ExxonMobil Exceed Flow m mLLDPE m 1020.QA Cast
- Product Name: ExxonMobil Exceed Flow m mLLDPE m 1020.QA Cast
- Factroy Site: Yudu County, Ganzhou, Jiangxi, China
- Price Inquiry: sales8@ascent-chem.com
- Manufacturer: Ascent Petrochem Holdings Co., Limited
- CONTACT NOW
- ExxonMobil Exceed Flow m mLLDPE m 1020.QA Cast is typically used in formulations when melt index and density and processing temperatures and line speed must be controlled within specific ranges.
| HS Code | 884537 |
| Density | 0.920 g/cm³ |
| Melt Index 190 C 2 16 Kg | 1.0 g/10 min |
| Melting Temperature Dsc | 116 °C |
| Crystallization Temperature Dsc | 100 °C |
| Vicat Softening Temperature | 91 °C |
| Tensile Strength At Yield | 9.7 MPa |
| Tensile Strength At Break | 30 MPa |
| Elongation At Break | 600% |
| Flexural Modulus | 200 MPa |
| Dart Drop Impact | 200 g |
| Elmendorf Tear Strength Md | 300 g |
| Elmendorf Tear Strength Td | 500 g |
| Haze | 1.5% |
| Gloss 45 | 85 |
As an accredited ExxonMobil Exceed Flow m mLLDPE m 1020.QA Cast factory, we enforce strict quality protocols—every batch undergoes rigorous testing to ensure consistent efficacy and safety standards.
| Packing | ExxonMobil Exceed Flow m mLLDPE m 1020.QA Cast is packaged in 25 kg polyethylene bags, palletized, stretch-wrapped, and shipped in bulk. |
| Container Loading (20′ FCL) | 20′ FCL loaded with ExxonMobil Exceed Flow m mLLDPE m 1020.QA Cast in 25 kg bags, palletized, shrink-wrapped, and secured. |
| Shipping | ExxonMobil Exceed Flow m mLLDPE m 1020.QA Cast is a non-hazardous polyethylene resin, shipped as solid pellets in 25 kg bags or 500–1000 kg octabins. Transport in dry, clean vehicles at ambient temperature; keep containers sealed and palletized. Avoid moisture, contamination, direct sunlight, and excessive heat. Not DOT/IMDG/IATA regulated. |
| Storage | Store ExxonMobil Exceed Flow m mLLDPE m 1020.QA Cast in a cool, dry, well-ventilated area away from direct sunlight, heat, sparks, and flames. Keep original containers or bags closed to prevent moisture, dust, and contamination. Avoid excessive stacking and prolonged UV exposure. Maintain clean, segregated storage. Do not store near strong oxidizers. Follow the manufacturer’s SDS and local regulations. |
| Shelf Life | No specific shelf life is assigned; stable under normal storage conditions. Store cool, dry, away from sunlight and incompatible materials. |
In cast stretch film converting, ExxonMobil Exceed Flow mLLDPE m 1020.QA Cast is dry-blended or coextruded into A/B/C structures where the core controls gauge uniformity and the skins carry the cling additive. The grade’s nominal melt index of 1.0 g/10 min measured according to ISO 1133-1 and density of 0.920 g/cm³ measured according to ISO 1183-1 set a melt temperature requirement of 240–270°C for cast film. A representative 3-layer die configuration at 2.4 m die width uses a 50 µm die lip, 120 mm air gap, and chill roll temperature of 22°C. The formulation typically combines 70–85 wt% mLLDPE with 10–20 wt% LLDPE and 5–10 wt% LDPE; the LDPE fraction raises melt strength and reduces neck-in during drawdown but begins to depress dart impact and MD tear resistance above 15 wt%. Polyisobutylene cling concentrate is added to the two skins at 0.5–2.0 wt% total PIB, and antiblock is included at 0.1–0.3 wt% in the outer skin to control reel blocking. The film is processed at 20–30 µm with a pre-stretch ratio of 200–300% on pallet-wrapping equipment. At 250% pre-stretch, the MD tensile target under ASTM D882 is commonly above 35 MPa; elongation at break is measured above 400%. Puncture resistance under ASTM D5748 is a critical predictor of wrapped-load integrity on irregular pallet edges, and dart impact under ASTM D1709 is preferred over creased paperboard corners. Cling force is quantified by ASTM D5458 on a 25 mm strip; a stable wrapper runs with cling force in the 120–250 g range after unwinding forces are accounted for. One operational boundary is the pre-stretch limit: exceeding 300% on older power pre-stretch units without closed-loop tension control produces transverse thickness variation and localized fibrillation at the film edge, because the mLLDPE long-chain branching content is low and the neck-in response becomes time-dependent at high line speed. Converters moving above 400 m/min should select a die with internal deckle seals that reduce edge bead oxidation and avoid edge trim reintroduction above 30% regrind, as gel accumulation on the chill roll surface degrades cling consistency.
