| HS Code | 912591 |
| Density | 0.924 g/cm³ |
| Melt Flow Rate 190 C 2 16 Kg | 4.0 g/10 min |
| Tensile Strength At Yield | 9.0 MPa |
| Tensile Strength At Break | 12.0 MPa |
| Elongation At Break | 600% |
| Tensile Modulus | 220 MPa |
| Shore D Hardness | 48 |
| Vicat Softening Temperature | 90 °C |
| Melting Point | 110 °C |
| Water Absorption | <0.01% |
| Thermal Conductivity | 0.33 W/mK |
| Dielectric Constant | 2.3 |
As an accredited Borealis LDPE NAV104 factory, we enforce strict quality protocols—every batch undergoes rigorous testing to ensure consistent efficacy and safety standards.
| Packing | Borealis LDPE NAV104 is supplied in 25 kg polyethylene bags, palletized and shrink-wrapped, or in 1,000 kg bulk bags. |
| Container Loading (20′ FCL) | Container Loading (20′ FCL): Borealis LDPE NAV104 resin, palletized 25 kg bags, shrink-wrapped, evenly stowed and secured inside container. |
| Shipping | Borealis LDPE NAV104 is a low-density polyethylene resin. Non-hazardous; not regulated for transport (no UN number, class, or packing group). Pack in moisture-resistant bags/octabins. Store dry, away from heat, ignition, and oxidizing agents. Avoid dust generation and environmental release. Keep containers closed. Use standard industrial packaging and handling. |
| Storage | Store Borealis LDPE NAV104 in a cool, dry, well-ventilated area, protected from direct sunlight, heat, ignition sources, and moisture. Keep the original packaging sealed and stacked securely on pallets to prevent dust, contamination, and odor pickup. Avoid incompatible materials. Use first-in, first-out stock rotation. Follow the supplier’s safety data sheet and all local storage regulations. |
| Shelf Life | Typically 24 months when stored unopened in original packaging under dry, cool conditions, away from direct sunlight and heat. |
In three-layer blown-film coextrusion of form-fill-seal structures, Borealis LDPE NAV104 is handled as the sealant-skin component where low seal-initiation temperature and bubble stability are the controlling variables. The layer distribution is typically held at 20–30 % of total film thickness, with a die gap of 1.8–2.4 mm and a blow-up ratio between 2.2:1 and 3.0:1. Frost-line height is set 600–1,100 mm above the die because the low-crystallinity fraction must leave the quench zone slowly enough to avoid internal haze. Calibration of the heat-seal plateau follows ASTM F88/F88M-21; seal strength is recorded after dwell times of 0.5 s and 1.0 s at 115–135 °C. Film converters observe that gels and micro-fisheyes in the LDPE skin cause visible defects in high-clarity medical and produce pouches, so melt filtration through 80–120 mesh screen packs is maintained before the die. The terminal products include polyethylene liners for flow-wrap bakery applications, frozen vegetable pouches, and sterile-device chevron pouches, where the seal layer must remain flexible below −20 °C without stress whitening. Because grade-specific gel and seal data are lot-dependent, plant trials should verify final heat-seal strength under production-line dwell times rather than laboratory dwell-time conditions.
High-pressure LDPE carrier resins are selected for carbon black and organic pigment concentrates because of their low crystallinity and rapid wetting of pigment aggregates. In co-rotating twin-screw extruders with a 40:1 L/D ratio and screw diameters of 40–70 mm, the carrier is fed at the main throat while pigments are side-fed downstream after the first melting zone. For carbon black masterbatch, loading is typically pushed to 40–50 wt%; for phthalocyanine blue and high-performance reds, the practical ceiling is 25–35 wt% because higher loadings reduce melt strength and increase strand breaks at the pelletiser. The temperature profile along the barrel is held at 130–190 °C, with the first barrel zone cooled to 90–120 °C to prevent premature melting and pigment compaction. Specific energy input typically ranges from 0.15 kWh/kg to 0.25 kWh/kg, while die-head pressure is kept below 120 bar to avoid excessive screen-pack fouling. Dispersion quality is measured against ISO 11420:1996 or internal film-filter tests using 25 μm mesh packs; a filter pressure value below 0.5 bar/g is common for film-grade masterbatch.
