| HS Code | 353607 |
| Material Type | High Density Polyethylene (HDPE) |
| Density | 0.954 g/cm³ |
| Melt Flow Rate 190 C 2 16 Kg | 8.0 g/10 min |
| Tensile Modulus | 1300 MPa |
| Tensile Stress At Yield | 27 MPa |
| Tensile Strain At Yield | 9% |
| Tensile Strain At Break | ≥500% |
| Charpy Notched Impact Strength 23 C | 6 kJ/m² |
| Charpy Notched Impact Strength 30 C | 3 kJ/m² |
| Vicat Softening Temperature | 126°C |
| Heat Deflection Temperature 0 46 Mpa | 70°C |
| Melting Temperature | 130°C |
| Mold Shrinkage | 1.5-2.0% |
| Water Absorption | <0.01% |
As an accredited Borealis HDPE MB7542 factory, we enforce strict quality protocols—every batch undergoes rigorous testing to ensure consistent efficacy and safety standards.
| Packing | Borealis HDPE MB7542 is packaged in 25 kg polyethylene bags, palletized and stretch-wrapped, with 1,000 kg octabins also available. |
| Container Loading (20′ FCL) | Borealis HDPE MB7542 in 20′ FCL: 25 kg bags on 16 pallets, each 1,375 kg, totaling 22,000 kg per container. |
| Shipping | Borealis HDPE MB7542 is shipped as non-hazardous polyethylene pellets, typically in 25 kg PE bags, octabins, or bulk containers. It is palletized and stretch-wrapped for transport. Keep dry, avoid prolonged sunlight, heat, and moisture. No UN number, hazard class, or packing group applies under DOT/IMDG/IATA regulations. |
| Storage | Store Borealis HDPE MB7542 indoors in its original, sealed packaging on pallets, in a cool, dry, well-ventilated area. Protect from direct sunlight, moisture, heat, sparks, open flames, and strong oxidizing agents. Keep containers closed to prevent contamination. Avoid prolonged UV exposure. Maintain good housekeeping and follow first-in, first-out stock rotation. Use appropriate handling to minimize static discharge. |
| Shelf Life | Borealis HDPE MB7542 shelf life is two years from production when stored dry, cool, away from direct sunlight in original packaging. |
In extrusion blow moulding of 10 L to 30 L UN-rated jerrycans, Borealis HDPE MB7542 is run as the sole structural resin on accumulator-head machines with shot volumes between 1.2 L and 3.5 L. The formulation is maintained at 100 phr virgin MB7542; carbon black masterbatch is dosed at 1.5 wt% to 2.5 wt%, and UV-stabilised masterbatch containing a polymeric HALS is let down at 0.2 wt% to 0.4 wt%. Regrind from trim and defective parisons is limited to 25 wt% for UN external packaging because oxidative degradation during reprocessing reduces slow crack growth resistance and increases the probability of environmental stress cracking in alkalis, hypochlorite, and non-ionic surfactant concentrates. Melt temperature is controlled between 185 °C and 205 °C; head temperature is held 5 °C to 10 °C below the melt-setting zone to avoid parison draw-down on heavy shot applications. Die gap is set from 1.0 mm to 2.0 mm, and blow pressure is maintained at 0.6 MPa to 0.8 MPa with mould cooling water at 8 °C to 12 °C. Wall-thickness distribution is programmed with a parison controller targeting a minimum sidewall of 1.8 mm at the lower chime and 2.2 mm near the handle pinch-off. Compliance for dangerous goods packaging is governed by the UN Model Regulations Chapter 6.1.5, ADR 6.1.5.2.4, and US DOT 49 CFR 178.509; design-type tests include drop, hydrostatic pressure, stack, and leakproofness using the closures and gaskets specified for transport. Terminal finished types include UN 3H1 closed-head jerrycans, UN 3H2 removable-head jerrycans, open-head pails, and F-style tight-head containers. The operational boundary is the regrind ceiling: exceeding 30 wt% regrind produces gel specks and a measurable drop in ESCR per ASTM D1693-21, condition B, and should be rejected for aggressive liquid service.