Why do cast lamination sealant webs replace a blown LLDPE on vertical form-fill-seal lines?
The substitution is driven by hot-tack performance and seal initiation temperature. A cast mLLDPE sealant web with thickness 25–40 µm is prepared on a single-screw extruder with a 30:1 L/D screw and barrier mixing section, using a melt temperature of 230–260°C and a 0.8–1.2 mm die gap. The extrudate is drawn onto a matte chill roll at 18–24°C, which controls crystal nucleation and preserves low haze after lamination to BOPP or PET. The sealant layer is normally blended with 5–15 wt% LDPE to raise web stiffness and reduce blocking on rewind; adding more than 20 wt% LDPE shifts seal initiation temperature upward by 8–12°C, measured under ASTM F1921, and this may move the seal window outside the dwell time available on a vertical form-fill-seal jaw set to 0.3–0.6 s. The target seal initiation temperature for the mLLDPE-rich blend is 92–105°C; hot tack strength at 110°C and 0.5 s dwell is evaluated at a seal pressure of 0.275 MPa to ensure the pouch can hold product weight before the seal cools. Seal strength is tested after cooling under ASTM F88 with a 25 mm strip; values above 12 N/25 mm are typical for 30 µm film at 120°C and 0.5 s. The converter qualified the structure under EU Regulation 10/2011, Annex I and FDA 21 CFR 177.1520(c); a migration limit of 10 mg/dm² total is applied to the food-contact sealant layer. Slip and antiblock concentrates are limited to 0.05–0.15 wt% erucamide and 0.2–0.5 wt% synthetic silica, since excess slip migrates to the adhesive lamination surface and reduces dry-bond peel strength measured under ASTM D1876. The cast web is also corona-treated inline to 42–48 mN/m; treatment decay below 38 mN/m before lamination produces adhesive wet-out defects visible as speckle after metallization.
Cast hygiene backsheet lines running at 250–350 m/min impose a different set of constraints: the web is embossed, corona-treated, and adhesively laminated to a polypropylene nonwoven within the same converting pass. A breathable backsheet structure often uses a filled core containing 45–60 wt% calcium carbonate masterbatch in a mLLDPE carrier; the outer skin is an unfilled mLLDPE blend with 10–20 wt% LDPE to provide thermal stability during embossing. The 20–25 µm cast film is stretched in the machine direction by 150–250% after casting to create micropores in the filled core, giving a moisture vapor transmission rate measured under ASTM D6701 between 2,000 and 5,000 g/m²·24 h depending on filler level and stretching ratio. The mLLDPE skin is monitored with an inline camera-based surface inspection system calibrated to detect defects larger than 200 µm; a count of fewer than 10 particles/m² is typical for this grade because visible gels in the skin are rejected on printed or tinted diaper backsheets. Tensile strength in the MD after stretching is evaluated under ISO 527-3, and the film is conditioned at 23°C and 50% RH for 40 h before testing. The cast grade’s narrow melting distribution allows the embossing roll to run at 85–105°C without sticking, while the polypropylene nonwoven is introduced at a nip pressure of 3–7 N/mm. The laminated structure is tested for laminate peel strength under ASTM D1876; targets above 1.5 N/25 mm are required to avoid delamination in high-motion waistbands. For medical-grade hygiene films, ISO 10993-5 cytotoxicity testing may be required on the final laminated stock, and the raw material documentation should confirm compliance with REACH Regulation 1907/2006, Annex XVII entries for phthalate-free and heavy-metal restrictions.