A process conflict arises when pigment loading is increased above the practical ceiling because the melt transitions from continuous matrix to paste-like behaviour, raising torque and reducing the cooling efficiency of the water ring pelletiser. In such cases, operators reduce screw speed to 300–500 rpm, but lower shear reduces dispersion unless kneading blocks are reconfigured. The most robust signal is the strand-break frequency across a 24-hour campaign; values above 3 breaks/hour indicate that the formulation has exceeded the carrier’s wetting capacity. Let-down ratios in downstream polyolefin films range from 2 wt% to 5 wt%, depending on opacity and layer thickness. The terminal products are pelletised colour concentrates, additive masterbatches, and UV stabiliser concentrates for agricultural film. Where the concentrate is intended for food-contact film, the converter must confirm that pigment and additive selections comply with EU 10/2011 and FDA 21 CFR 177.1520 migration limits, because the carrier resin alone does not confer food-contact compliance.
Tandem extrusion coating lines processing Borealis LDPE NAV104 for liquid-packaging board operate at melt temperatures between 290 °C and 320 °C, because lower temperatures increase melt elasticity and cause edge weave, while higher temperatures generate oxidative gels and affect odour and taint. Coating weights are set from 12 g/m² to 25 g/m², with die gaps of 0.5–0.8 mm and air gaps from die lip to nip of 100–180 mm. A longer air gap permits neck-in and draw resonance, while a shorter air gap reduces adhesion to the paperboard unless corona discharge or a primer is used. Neck-in is controlled by melt strength and is monitored as edge-bead width variation; modern dies maintain neck-in below 20 mm per edge at line speeds up to 500 m/min.
Bond strength to liquid-packaging board is measured by peel adhesion according to ASTM D903-98 or internal board converter specifications, with acceptable values typically above 1.5 N/15 mm for barrier structures. In aseptic brick structures, the LDPE layer is laminated to aluminium foil; the adhesion level after wet-board exposure is the critical failure criterion because steam sterilisation can reduce peel strength if the board surface starch content is high. The compliance framework includes EU 10/2011 overall migration below 10 mg/dm², FDA 21 CFR 177.1520 for olefin polymers, and REACH substance restrictions for food-contact articles. Terminal products include gable-top milk and juice cartons, paper cups, and aseptic brick packs, where the LDPE layer is not the oxygen barrier but provides heat-seal integrity, liquid barrier, and adhesion to aluminium foil or paperboard. Because the specific neck-in and adhesion window for NAV104 depends on the coextruder configuration and board moisture content, line qualification trials are required before commercial run rates are locked.
On accumulator-assisted injection moulding lines producing overcaps and plug seals, Borealis LDPE NAV104 is processed at melt temperatures between 190 °C and 230 °C and mould surface temperatures of 15–40 °C. Clamp tonnage is calculated at 3–5 kN/cm² of projected cavity area, and gate land length is held at 0.5–1.0 mm to prevent jetting. The flexural modulus of LDPE NAV104, measured by ISO 178:2019, generally falls below 300 MPa, restricting the grade to flexible overcap retention features rather than load-bearing caps. Mould-shrinkage corrections of 1.5–2.5 % are applied along flow and transverse axes. Terminal products are tamper-evident plug seals for detergent bottles, overcaps for dairy tubs, and flexible dosing caps requiring low opening torque.
Foam extrusion of LDPE NAV104 is constrained by the need to keep the melt below the crystallisation onset until the pressure drop at the die. For physical blowing agents such as isobutane or n-pentane, the extruder barrel after gas injection is held at 110–130 °C, which is lower than the 160–200 °C melting zone upstream. The die lips are cooled to 105–115 °C to increase melt strength and prevent premature bubble collapse. Chemical blowing agents, typically azodicarbonamide or sodium bicarbonate–citric acid systems, are metered at 0.5–2.0 wt%; azodicarbonamide decomposition is matched to the screw zone where melt temperature exceeds 180 °C. A nucleating agent such as talc is added at 0.5–1.5 wt% to control cell size, with target cell densities between 1×10⁵ cells/cm³ and 1×10⁶ cells/cm³. Density reduction is limited to 20–40 % for stable LDPE foam; higher reductions produce open-cell collapse unless the grade is blended with a high-melt-strength PP or LDPE. The terminal products are protective corner profiles, electronics cushioning, and expanded sealing gaskets. Compliance with REACH is required for blowing agent decomposition residues, and DIN 4102-1 class B2 is typically assessed for construction-related foam profiles. Published data for this specific configuration is limited, so the blowing-agent solubility and cell stability window for NAV104 should be confirmed by pilot-scale foam density trials.
