Borealis Queo VLDPE 1007 is introduced into the sealant skin of three-layer coextruded blown-film structures at 10–20 wt% of the skin layer, while the remainder is a C₈ LLDPE with a density of 0.918–0.925 g/cm³ and an MFR of 1.0 g/10 min. The plastomer has a nominal density of 0.910 g/cm³ (ISO 1183-1) and an MFR of 7.0 g/10 min (ISO 1133-1, 190°C/2.16 kg), which lowers seal initiation by 8–12°C relative to a pure LLDPE sealant and permits seal-bar dwell times below 0.3 s on vertical form-fill-seal equipment. On a 400 mm three-layer blown-film line equipped with internal bubble cooling, a die gap of 1.8 mm, melt temperature 185–200°C, blow-up ratio 2.2–2.5, and frost line height 700–900 mm, the formulation raises dart impact energy measured under ASTM D1709 method A and puncture propagation resistance under ASTM D5748. Above 20 wt% addition, shear viscosity mismatch between the plastomer and the LLDPE matrix can destabilise the bubble, producing variation in frost line height and gauge bands; the operator compensates by increasing internal bubble cooling air flow or reducing screw speed. Food-contact compliance is established under FDA 21 CFR 177.1520(c) for olefin polymers and under Commission Regulation (EU) No 10/2011 Annex I with an overall migration limit of 10 mg/dm². When the packaged matrix is a fatty or acidic simulant, a coextruded barrier layer is inserted to keep the sealant within the specified migration condition. Terminal product forms are hermetically sealed flexible pouches, frozen-food films, and lamination sealant webs for stand-up pouches.

What Changes When Queo VLDPE 1007 Replaces Conventional EPDM in Injection-Grade TPO Compounds?

Compounding trials on a 40:1 L/D co-rotating twin-screw extruder with a 10-barrel temperature profile from 180°C at the feed zone to 220°C at the die show that replacement of 5–25 wt% EPDM with Queo VLDPE 1007 shifts instrumented puncture failure under ISO 6603-2 from brittle crack growth to yielding, but requires screw-speed reduction to 350–450 rpm to avoid pellet fines caused by the lower melt viscosity. Formulation addition is defined as 5–25 wt% in a PP block-copolymer matrix with 0.1–0.3 wt% of a primary hindered phenolic antioxidant and 0.1–0.2 wt% of a phosphite secondary antioxidant. The resulting TPO compound must meet volatile organic compound limits under VDA 278 and, for electrical or electronic components, Directive 2011/65/EU with lead, mercury, cadmium, hexavalent chromium, PBB, and PBDE thresholds at 0.1 wt% or 0.01 wt% for cadmium. Injection moulding is performed at a melt temperature of 200–230°C, mould surface temperature 30–60°C, and clamp force sufficient to maintain a cavity pressure of 40–60 MPa. Terminal product forms include automotive bumper fascia, lower rocker panels, interior glove-box doors, and appliance housings. In thin-wall interior parts, a mould-flow-balance audit is required because the high MFR of Queo 1007 reduces filling pressure at a faster rate than the EPDM it replaces, which can shift weld-line location and alter impact failure under ISO 6603-2.

In halogen-free flame-retardant sheathing compounds, Queo VLDPE 1007 is compounded as a partial replacement for the ethylene-vinyl acetate fraction at 30–50 wt% of the total polymer phase, alongside precipitated or surface-treated aluminium trihydrate at 55–65 wt% of the total compound and a silicone processing aid at 0.5–1.5 wt%. The production constraint is thermal: aluminium trihydrate releases water of crystallisation at approximately 190–220°C, while the compound must still achieve homogeneous filler dispersion. A Buss MX 70 reciprocating single-screw kneader with a 15–20 L/D ratio and a screw temperature profile of 120–150°C is preferred over a long co-rotating twin-screw extruder because shear heating can exceed 180°C in poorly vented configurations. Total volatile condensates and acid gas evolution are tested under IEC 60754-1/-2, smoke density under IEC 61034-2, and tensile properties after ageing under IEC 60811-501. The addition of Queo 1007 improves low-temperature flexibility as measured by cold bend at −40°C under IEC 60811-504, but a processing window above 170°C can initiate premature aluminium hydroxide dehydration and surface porosity. Terminal product forms are single-core and multi-core control cable sheaths, building wire insulation for flame-retardant installations, and fibre optic distribution cable jackets.