Surface protection cast webs and the role of gel screening in electronics applications
Surface protection films coextruded for display and appliance masking require a transparent backing layer with controlled low adhesion. The structure consists of a backing layer of mLLDPE blended with 5–15 wt% LLDPE and a tie layer, with an adhesive skin based on ethylene-vinyl acetate containing 18–28 wt% VA or a polyolefin plastomer tackified with 3–8 wt% aliphatic hydrocarbon resin. The adhesive layer thickness is 5–15 µm, while the total film is 30–60 µm. Cast film lines used for this application run at 150–300 m/min with a 0.7–1.0 mm die gap and a polished chill roll at 16–20°C; the low roll temperature reduces post-crystallization haze and preserves the required clarity under ASTM D1003 below 5%. Gel content in the backing layer is controlled by filter packs with mesh sizes down to 100 µm, and gel counts are verified on take-off samples using a camera-based surface inspection system with 100 µm resolution. A gel protrusion in a 30 µm film used on a display surface can transfer a visible mark under peel, so converters reject reels with gel counts above 20 particles/m² for gels larger than 300 µm. Adhesion to stainless steel is measured under ASTM D3330 with a 180° peel at 300 mm/min; the target is typically 0.1–0.5 N/25 mm for light protection and 1.0–3.0 N/25 mm for appliance masking. Higher adhesion demands a thicker EVA skin, but the VA content above 28 wt% can exude and leave adhesive residue after 60°C aging for 72 h, a failure mode observed when the cast web is wound at tension above 60 N/m. The backing layer tensile modulus at 1% secant under ASTM D882 is maintained below 120 MPa to avoid edge curl during die-cutting.
| Cast film segment | Regulatory/standards matrix | Critical measured parameter |
|---|---|---|
| Machine stretch film | ASTM D882, ASTM D5748, ASTM D5458, FDA 21 CFR 177.1520 | Pre-stretch 200–300%; cling force 120–250 g/25 mm |
| Lamination sealant web | ASTM F1921, ASTM F88, EU 10/2011, FDA 21 CFR 177.1520(c) | Seal initiation 92–105°C; hot tack at 110°C/0.5 s |
| Hygiene backsheet laminate | ISO 527-3, ASTM D6701, ISO 10993-5, REACH 1907/2006 | MVTR 2,000–5,000 g/m²·24 h; gel count <10 particles/m² at 200 µm |
| Surface protection film | ASTM D1003, ASTM D3330 | Haze <5%; peel adhesion 0.1–3.0 N/25 mm |
| Agricultural silage wrap | ISO 4892-2, ASTM D5748, ASTM D3985, EU 10/2011 | UV retention ≥70% at 1,500 h; pre-stretch 55–70% |
| Heat-seal lamination replacement | ASTM F1921, ASTM F88, ASTM F1140 | Seal initiation 92–100°C; burst 50 kPa |
| Fresh produce overwrap | ASTM D1003, ISO 527-3, EU 10/2011 | Haze <3%; elongation >500% |
Because agricultural silage wrap is applied with pre-stretch in the field, the cast film is conditioned at 23°C and 50% RH for 24 h before bale-wrapper trials. Agricultural stretch silage film is converted at 25 µm nominal thickness and 500–750 mm reel width; the cast film line uses a 2.7 m die, 1.0 mm die gap, and air gap of 90–150 mm to balance edge neck-in and MD orientation. The formulation includes 85–92 wt% mLLDPE, 5–10 wt% LLDPE, and a UV masterbatch dosed to give 0.5–1.0 wt% hindered amine light stabilizer active. PIB cling concentrate is added to both skins at 0.8–2.0 wt% total PIB, and the film is wound on paper cores with a taper tension of 15–25 N/m to prevent blocking in field storage. UV resistance is assessed under ISO 4892-2 using a xenon-arc source at 0.35 W/m² at 340 nm; the film is required to retain at least 70% of its initial MD tensile strength after 1,500 h exposure. Dart impact under ASTM D1709 and slow-puncture under ASTM D5748 are used as field-performance indicators, because bale wrap failure is most often triggered by stubble puncture during handling rather than tensile overload. The wrapper applies 55–70% pre-stretch; higher pre-stretch above 80% on some wrappers reduces overlap consistency and leads to oxygen ingress at the bale shoulder. The oxygen transmission rate of the 25 µm film at 23°C and 0% RH is measured under ASTM D3985, with typical values around 3,000–5,000 cm³/(m²·24 h·atm); this is sufficient to maintain anaerobic silage fermentation when combined with 6–8 film wraps. The resin lot must comply with EU Regulation 10/2011 migration limits if the film may be sold in the EU, and the UV masterbatch must not contain substances restricted under REACH Annex XVII, particularly those migrating to silage moisture at low pH.