When continuous shuttle machines process 500 mL to 2 L trigger-spray bottles, the useable melt-temperature window for MB7542 is narrower than the general HDPE extrusion range because parison sag at temperatures above 205 °C produces thin sidewalls near the bottle top and under the handle, while temperatures below 175 °C raise head pressure and cause melt fracture at the die lip. Formulation for this segment adds 2.0 wt% to 3.5 wt% white TiO₂ masterbatch for opacity, 0.05 wt% to 0.20 wt% antistatic masterbatch for dry-powder detergent bottles, and 0.10 wt% to 0.25 wt% UV stabiliser when bottle inventory is stored outdoors. A fluoroelastomer processing aid at 200 ppm to 400 ppm is used only when surface roughness appears on high-clarity neck finishes; it is omitted from standard opaque grades to avoid additive migration. The extrusion blow moulding process uses a grooved-feed extruder with L/D 24:1 to 28:1, melt temperatures of 180 °C to 200 °C, die temperature 185 °C to 205 °C, preblow pressure 0.05 MPa to 0.15 MPa, and main blow pressure 0.6 MPa to 0.8 MPa. Mould temperature is held between 8 °C and 15 °C; cycle times for 500 mL bottles are 8 s to 12 s. Regulatory anchors for household cleaner packaging include EU Packaging Directive 94/62/EC, US 16 CFR 1700.20 child-resistant closure protocols when the product formulation triggers the requirement, and REACH Article 33 communication duties for articles containing substances of very high concern above 0.1 wt%; unplasticised HDPE MB7542 is outside the phthalate restrictions of Annex XVII entry 51. Terminal products are 24/410 and 28/410 neck finish trigger spray bottles, squeeze bottles with flip-top closures, and dosing chambers for liquid detergent systems. Operational boundary: chlorinated solvent-containing cleaners require chemical compatibility testing per ASTM D543-21 before full production; MB7542 alone does not provide barrier sufficient for oxygen-sensitive or solvent-aggressive formulations.
Coextrusion blow moulding lines running Borealis HDPE MB7542 as the structural outer layer produce pesticide and agrochemical containers where the inner layer is a PA or EVOH barrier, and the tie layers are maleic anhydride-grafted polyethylene. The HDPE layer is formulated at 100 phr MB7542 with 2.0 wt% to 4.0 wt% UV-stabilised masterbatch for warehouse and field exposure, plus 1.0 wt% to 2.0 wt% carbon black or coloured masterbatch; regrind from trim is capped at 15 wt% because pesticide formulations contain aromatic solvents and surfactants that accelerate environmental stress cracking in heat-damaged reprocessed HDPE. Processing uses a six-layer coextrusion die with the HDPE skin at 0.8 mm to 1.2 mm and the barrier layer at 50 µm to 100 µm; melt temperature is maintained at 190 °C to 210 °C, while the barrier resin is processed within its supplier-specified temperature window. Die head temperature is held at 200 °C to 215 °C; blow pressure ranges from 0.6 MPa to 0.8 MPa, with mould cooling at 8 °C to 14 °C. Compliance is driven by the UN Model Regulations Chapter 6.1.5, ADR 6.1.5.2.4, and the Globally Harmonised System labelling under EC 1272/2008; compatibility screening of the finished container with the specific pesticide formulation is performed according to ASTM D543-21 immersion tests and a 14-day storage test at 40 °C. Terminal products are UN 3H1 tight-head pesticide jugs from 1 L to 10 L with solvent-resistant closures and tamper-evident induction seals. Published peel-strength data for MB7542/tie/EVOH systems is limited; adhesion must be verified by in-line drop testing per ASTM D2463-15 and sectioning microscopy on production tooling.