Because cast-film lines operating with LDPE-rich cling layers generate edge trim at 5–10 % of line output, the recycled material is often recompounded with Borealis LDPE NAV104 as a viscosity modifier and gel diluent. The cling layer of pallet-wrap film is typically a blend of LLDPE and LDPE at 5–20 wt% LDPE, with polyisobutylene tackifier at 1–3 phr; the LDPE contributes processability and optical clarity without significantly increasing cling force. Cast-film extrusion uses a flat die with die gap of 0.3–0.6 mm, chill-roll temperature of 18–30 °C, and line speeds above 300 m/min. The low melt strength of LDPE is less critical in cast film than in blown film, but edge stability and die-lip build-up are controlled by maintaining melt temperature below 240 °C and by using low-gel resin. The terminal products are pre-stretched hand wrap, machine wrap for pallet unitisation, and silage films where high cling and puncture resistance are required. Data for the specific recycled-content configuration involving NAV104 is limited, so each converter must validate the edge-trim ratio and tackifier migration under ISO 1133-1:2022 melt-flow stability trials.
| Downstream segment | Standard / regulation | Test method | Controlling limit |
|---|---|---|---|
| Blown film sealant layer | EU 10/2011 | EN 1186-1 | overall migration 10 mg/dm² |
| Extrusion coating | FDA 21 CFR 177.1520 | 21 CFR extraction cells | condition of use A–H |
| Masterbatch for food-contact film | EU 10/2011 | EN 1186-1 | overall migration 10 mg/dm² |
| Foam extrusion | REACH | EN 14582:2016 | SVHC 0.1 wt% |
| Cast film industrial wrap | REACH | article communication duty | 0.1 wt% SVHC threshold |
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Borealis LDPE NAV104 is a commercial low-density polyethylene resin supplied by Borealis AG under the grade designation NAV104. The resin belongs to the high-pressure free-radical polyethylene family, in which ethylene is polymerised at elevated pressure to create a branched molecular architecture. The grade identifier separates NAV104 from adjacent Borealis LDPE products through its melt rheology, density, stabiliser system, and conversion profile. The material is supplied in pellet form and is normally characterised using ISO 1183-1 for density, ISO 1133-1 for melt mass-flow rate, and ISO 527-1/-2 for tensile properties. The current Borealis datasheet is the authoritative source for certified NAV104 values; published data for this specific configuration is limited, and nearby LDPE grades should not be used as a substitute for the NAV104 datasheet. Property categories that are typically reported on the datasheet include melt mass-flow rate at 190 °C under 2.16 kg load, density after annealing, tensile stress at yield, elongation at break, and optical haze or gloss where relevant to the intended conversion route.
Batch-to-batch variability in LDPE grades is assessed by the manufacturer’s release testing. Converters should verify that the certificate of analysis attaches the NAV104 lot number and test date. The melt mass-flow rate is usually measured according to ISO 1133-1 at 190 °C under 2.16 kg load. Density is measured after annealing according to ISO 1183-1. Granule dimensions and bulk density are also relevant to silo discharge and feeder stability. A bridging silo or an unheated outdoor silo can create feed interruptions that appear as extruder surging. Vacuum receivers and hopper level controls should be set to maintain a constant pellet feed. Feed-throat bridging is more frequent with LDPE pellets at high ambient temperatures because pellet surface softening may create agglomerates. A water-cooled feed throat with a jacket temperature below 40 °C is a standard preventive measure on production lines running high-pressure LDPE at high throughput.
High-pressure LDPE extrusion is usually operated with a reverse temperature profile in which the feed zone is set at 140–160 °C, the compression zone at 170–200 °C, and the metering zone and adapter at 200–230 °C. Die temperatures for extrusion coating are typically held between 220 °C and 260 °C to promote adhesion to paper or foil while retaining a stable melt curtain. The exact processing window for NAV104 should be derived from the manufacturer’s processing guide, but the general upper boundary for many peroxide-free high-pressure LDPE resins is 280 °C. Above that threshold, thermal degradation accelerates by free-radical chain scission, producing volatile aldehydes, ketones, and carboxylic acids. These by-products increase smoke generation and may create odour and taint in food-contact films. The melt-temperature rise across a screw should be measured with an immersion thermocouple at the die adapter, not only from barrel setpoints. For a single-screw extruder with an L/D ratio of 30:1 and a barrier screw, the measured melt temperature can exceed the barrel setpoint by 5–15 °C due to viscous dissipation. Processing NAV104 without this measurement can place the melt above the thermal degradation threshold even when barrel settings appear conservative.