When a cast sealant web replaces blown LLDPE in heat-seal lamination
The replacement of a blown LLDPE with a cast mLLDPE sealant web changes the heat-seal response of the final laminate. In a duplex structure of 12 µm PET adhesive-laminated to 30 µm cast mLLDPE, the sealant layer is corona-treated to 44–48 mN/m and the adhesive coat weight is controlled at 2.5–3.5 g/m² dry. The seal initiation temperature drops from 105–115°C for the blown LLDPE to 92–100°C for the cast mLLDPE, allowing the packaging line to reduce jaw temperature by 10–15°C or increase throughput by 20–30%. Hot tack measured under ASTM F1921 at 105°C and 0.3 s dwell is higher for the mLLDPE, but the plateau hot-tack window narrows; below 90°C seal strength drops rapidly, and above 125°C the seal bar can displace molten polymer and cause edge thinning. The laminate is tested for seal strength under ASTM F88 after 24 h conditioning; a target of 15 N/25 mm at 120°C and 0.5 s dwell is used for dry food pouches, while liquid-filled pouch validation adds a burst test under ASTM F1140 at 50 kPa internal pressure. The lower melt temperature of the cast sealant web requires that the laminating adhesive cure be complete before heat sealing; residual isocyanate in a solventless adhesive can react with erucamide from the sealant and produce a brittle interfacial layer. Converters therefore limit erucamide to 0.05–0.10 wt% and specify a slip system based on silica only for retort or hot-fill structures. The final laminate is compliant with FDA 21 CFR 177.1520(c) and EU Regulation 10/2011, but the specific migration of the adhesive component must be covered under the adhesive manufacturer’s declaration; the polyolefin layer itself is generally accepted without additional migration testing when the total extractives limit of 2.0% in 21 CFR 177.1520(c)3.1 is met.
A low-haze cast overwrap for fresh produce is produced on a line where the chill roll is kept at 16–18°C and the die gap is set to 0.6–0.8 mm to minimize crystallite size and maximize clarity under ASTM D1003. The 15–20 µm film is formulated with 95–98 wt% mLLDPE and 2–5 wt% LDPE; the LDPE improves bubble stability if the converter also runs a blown line, but on a cast line the LDPE fraction is kept low to maintain the haze target below 3%. Antifog additive is incorporated at 0.2–0.5 wt% through a concentrate; without antifog, condensation droplets form on the film surface at 4°C and reduce visibility of the packaged leafy greens. The film is perforated in-line after casting using a needle roll with 40–80 holes/100 cm², and oxygen permeability through the perforated area is calculated from hole geometry rather than measured under ASTM D3985 alone. The tensile elongation at break under ISO 527-3 is maintained above 500% to withstand automatic wrapping stretch without tearing at the tray corners. Slip additive is dosed at 0.02–0.08 wt% erucamide; higher slip reduces film-to-film friction below the level needed for stable tray wrapping. The film is certified for food contact under FDA 21 CFR 177.1520(c) and EU Regulation 10/2011, and the antifog concentrate must be selected from permitted substances listed in 10/2011 Annex I with a specific migration limit below 10 mg/dm².
Competitive ExxonMobil Exceed Flow m mLLDPE m 1020.QA Cast prices that fit your budget—flexible terms and customized quotes for every order.