When Machine-Direction Puncture Propagation Determines Pallet-Unit Load Integrity

Cast stretch film formulations introduce Queo VLDPE 1007 at 15–25 wt% into a C₆/C₈ LLDPE backbone having a density of 0.917–0.920 g/cm³ and an MFR of 3.5–4.5 g/10 min. The production equipment is a single-screw cast film line with a 75–100 mm barrier screw, slot die, melt temperature 245–270°C, and a chill-roll temperature of 15–20°C. At line speeds above 350 m/min, melt resonance and edge neck-in are controlled by the higher melt flow of Queo 1007, but over-dilution above 30 wt% lowers the yield point and increases permanent set. Cling performance is tested according to ASTM D5458, puncture propagation by ASTM D5748, and tensile elongation at break by ASTM D882. Regulatory compliance is confined to general chemical safety under REACH (EC) No 1907/2006. Where the film is used as a temporary protective layer on imported machinery or appliances, the importer verifies that the film does not contain substances of concern above the 0.1 wt% cut-off established under REACH Article 33. Terminal forms are hand pallet wraps, pre-stretched machine film, and silage bale wrap for agricultural containment.

Aseptic Liquid-Packaging Extrusion Coating: Neck-In Reduction and Seal-Through-Perforation Resistance

For aseptic liquid packaging extrusion coating, Queo VLDPE 1007 is blended into low-density polyethylene extrusion coating at 20–30 wt% for deposition onto paperboard in liquid packaging. The coextrusion coating line uses a 35:1 L/D single-screw extruder, an internal deckle width of 800–1200 mm, and a melt temperature of 285–320°C to promote oxidation adhesion to the polyboard substrate; the addition rate is limited by fume generation at the die exit above 320°C. Neck-in measured from die width to coated width is reduced by 15–25% relative to a straight LDPE control, but published data for this specific configuration is limited and line-specific die-lip geometry dominates. Compliance is governed by FDA 21 CFR 176.170(c) for paper and paperboard components, EU No 10/2011 for food contact plastics, and ISO 1133-1:2022 for incoming melt flow control. Corona treatment is held at 42–46 mN/m before winding to ensure sealant-layer lamination adhesion. Terminal products are gable-top carton sealants, paper cups, and paper-based sachet laminates for beverage and dairy filling lines.

Rotomolding Impact Modification Versus Wall-Thickness Uniformity in Low-Flow LLDPE Bases

Dry-blended Queo VLDPE 1007 at 10–30 wt% with a rotomolding-grade LLDPE having an MFR of 3–6 g/10 min and a density of 0.934–0.940 g/cm³ raises low-temperature impact under ISO 6603-2 without shifting the optimum peak internal air temperature beyond 195–210°C. The process is conducted in a biaxial carousel machine with an oven dwell of 15–25 min and a forced-air cooling phase of 10–20 min; cooling rates above 10°C/min produce warpage in double-walled parts. Because the density of Queo 1007 is lower than the LLDPE base, particle segregation in dry blending is observed if the plastomer pellet is larger than 3 mm or if blend free-fall discharge exceeds 2 m; grind-mix or extrusion compound feed is applied when wall-thickness variation measured by ultrasonic gauge exceeds ±10%. Compliance for potable water tanks uses NSF/ANSI 61, for general chemical containers uses UN/DOT packaging group requirements, and for toys uses EN 71-3 migration limits. Terminal products include agricultural spray tanks, recreational kayaks, insulated food transport boxes, and deep-freeze storage containers.