The dependence of melt viscosity on shear rate is critical. High-pressure LDPE with long-chain branching exhibits a Carreau-type shear-thinning transition at lower shear rates than a linear polyethylene of similar density. This permits thinner die gaps and higher throughputs without excessive motor load. In industrial practice, the shear-thinning ratio calculated from melt mass-flow rate at 2.16 kg and 10 kg loads is a fast indication of processing breadth. A branched LDPE will generally show a broader shear-thinning ratio than an LLDPE of identical 2.16 kg melt-flow rate. Equipment operators should record head pressure and motor amperage at a fixed screw speed to detect batch-to-batch variations. A melt pressure drift greater than ±5% under steady-state conditions often indicates an additive dispersion problem, recycled-material contamination, or feed inconsistencies.
In high-speed extrusion coating of paperboard and aluminium foil, the melt curtain leaving the flat die is stretched in the air gap. Long-chain branching increases the elongational viscosity of the LDPE melt and resists draw resonance. On lines with a die width of 800–1600 mm and an air gap of 150–300 mm, the neck-in of a high-pressure LDPE curtain is commonly recorded at 30–90 mm per side. For NAV104, published data for this specific configuration is limited; therefore line trials should measure neck-in at three line speeds and at the maximum target coat weight before the production run is approved. Higher melt temperature reduces neck-in but accelerates oxidation and can lower adhesion. Lower melt temperature increases edge waving and can produce pinholes in the coating. The minimum stable coating weight of an LDPE grade is a combined function of melt temperature, air gap, die gap, and polyolefin melt strength. A shift from 15 g/m² to 10 g/m² coating weight may require a die gap reduction from 0.8 mm to 0.5 mm or an increase in melt temperature of 5–10 °C. These changes should be evaluated with differential scanning calorimetry and melt-flow measurements after each trial to ensure that the NAV104 resin has not undergone thermo-oxidative chain scission.
Adhesion of LDPE coatings to aluminium foil is controlled through oxidation at the melt-air interface. A thin oxidised layer at the interface improves polar bonding to metal oxides, but excessive oxidation degrades the polymer backbone and compromises seal strength. For NAV104, the interfacial adhesion should be measured by peeling at 180° using a tensile tester with a constant crosshead speed of 100 mm/min; the test configuration should follow the converter’s internal procedure because no single ISO method covers all foil and paperboard combinations. If peel strength falls below the target value while melt pressure remains stable, the air gap and melt temperature should be checked before the resin is suspected.
Comparative resin classification requires more than density. High-pressure LDPE resins may be produced in tubular or stirred autoclave reactors. Tubular reactors produce a narrower molecular weight distribution and fewer long-chain branches at a given density than autoclave reactors; autoclave materials often have a broader distribution and higher melt elasticity. Linear low-density polyethylene produced with Ziegler-Natta or metallocene catalysts contains essentially no long-chain branching. As a result, LLDPE has lower extensional viscosity and lower melt strength in film and coating processes. The melt strength difference becomes important in extrusion coating, cast film, and blown film. In such operations, an LDPE such as NAV104 can be blended with LLDPE to combine processability with mechanical toughness. Typical LDPE/LLDPE dry blends contain 10–30% LDPE by weight, depending on gauge and line speed. However, published data for the specific NAV104 blend configuration is limited, so pilot-line trials at the converter’s intended die gap and chill-roll temperature are required.
Density and melt mass-flow rate are insufficient to predict performance. The molecular weight distribution, branching index, and thermal history all influence optical haze, dart impact, and tear strength. Converters using NAV104 should compare gel level, haze, and melt pressure against the incumbent LDPE at the same film gauge and die gap. The visible gel count can be assessed with an internal camera system; film haze and dart impact are measured according to ASTM D1003 and ISO 7765-1 or ASTM D1709. Differences in gel level may indicate contamination rather than a true resin difference. Before rejecting a lot, the converter should verify that the change is reproducible on a second production line, because screen-pack condition, die-lip cleanliness, and regrind quality can all affect gel counts.