For samples, pricing, or more information, please contact us at +8618005193850 or mail to sales8@ascent-chem.com.
We will respond to you as soon as possible.
Tel: +8618005193850
Email: sales8@ascent-chem.com
Get Free Quote of Ascent Petrochem Holdings Co., Limited
Flexible payment, competitive price, premium service - Inquire now!
- ExxonMobil Exceed Flow m mLLDPE m 1020.QA Cast 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.
ExxonMobil Exceed Flow m mLLDPE m 1020.QA Cast is a metallocene-catalyzed linear low-density polyethylene grade supplied as a pelletized resin for cast film extrusion. Supplier literature identifies the nominal density as 0.920 g/cm³ when tested in accordance with ASTM D792-20 and a melt index of 1.0 g/10 min when determined at 190°C/2.16 kg under ASTM D1238-20. The product belongs to the Exceed Flow m family, in which metallocene single-site catalysis narrows both molecular weight distribution and short-chain branching distribution relative to Ziegler-Natta LLDPE. The term “Cast” in the grade designation directs the resin to chill-roll cast film lines, where the melt curtain is extruded through a flat die and quenched on a cooling roll; this process differs from blown film in cooling rate, orientation balance, film optics, and seal performance. The “QA” suffix is associated in supplier documentation with a package specified for cast film contact, including additive selection for surface performance during unwind and downstream converting.
Primary application positions include industrial stretch film, silage wrap, hygiene film, and monolayer or coextruded food packaging where gel count and optical defects must be controlled. The melt index of 1.0 g/10 min is selected for a balance between extruder motor load and melt-curtain integrity; the density of 0.920 g/cm³ contributes to the toughness and stress-cracking response expected in thin cast film. Because the product is a metallocene resin, its shear rheology differs from that of a conventional LLDPE of identical melt index: lower shear thinning raises back pressure in deep-channel screws and can require adjustments in barrel temperature profile and die gap. The product is typically used in coextrusion with polypropylene, LDPE, or adhesive tie layers. Published data for the specific final film properties of this grade is limited, and lot-specific technical data sheets should be consulted before final equipment configuration.
What Molecular Weight and Comonomer Distribution Effects Are Measurable in Cast Film?
Metallocene catalysis produces a narrower molecular weight distribution and a more regular comonomer incorporation than conventional multi-site catalysts. For a cast film resin of 0.920 g/cm³ density, the measurable consequences appear in haze, gloss, dart impact, Elmendorf tear, and seal initiation temperature. The relevant test methods are ASTM D1003-21 for haze, ASTM D2457-21 for 60° gloss, ASTM D1709-16a for dart drop impact, ASTM D1922-15 for Elmendorf tear, and ASTM F88/F88M-21 for seal strength. In metallocene LLDPE cast films, the narrower distribution reduces the number of high-molecular-weight tails that contribute to micro-gels and optical defects. This permits lower melt temperatures during extrusion and improves the sealing window because the melting range is narrower.
The short-chain branching distribution is significant because comonomer placement controls the concentration of tie molecules between crystallites. In a metallocene resin, comonomer units are distributed more uniformly along the chain, which increases the fraction of load-bearing tie molecules at a given density. Under ASTM D1709-16a, this translates into higher dart impact values in thin films than a Ziegler-Natta LLDPE of the same density and melt index; under ASTM D1922-15, tear balance often shifts toward higher transverse-direction tear when the film is drawn in the machine direction because differentiated orientation is less dependent on broad chain-length distribution. However, the exact numerical values for m 1020.QA Cast are not available in the public summary. Film properties depend on die gap, chill roll temperature, line speed, and draw ratio. Published data for this specific configuration is limited, and the direction of property changes should not be used as a substitute for lot-specific film testing.