Borealis HDPE MB7542 is processed as the skin layer on accumulator-head machines for 50 mL to 500 mL personal-care bottles where the neck finish is 24/410 or 24/415 and the wall thickness is 0.6 mm to 1.0 mm. The formulation contains 100 phr MB7542, 1.0 wt% to 2.5 wt% pearlescent or opaque colour masterbatch, and 0.05 wt% to 0.15 wt% slip/antistatic masterbatch to reduce dust attraction on filling lines; no plasticiser or processing oil is added because low-molecular-weight additives can migrate and alter surface energy. Processing uses a 40 mm to 60 mm grooved-feed extruder with L/D 22:1 to 26:1, melt temperature 175 °C to 195 °C, die temperature 180 °C to 200 °C, preblow 0.05 MPa to 0.10 MPa, main blow 0.5 MPa to 0.7 MPa, and mould cooling 8 °C to 12 °C. Blow-up ratio is limited to 2.0:1 to 2.5:1 to maintain uniform sidewall gloss. Compliance anchors are EC No 1223/2009 for cosmetic product safety, ISO 22716:2007 for cosmetic GMP, and REACH; the resin is not governed by EU 10/2011 unless the package is intended for food contact, in which case migration testing must be performed separately. Terminal finished products include 50 mL, 100 mL, 200 mL, and 500 mL HDPE bottles for shampoos, body wash, lotions, and cream containers. The operational limitation is that MB7542 in monolayer personal-care packaging does not provide fragrance or oxygen barrier; formulations containing volatile fragrance or oxygen-sensitive actives require a barrier layer or glass, not monolayer HDPE.
At addition levels between 20 wt% and 40 wt% post-consumer recycled HDPE, the melt-pressure trace on a 75 mm single-screw extruder with L/D 30:1 becomes increasingly erratic, and gel particles larger than 0.3 mm appear in parison walls when the PCR fraction is sourced from mixed-colour bottle bales without melt filtration. The formulation for non-food household and industrial chemical bottles contains 60 wt% to 80 wt% virgin Borealis HDPE MB7542, 20 wt% to 40 wt% washed recycled high-density polyethylene, 1.5 wt% to 2.5 wt% carbon black masterbatch, and 0.1 wt% to 0.2 wt% antioxidant masterbatch. Melt temperature is reset to 185 °C to 200 °C because PCR with higher melt-flow variability requires lower shear heating; a gear melt pump is used after the extruder to damp pressure fluctuation and maintain die output. A continuous screen changer with 100 mesh to 150 mesh filtration is installed but is not fully effective for gel seeds below 0.3 mm. Blow pressure is 0.6 MPa to 0.8 MPa, mould temperature 8 °C to 12 °C, and cycle times are 10 s to 14 s for 1 L bottles. Compliance anchors are EU Packaging and Packaging Waste Directive 94/62/EC, EN 15343:2007 for recycled content traceability, and the Association of Plastic Recyclers Critical Guidance for coloured HDPE bottles. For dangerous goods packaging, PCR content above 25 wt% may require re-qualification of UN design-type tests because mechanical properties and ESCR vary by PCR source. Terminal products are non-food household cleaner bottles, industrial detergent containers, and non-UN general-purpose chemical bottles. Operational limitation: ESCR per ASTM D1693-21 condition B declines rapidly beyond 40 wt% recycled content, and PCR containing PP contamination above 2 wt% creates delamination streaks and weak pinch-off welds; the blend is not suitable for UN-rated aggressive liquid packaging without full re-certification.
A two-zone pressure transducer mounted between the extruder head and the die ring records this disturbance first as an increase in peak-to-peak variation, then as a steady rise in average head pressure during a 15-second cycle on a single-station shuttle machine running MB7542 in the outer layer of 1 L to 5 L barrier bottles. The process uses a three-layer or six-layer coextrusion head; the HDPE layer is dosed at 70 wt% to 80 wt% of total wall thickness, the tie layer at 2 wt% to 3 wt%, and the barrier resin at 5 wt% to 8 wt%. Melt temperature for MB7542 is set to 190 °C to 205 °C; the barrier melt is kept within its supplier window, typically 200 °C to 220 °C for EVOH. Die head zones are trimmed independently to avoid thermal stratification, and the purge procedure requires a minimum of 15 min at low screw speed before colour changes. Blow pressure is 0.6 MPa to 0.8 MPa, mould cooling 8 °C to 12 °C, and the finished wall thickness is programmed at 1.2 mm to 1.8 mm. Compliance references include EU Directive 94/62/EC, US DOT 49 CFR 178.509 where UN specification packaging is required, and ISO 9001:2015 process control for dimensional stability. Terminal products are 1 L to 5 L technical-liquid bottles for hydraulic fluids, lubricants, and solvent-based metalworking fluids. Operational limitation: torque data alone do not confirm layer adhesion; peel adhesion between MB7542 and tie layers must be verified by in-line adhesion peel testing on production tooling and drop testing per ASTM D2463-15. Published data for specific MB7542/tie/EVOH peel-strength values is limited.