| Resin class | Density range | Branching architecture | Melt strength | Typical conversion |
|---|---|---|---|---|
| High-pressure LDPE | 0.910–0.940 g/cm³ | long-chain and short-chain branches | high | extrusion coating, blown film, cast film |
| LLDPE | 0.915–0.940 g/cm³ | short-chain branches only | moderate | stretch film, cast film, injection moulding |
| HDPE | 0.941–0.970 g/cm³ | minimal branching | low | blow moulding, pipe, caps |
Blown film conversion of NAV104-type high-pressure LDPE is controlled through the ratio of bubble diameter to die diameter, the frost-line height, and the internal bubble cooling flow. A blow-up ratio above 3.5:1 can reduce transverse direction tear resistance and create gauge variations if the die and air ring are not optimised for the resin. Frost-line heights between 400 mm and 800 mm are common for LDPE films in the 25–100 µm gauge range. Haze is measured according to ASTM D1003, gloss according to ASTM D2457, and dart impact according to ISO 7765-1 or ASTM D1709. Optical values depend on film thickness and cooling rate; a thin film quenched rapidly produces smaller spherulites and lower haze, while a thick film cooled slowly has higher haze. Moisture absorption in polyolefin pellets is low, but condensation on cold pellets can cause surface splay. When bulk handling exposes pellets to relative humidity above 60%, pre-drying in a hot-air hopper dryer at 50–60 °C for 2–4 h is a typical precaution. Exact drying guidance for NAV104 should be confirmed with Borealis.
Heat-seal behaviour is a critical performance boundary for LDPE packaging. The seal-initiation temperature of high-pressure LDPE films typically falls between 88 °C and 120 °C, depending on density, molecular weight, film thickness, and dwell time. NAV104 must be evaluated against a reference film of the same gauge and thermal history because published data for this specific configuration is limited. Heat-seal strength is measured on specimens sealed at fixed jaw temperature, dwell time, and pressure; standardised methods include ASTM F88 and ASTM F2029 for sealability. Hot-tack testing measures the seal strength while the seal is still molten, commonly using ASTM F1921. A resin with a broader melting distribution will often show a wider hot-tack window than a resin with a narrower melting peak.
Rheological stability in the melt is monitored by melt pressure variation and melt temperature stability. A drift of more than ±5% in melt pressure at constant screw speed can indicate a feed inconsistency, a change in regrind level, or a partial blockage of the screen pack. For long extrusion campaigns, the screen-pack pressure drop is logged at 30 min intervals. A rapid increase in pressure before stabilisation often indicates gel formation or carbonised residue; a gradual increase is normal and reflects contamination capture. When a pressure change occurs, the operator should compare the melt mass-flow rate of the incoming NAV104 pellets and the extruded pellets. A loss of more than 10% in melt mass-flow rate indicates molecular degradation or crosslinking and requires shutdown to inspect the screw and die.
Regrind of LDPE films and coatings is introduced to reduce raw-material consumption, but the rheology of regrind differs from virgin pellets because of prior thermal history, printing inks, and possible adhesive residues. At regrind levels below 10% by weight, the effect on melt pressure is usually minor. At 20% or more, the melt pressure at a constant screw speed may shift enough to require recalibration of the feeder and die gap. A gravimetric blending system with a tolerance of ±0.5% by weight is commonly used to control high-value LDPE regrind. The regrind fraction should be free of polyethylene films containing polyvinylidene chloride, aluminium fragments, or high levels of mineral oil because these contaminants can form gels, acid species, or char in the melt. If NAV104 is to be used in a food-contact structure, the regrind must be limited to materials that comply with the same food-contact regulations and must be used only after the converter has validated migration compliance under the applicable EU or FDA provisions.
Cast-film chill-roll conversion of high-pressure LDPE uses lower melt temperatures than extrusion coating and relies on air-knife pinning. The melt curtain is pinned to a polished chromium chill roll maintained at 15–30 °C. In this process, NAV104-type LDPE may be blended with LLDPE in outer layers to obtain puncture resistance. The addition of LDPE improves melt-curtain stability and reduces edge neck-in. The ratio of LDPE in such blends is determined by the target dart impact, tear propagation, and stretch behaviour. Published data for the specific NAV104 blend configuration is limited, so pilot-line trials at the converter’s intended die gap and chill-roll temperature are required.
Regulatory status for NAV104 cannot be assumed from the LDPE polymer class. The manufacturer’s compliance statement should be consulted for food-contact, medical, and toy applications. The resin may be compliant with EU Framework Regulation 1935/2004, the Plastics Regulation 10/2011, and relevant FDA 21 CFR 177.1520 sections if specified by Borealis, but additive packages and conversion conditions influence migration. Users should test finished articles for overall migration and specific migration according to EN 1186 and EN 13130 when the application requires such compliance.