On a cast film line configured with a 75 mm single-screw extruder, 30:1 L/D barrier screw, and a 1500 mm flat die, the processing response of Exceed Flow m mLLDPE m 1020.QA Cast is governed by the melt viscosity at shear rates from 10 to 1000 s⁻¹. The grade’s melt index of 1.0 g/10 min provides a reference point for flow, but the low shear-thinning character of metallocene LLDPE means that extruder head pressure at constant screw speed is typically higher than a conventional LLDPE of equal melt index. This behavior is documented in polymer processing literature for metallocene LLDPE; batch-to-batch variation and specific extruder geometry influence the magnitude. The practical consequence is that operators may need to raise barrel temperatures in the feed and compression zones by 5°C to 15°C while keeping the metering zone and die temperatures below the threshold at which oxidative gel formation accelerates.
Melt temperature at the die exit is a critical process parameter. For cast film, a lower melt temperature reduces cooling load and improves chill-roll release, but if the melt temperature falls below approximately 210°C, the high-viscosity components may not fully homogenize, causing streak defects and unstable melt curtain. If the melt temperature exceeds 280°C, particularly with prolonged residence time in stagnation zones at the die, oxidative degradation and crosslinking can produce gel particles that appear as specks in thin film. The die gap is often set between 0.5 mm and 1.2 mm for cast film; for this grade, the gap should be selected with consideration of the draw ratio and the air gap. A shorter air gap, commonly 10 mm to 50 mm, improves melt curtain stability and reduces neck-in, but excessively short gaps can trap air between the melt and the chill roll.
Chill roll temperature influences haze and blocking. In production-scale cast film lines, chill roll temperatures for metallocene LLDPE are commonly maintained between 15°C and 35°C, but the optimum depends on line speed and the specific additive package. Lower chill roll temperatures increase quench rate and reduce crystal size, which tends to improve optical clarity; however, condensation at high ambient humidity can cause surface defects if the roll temperature falls below the dew point. Published data for this specific grade’s cooling-roll response is limited, but the QA package is specified for cast film contact and generally includes slip and antiblock additives to control coefficient of friction and rewinding behavior. The line should be purged with the grade at a low screw speed before ramping to target throughput because metallocene LLDPE can retain previous resins in dead spots and produce cross-contamination gels.
When the Grade Is Coextruded With Polypropylene Skin Layers or LDPE Seal Layers
Coextrusion structures place the mLLDPE in core layers where its puncture resistance and tear strength contribute to film performance, while skin layers of polypropylene or LDPE provide heat resistance or sealability. In a three-layer A/B/A cast line, the mLLDPE core is often processed in the middle extruder, and the skin layers are run at different melt temperatures. Polypropylene skin layers generally require melt temperatures 230°C to 260°C, whereas the mLLDPE core can be run at 220°C to 250°C; the combined melt streams must arrive at the feedblock within a viscosity window that prevents interfacial instability. Interfacial instability is observed as wavy or layer-thickness nonuniformity and is more likely when the viscosity ratio between skin and core at the die shear rate deviates significantly from 1:1. Because Exceed Flow m mLLDPE m 1020.QA Cast has a narrow molecular weight distribution, its viscosity at a given shear rate is more sensitive to temperature than a conventional LLDPE. Skin and core temperature settings should be adjusted using rheology data from ISO 11443 or capillary rheometry rather than melt index alone.
For LDPE skin layers, the lower melting point and higher melt strength of LDPE can improve edge stability and reduce neck-in; however, LDPE and mLLDPE have different crystallization rates, and cooling from the melt on a single chill roll can induce curl if the skin layers are unbalanced. In production-scale cast film, curl is controlled by balancing skin-layer crystallinity, die temperatures, and chill-roll contact time. Published data for the coextrusion of m 1020.QA Cast with LDPE at high line speeds is limited; pilot-line trials are required to establish the exact process window for each die width and cooling configuration.