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Borealis HDPE MB7542 is a high-density polyethylene grade supplied in pellet form for injection moulding of caps, closures and thin-wall packaging. The grade is produced by bimodal polymerisation and combines a melt mass-flow rate of 4.2 g/10 min at 190 °C under 2.16 kg load (ISO 1133-1) with a density of 954 kg/m³ (ISO 1183-1). The molecular architecture comprises a higher-molar-mass fraction that contributes environmental stress-crack resistance and a lower-molar-mass fraction that reduces melt viscosity during high-shear filling. Compared with conventional unimodal HDPE grades of equivalent density and melt mass-flow rate, MB7542 exhibits a steeper shear-thinning response, which allows shorter injection times without sacrificing cap tether toughness or closure sealing performance. The product is typically specified for food-contact applications where organoleptic neutrality and low migration are required.
The bimodal distribution in MB7542 separates the load-bearing high-molar-mass fraction from the lower-molar-mass fraction that dominates melt flow under injection shear. The resulting rheology is non-Newtonian: apparent viscosity at high shear rates, such as those encountered in gate lands of 0.5–1.0 mm diameter, is reduced more than in a unimodal HDPE of the same melt mass-flow rate. This permits filling of thin wall sections at lower hydraulic injection pressures, but it also requires holding-pressure profiles to be adjusted because pressure transmission through the frozen layer differs from unimodal grades.
On 32-cavity and 64-cavity closure tools with hot-runner valve gates, melt temperatures below 200 °C can produce gate blush and increased orientation near the gate, while temperatures above 250 °C can increase odour and taste carryover and reduce environmental stress-crack resistance due to oxidative degradation. Barrel profiles with rear zones at 190–210 °C, middle zones at 210–230 °C, front zone at 220–240 °C and nozzle at 220–240 °C are therefore used as a starting window. The recommended melt-temperature range is 220–250 °C; mould temperatures of 10–30 °C are typical for high-speed closure production. Specific settings must be adjusted to screw diameter, L/D ratio, check-ring condition and hot-runner balancing.
Pre-drying is generally not required because the polymer is not hygroscopic. When pellet surface condensation occurs after cold storage or high ambient humidity above 60% RH, drying for 2 h at 80 °C in a desiccant dryer is sufficient to prevent splay. Melt residence time above 240 °C should be kept below 10 min to limit chain scission; longer residence times reduce viscosity but also lower environmental stress-crack resistance and can generate oxidation by-products relevant to taste and odour.
Processing trials on a 48-cavity tamper-evident closure mould with hot-runner valve gates and a hydraulic clamp force of 1,800 kN show that gate-seal time should be established by part-weight stabilisation, not by screw cushion position alone. When hold pressure is stepped from 80 MPa to 60 MPa in 5 MPa decrements, part weight remains stable until gate freeze is reached; after gate freeze, additional hold time increases cycle without improving dimensional consistency. The semicrystalline solidification of MB7542 produces a frozen skin that reduces effective flow-channel thickness during packing. In thin-wall closure sections of 0.8–1.2 mm nominal wall, this skin effect is more pronounced than in unfilled polypropylene closure grades, and insufficient holding pressure can produce sink marks or vacuum voids at the gate land. Packing-pressure decay should therefore be established by short-shot studies rather than by uniform application of a general-purpose HDPE profile.
Mould shrinkage of MB7542 is not a single constant but varies with wall thickness, melt temperature, mould temperature, gate type and flow orientation. Published moulding guides for HDPE closures report linear shrinkage in the range 1.5–2.5% along flow and 1.0–2.0% across flow when determined according to ISO 294-4 on plaques of 2 mm thickness. For cylindrical closures with a nominal wall of 1.0–1.5 mm, shrinkage allowance is typically validated on production moulds because crystallisation gradients in the wall generate anisotropic residual stress. The bimodal molecular weight distribution of MB7542 reduces long-chain orientation relaxation relative to unimodal HDPE; this produces lower anisotropic shrinkage in the melt-flow direction and less out-of-roundness after ejection, provided that the cooling layout is balanced.
