1:2022), a tensile modulus of 1100 MPa (ISO 527-2), and a notched Charpy impact strength of 16 kJ/m² at 23 °C (ISO 179-1/1eA). The Vicat softening temperature is listed as 128 °C (ISO 306/A50).
Under EN ISO 17855-2, the resin belongs to the PE-HD family of polyethylene moulding and extrusion materials. The commercial designation HE2558 does not by itself communicate the density and melt flow rate classes; those values are assigned by the manufacturer and verified on the certificate of analysis for each lot. Converters should therefore avoid using the grade number as a substitute for internal release testing.
The Borstar PE reactor configuration is a cascade of a loop reactor and a gas-phase reactor. In the loop reactor, the low-molecular-weight fraction is polymerised at high activity with limited comonomer incorporation. The product is transferred to a gas-phase reactor where the high-molecular-weight fraction is formed in the presence of a controlled amount of alpha-olefin comonomer. The resulting bimodal distribution has a larger difference between number-average and weight-average molecular weight than typical unimodal Ziegler-Natta HDPE. The bimodal molecular weight distribution separates the low-molecular-weight portion that controls shear flow during extrusion from the high-molecular-weight portion that establishes tie-molecule density and environmental stress crack resistance. Published ESCR values for the grade under ASTM D1693-B with 100% Igepal CO-630 at 50 °C are typically reported in excess of 600 h; exact lot values should be confirmed because ESCR failure time is statistically distributed. The combination of 0.958 g/cm³ density and elevated ESCR is not available from many single-reactor unimodal HDPE materials, where density and stress crack resistance are inversely related.
At shear rates between 10 s⁻¹ and 1000 s⁻¹ typical of grooved-barrel extrusion, the low-molecular-weight fraction in HE2558 depresses melt viscosity and reduces viscous heat generation compared with a unimodal HDPE of identical melt flow rate. The high-molecular-weight fraction increases elongational viscosity, which limits parison sag between die exit and mould closure. In practice, parison sag velocity is also affected by melt temperature and die gap; published data for this specific configuration is limited, but the grade is recognised in blow moulding technical literature as a high-melt-strength resin. Die swell can be larger than that of low-molecular-weight bottle grades because of the broad molecular weight distribution. Transferring a tool from a conventional unimodal HDPE requires recalibration of the parison programming, because the heavier die swell often demands a wider die gap or modified pre-blow air delay.
The mechanical failure of a blow-moulded container made from HE2558 is governed by the wall thickness distribution at the pinch-off, the degree of orientation in the bottle walls, and the resistance of the polymer to slow crack growth. The notched Charpy value of 16 kJ/m² at 23 °C is a resin-level comparison point and does not by itself predict drop impact performance. Full-container drop testing according to ASTM D5276-19 or customer-specific protocols at -18 °C, 23 °C, and 40 °C must be executed on production-line bottles. The lower pinch-off and the labelled shoulder region are typical failure zones. Processing parameters that increase melt temperature above 230 °C or prolong residence time above 5 min can reduce the high-molecular-mass fraction and lower ESCR without changing density.
Thermal stability during continuous extrusion blow moulding of HE2558 is governed by the stabiliser package and by residence time distribution in the extruder head. The resin should not be held above 230 °C for more than 5 min, because oxidative chain scission can increase melt flow rate and reduce the high-molecular-mass tail. Typical barrel profiles for a 50 mm grooved-barrel extruder with 24:1 L/D are feed zone 180 °C, compression zone 190–200 °C, metering zone 200–210 °C, and head/die zones 190–210 °C. Actual setpoints must be adjusted for screw design, throughput, and accumulator head size. The resin is not hygroscopic, but condensation on cold pellets at relative humidity above 60% can produce surface splay in the parison. Surface moisture should be removed by pre-drying at 80 °C for 2–4 h. Desiccant hot-air drying above 90 °C should be avoided because HDPE pellets can soften, bridge, and form agglomerates in the hopper. The material is compatible with standard polyolefin masterbatches; chlorinated or strongly acidic flame retardant packages should not be combined with the resin at processing temperature because acid-catalysed chain scission may occur.
Blow moulding of HE2558 should be performed with a screw that provides sufficient mixing and uniform melt temperature. Barrier screws with Maddock shear mixing elements may be used, but high-shear mixing sections should not be combined with excessive screw speed because shear heating can create local melt temperatures above 230 °C. The recommended screw speed depends on the extruder diameter; a 50 mm extruder translating to 60 kg/h may operate near 80–120 min⁻¹ depending on head pressure. These are starting conditions, not specification values.
For converters, the principal difference is the relationship between melt flow rate, density, and slow crack growth resistance. Unimodal single-reactor grades generally show a trade-off between density and ESCR; increasing density for top-load stiffness reduces flexibility and stress crack resistance. Borealis HDPE HE2558 uses the bimodal distribution to decouple those properties. The high-density low-molecular-weight fraction contributes to the modulus and chemical resistance, and the high-molecular-weight fraction supplies tie-molecules that obstruct crack propagation. The melt flow rate of 0.25 g/10 min is not therefore a direct indicator of processability; the grade may extrude with lower melt pressure than a unimodal HDPE with a comparable low MFR because of stronger shear-thinning behaviour.
Compared with low-density HDPE blow moulding grades of 0.945–0.952 g/cm³, HE2558 provides greater top-load stiffness and better chemical resistance but requires closer control of die lines and melt temperature. Compared with high-melt-flow grades with MFR above 0.8 g/10 min, it sacrifices some cycle time for higher parison melt strength and improved stress crack resistance. These are not absolute distinctions; they are graded by bottle design, wall thickness, and tooling conditions.