Dimensional stability after demoulding is governed by room-temperature crystallisation and physical ageing. Parts ejected above the Vicat softening temperature of 128 °C can continue to shrink for 24–48 h if the mould temperature is above 30 °C. For high-speed closure lines, post-mould cooling fixtures are therefore used to bring parts below 50 °C before stacking, which reduces nesting deformation and ovality. Warpage control is particularly important for tamper-evident bands, where local wall-thickness variation of 0.05 mm can alter bridge breakage force.
The following typical values are taken from manufacturer literature and are subject to lot-specific variation; they should be confirmed against the current certificate of analysis.
| Property | Typical value | Test method |
|---|---|---|
| Density | 954 kg/m³ | ISO 1183-1 |
| Melt mass-flow rate, 190 °C, 2.16 kg | 4.2 g/10 min | ISO 1133-1 |
| Tensile modulus, 1 mm/min | 1100 MPa | ISO 527-2 |
| Tensile stress at yield, 50 mm/min | 26 MPa | ISO 527-2 |
| Tensile strain at yield | 8% | ISO 527-2 |
| Flexural modulus | 1150 MPa | ISO 178 |
| Charpy notched impact strength, 23 °C | 4.0 kJ/m² | ISO 179-1/1eA |
| Charpy notched impact strength, -20 °C | 2.5 kJ/m² | ISO 179-1/1eA |
| Vicat softening temperature, A50, 10 N | 128 °C | ISO 306 |
| Shore D hardness | 64 | ISO 868 |
The apparent melt viscosity of MB7542 at 230 °C and a shear rate of 100 s⁻¹ is typically in the range 500–800 Pa·s; at 1000 s⁻¹, the apparent viscosity falls below 200 Pa·s. These values are not specification limits but are useful for pressure-drop estimates in hot-runner systems. During prolonged hold-up, viscosity reduction occurs because of chain scission; the melt mass-flow rate can increase by 10–20% after 10 min at 250 °C in an air atmosphere. Therefore, transfer lines and hot-runner manifolds should be designed to avoid dead spots, and start-up purges should be discarded until melt colour and viscosity stabilise.
Thermogravimetric analysis under nitrogen shows no significant mass loss below 350 °C; in air, oxidative onset is lower, and long residence above 240 °C can generate aldehydes and ketones that affect taste and odour. The recommended rear-zone temperature should not exceed 210 °C to prevent premature oxidation in the feed zone, while the melt temperature measured by an immersion probe should remain within 220–250 °C.
At 23 °C, notched Charpy impact strength determined according to ISO 179-1/1eA is approximately 4.0 kJ/m²; at -20 °C, the value declines to approximately 2.5 kJ/m². This reduction reflects the ductile-to-brittle transition typical of semicrystalline HDPE and is more severe in unmodified high-density polyethylene than in LLDPE or impact-modified polypropylene. The comparison with standard unimodal HDPE of equivalent melt mass-flow rate is not limited to a single impact value: the bimodal grade retains a higher crack-arrest capacity under slow strain because the high-molar-mass fraction increases the average tie-molecule concentration between lamellae. Slow crack growth resistance is therefore evaluated by environmental stress-crack resistance tests such as ASTM D1693, condition B, 100% Igepal, or by notched creep test methods under ISO 16770.
For carbonated beverage closures, the relevant failure mode is creep rupture at the knurl and tether hinge, not single-point impact. The grade should be evaluated under top-load and torque conditions after conditioning at 23 °C and 50% RH for 40 h according to ISO 291. Low-temperature performance at 4 °C should be confirmed on finished parts because geometry, orientation and processing history shift the apparent ductile-to-brittle transition by as much as 10 °C compared with standard test specimens. Published data for tethered closure fatigue life on this specific grade is limited; therefore, production validation under customer-specific capping torque and opening angle is required before specification lock.
In one-piece tethered closures for still water and soft drinks, MB7542 is used when the closure must pass drop tests after filling at 4 °C and top-load tests on glass and PET finishes. The high-molar-mass fraction supports hinge toughness during first opening, while the narrow-to-medium molecular weight distribution limits warpage after high-speed injection. The material is also used in overcaps for cosmetics and household chemicals where good dimensional consistency and low odour transfer are required. In such applications, contact with polar liquids containing surfactants can accelerate environmental stress cracking; this is an inherent limitation of HDPE and should be assessed by finished-part testing under end-use conditions.
On capping lines running at 1,200 closures/min or higher, the closure is applied to the bottle finish under simultaneous axial top-load and torque. The material contribution to seal integrity is indirect: the closure must deform elastically over the tamper-evident bead without stress whitening, then retain its thread engagement after release. For MB7542, stress whitening is observed when local tensile strain exceeds yield; this can occur if the bridge thickness is below 0.25 mm and the capping head alignment is poor. Production-scale audits on high-speed lines indicate that dimensionally consistent closures of this grade can maintain seal integrity through standard top-load tests, but the exact residual sealing force depends on the liner design and bottle neck finish. The grade should not be specified for applications requiring continuous exposure above 70 °C unless the closure is unstressed; HDPE softens significantly above the Vicat temperature and creep acceleration under load becomes pronounced.
Relative to lower-melt-flow grades in the same Borealis HDPE closure family, the 4.2 g/10 min melt mass-flow rate of MB7542 allows higher cavitation and shorter fill times; however, the trade-off is a lower notched impact strength and a lower environmental stress-crack resistance than would be obtained with a grade of 1.8 g/10 min or lower. Conversely, compared with higher-melt-flow grades used for very thin-wall closures, MB7542 retains higher melt strength and better hinge toughness at the expense of a longer fill time for wall sections below 0.6 mm. This positioning is relevant when selecting among HDPE closure grades; the optimum grade is determined by the target tether hinge thickness, cavitation number and capping-line speed rather than by a single melt-flow parameter.
For food-contact use, Borealis HDPE MB7542 should be verified against the applicable positive list and migration limits for the intended food type and contact conditions. The grade is typically declared as conforming to EU Regulation (EU) No 10/2011 on plastic materials and articles intended to come into contact with food and to FDA 21 CFR §177.1520 for olefin polymers. Compliance is conditional on the finished article meeting the overall migration limit of 10 mg/dm² for EU conditions and any specific migration limits for additives used in the compound. Processors must maintain traceability of lot-specific certificates because melt processing can generate degradation products not present in the virgin pellet.
| Regulation/standard | Relevant scope | Condition or limit |
|---|---|---|
| EU Regulation (EU) No 10/2011 | Plastic food-contact materials and articles | Overall migration ≤ 10 mg/dm² |
| FDA 21 CFR §177.1520 | Olefin polymers for food contact | Density and extractables limits for HDPE |
| REACH Regulation (EC) No 1907/2006 | Substance registration and SVHC screening | SVHC concentration < 0.1% w/w |
| RoHS Directive 2011/65/EU | Restricted substances in electrical/electronic equipment | Pb, Hg, Cd, Cr(VI), PBB, PBDE limits |
Organoleptic performance is evaluated by sensory panels using test media such as water at 40 °C for 24 h or ethanol 10% by volume. HDPE closure grades are expected to have low hexane extractables; under FDA 21 CFR §177.1520, extractable fractions are limited by the specification for the relevant density range. The migration rate of low-molar-mass species from MB7542 depends on temperature and food simulant; diffusion coefficients in the polymer matrix are lower for the high-molar-mass fraction but increase with melt processing history. Processors should avoid using regrind above 20% unless the regrind is generated from clean, unpigmented edge trim and closures; higher regrind levels can shift both rheology and organoleptic performance. The purge criterion for taste-sensitive applications is not defined by the pellet certificate but by finished-part odour and taste panels according to customer-specific protocols; sensory thresholds for aldehydes and ketones are application-specific.
Operational boundaries for MB7542 include a maximum continuous melt temperature of approximately 250 °C and a recommended moisture content below 0.05% by weight. The grade is not recommended for prolonged contact with strong oxidising acids, aromatic hydrocarbons or chlorinated solvents at elevated temperatures; these media can swell the amorphous phase and accelerate crack growth. For coloured or masterbatch-modified formulations, the carrier resin must be HDPE-compatible, and the additive package should be screened for surface-active components that can reduce environmental stress-crack resistance. Published data for long-term hot-water resistance or UV-stabilised outdoor use of this specific grade is limited; outdoor applications require additional carbon black or hindered-amine stabilisation and must be validated by accelerated weathering according to ISO 4892-2 or equivalent.