The following table compares the manufacturer-published typical property profile of HE2558 with the general reference envelope for extrusion blow-moulding HDPE grades. The reference envelope is assembled from published HDPE blow-moulding literature and is not a specification limit.
| Property | Test method | Unit | HE2558 typical value | Reference envelope | Engineering consequence |
|---|---|---|---|---|---|
| Density at 23 °C | ISO 1183-1 | g/cm³ | 0.958 | 0.945–0.965 | Stacking stiffness and chemical resistance |
| Melt flow rate | ISO 1133-1:2022 | g/10 min | 0.25 | 0.15–0.50 | Parison hang strength versus cycle time |
| Tensile modulus | ISO 527-2 | MPa | 1100 | 800–1300 | Panel stiffness and top-load resistance |
| Notched Charpy impact at 23 °C | ISO 179-1/1eA | kJ/m² | 16 | 8–20 | Drop impact screening |
| ESCR F50 | ASTM D1693-B | h | >600 | 50–1000 | Detergent bottle stress cracking |
| Vicat A50 softening temperature | ISO 306/A50 | °C | 128 | 115–132 | Thermal resistance under low load |
The table confirms why HE2558 is positioned for demanding detergent and industrial chemical bottles. The density is near the upper end of the reference envelope, while the ESCR is above the median for blow-moulding grades. However, the reference envelope should not be used for lot acceptance; only the manufacturer’s specification and the converter’s internal release limits apply.
Top-load resistance of containers made from HE2558 should be verified by compression testing on complete bottles rather than by calculation from resin tensile modulus. Wall-thickness optimisation can exploit the high melt strength of the grade to reduce average bottle weight versus a unimodal HDPE in tall containers, provided that the minimum wall thickness at the lower pinch-off is maintained. Weight reduction below the validated range may produce stress whitening at the shoulder and premature slow crack growth after filling. Environmental stress crack resistance in HDPE containers is controlled not only by density but also by the concentration of tie-molecules that bridge adjacent crystals. In HE2558, the high-molecular-weight fraction increases the probability that a single chain participates in multiple crystalline lamellae. Under ASTM D1693-B, this is observed as slower crack propagation when the inner surface is wetted by nonionic surfactants such as Igepal CO-630. The test differs from real detergent formulations because the alkoxylated surfactant environment can be more aggressive. Therefore, a passing ESCR value does not remove the need for storage testing with the actual filled liquid at 50 °C and 70–90% relative humidity.
Switching a rotary wheel line from a high-flow HDPE bottle grade with MFR 0.6–1.0 g/10 min to HE2558 requires attention to die head pressure, parison formation time, and pinch-off flash removal. The lower melt flow rate of 0.25 g/10 min can increase melt pressure at the die head if the same die gap and temperature profile are retained. Process adjustments may include raising the die and head temperature to 210–220 °C or widening the die gap by 0.1–0.3 mm. The higher parison melt strength reduces sag, which can permit taller parisons without excessive wall thinning. Cycle time may remain unchanged if the extruder can supply the required throughput; otherwise a small extension of parison programming can be necessary. Published data for this specific configuration is limited, and start-up trials should map melt pressure, flash weight, and container weight at three throughput levels.
The difference in trim behaviour is also relevant. The broader die swell of HE2558 can produce thicker flash at the pinch-off, which increases regrind generation. The converter should monitor flash weight as a percentage of total shot weight and keep it below 20% unless the regrind blend is validated by drop impact and ESCR testing. Repeated processing of regrind at high temperature can shift the molecular weight distribution and reduce the high-molecular-mass tail, so regrind blend ratios above 20% should be treated as a material change requiring full container qualification.
The following compliance verification matrix identifies the standard test methods and typical conditions used for lot acceptance and specification review of Borealis HDPE HE2558. It is not a regulatory certification and does not replace the manufacturer's certificate of analysis or food-contact statement.
| Control function | Test method | Typical condition | Variable controlled |
|---|---|---|---|
| Density | ISO 1183-1 | 23 °C, compression-moulded specimen | Batch consistency and stiffness |
| Melt flow rate | ISO 1133-1:2022 | 190 °C, 2.16 kg | Processability |
| Tensile modulus | ISO 527-2 | 1A specimen, test speed 1 mm/min | Stiffness and top-load resistance |
| Notched Charpy impact | ISO 179-1/1eA | 23 °C and -20 °C | Impact resistance |
| Environmental stress crack resistance | ASTM D1693-B | 100% Igepal CO-630, 50 °C, F50 | Slow crack growth resistance |
| Vicat softening temperature | ISO 306/A50 | 10 N, 50 K/h | Thermal resistance |
Incoming resin quality control for Borealis HDPE HE2558 should include melt flow rate, density, and visual contamination checks against the lot certificate. The melt flow rate shall be measured according to ISO 1133-1:2022 using a 190 °C barrel and 2.16 kg load. Density shall be measured by ISO 1183-1 on compression-moulded plaques cooled at a controlled rate. The product should be stored in sealed octabins or silos and kept away from direct sunlight and ambient temperatures above 40 °C. Contact with oxidising chemicals, strong mineral acids, and aromatic or chlorinated hydrocarbons should be avoided in long-term service because these fluids can permeate or degrade the polymer. Heat stabilisation is adequate for normal blow moulding conditions, but the natural grade is not UV-stabilised; outdoor service requires a carbon black masterbatch or an approved UV stabiliser package. The continuous service temperature under load is below the Vicat softening temperature of 128 °C; long-term exposure above 60–80 °C in air may embrittle unstabilised or thin-walled containers. These operational boundaries must be validated under final use conditions.