Food Contact and Industrial Packaging Compliance Boundaries
The product is a polyolefin and may be covered by food-contact regulations when processed appropriately. In the United States, olefin polymers used in contact with food may be evaluated under 21 CFR 177.1520; the relevant subparagraph depends on the density and final use conditions, and finished articles must be tested for extractives and end-use suitability. In the European Union, materials intended for food contact must comply with Regulation (EU) No 10/2011, including the overall migration limit of 10 mg/dm² and specific migration limits for any additives. The product is manufactured under chemical control systems aligned with REACH Regulation (EC) No 1907/2006, and the supplier safety data sheet provides hazard and exposure information. For industrial packaging, compliance with RoHS Directive 2011/65/EU is not a resin property but may be required for electrical and electronic equipment packaging; packaging specifications should be verified with the supplier for the specific lot and production site.
| Requirement | Designation | Test or Certification Boundary |
|---|---|---|
| Melt index | ASTM D1238-20 | 190°C, 2.16 kg |
| Density | ASTM D792-20 | Solid resin, specified conditioning |
| Food contact, US | 21 CFR 177.1520 | Finished article end-use test |
| Food contact, EU | EU No 10/2011 | Overall migration ≤ 10 mg/dm² |
| Tensile film test | ASTM D882-18 | Machine and transverse direction specimens |
| Dart impact | ASTM D1709-16a | Method A or B based on film thickness |
| Elmendorf tear | ASTM D1922-15 | Notched film specimen |
| Haze | ASTM D1003-21 | Film sample, standard illuminant |
Direct substitution of Exceed Flow m mLLDPE m 1020.QA Cast for a conventional Ziegler-Natta LLDPE of the same nominal melt index and density changes the cast film extrusion process and the final film property balance. Conventional Ziegler-Natta LLDPE has a broader molecular weight distribution and a heterogeneous comonomer distribution; this broad distribution provides greater shear thinning and lower extruder head pressure, but it also raises gel count and optical haze. Under ASTM D1003-21, metallocene LLDPE cast films generally show lower haze than Ziegler-Natta films of equal density and thickness because the reduced high-molecular-weight tail limits surface irregularities and because the narrower comonomer distribution produces smaller crystallites. The trade-off appears in extrusion: the mLLDPE can require higher torque at equal screw speed and may be more difficult to purge from dead spots.
Compared with non-flow Exceed metallocene LLDPE grades of similar density, the Flow m designation indicates a molecular architecture designed for lower melt viscosity at processing shear rates. This can allow lower die temperatures or increased throughput on a given cast film line. However, a lower-viscosity resin can reduce melt curtain strength, increasing neck-in if the air gap is not adjusted. Operators should not interpret the higher flow as equivalent to a lower-density or lower-molecular-weight product; the melt index remains 1.0 g/10 min, but the viscosity curve is shifted relative to a non-flow mLLDPE by the molecular design. Published data for the exact viscosity curve of m 1020.QA Cast is limited; capillary rheometry according to ISO 11443 should be used to construct shear viscosity master curves for die and feedblock design.
Compared with metallocene plastomers of lower density, the 0.920 g/cm³ density provides higher crystallinity and greater stiffness, which can improve web handling and reduce blocking. Compared with high-density polyethylene cast films, this product provides lower stiffness and lower seal initiation temperature, making it suitable for sealable layers and puncture-resistant structures. Each substitution requires verification of the final film’s tensile properties according to ASTM D882-18, tear according to ASTM D1922-15, and seal strength according to ASTM F88/F88M-21, because film performance is not a direct translation of pellet properties.
What Operational Boundaries Are Observed on High-Output Cast Lines?
High-output cast film lines operating above 300 m/min impose additional constraints on melt curtain stability, air gap turbulence, and winding. For Exceed Flow m mLLDPE m 1020.QA Cast, the melt index of 1.0 g/10 min is a compromise between extruder flow and curtain stability; at high line speeds, a longer air gap or a lower melt temperature may be required to prevent draw resonance. Draw resonance is a periodic thickness variation in the melt curtain that occurs when the draw ratio exceeds a critical value; for metallocene LLDPE, the narrower molecular weight distribution can narrow the stable draw ratio window relative to branched LDPE. The critical draw ratio is not a single resin property but depends on die gap, chill roll distance, melt temperature, and line speed. Published data for this specific grade at line speeds above 300 m/min is limited; pilot-line trials are required.
Winding and roll quality are also influenced by the QA package. At high speed, the film must transfer from the chill roll to the winding section without blocking or wrinkles; slip and antiblock additives in the QA designation reduce coefficient of friction and maintain roll hardness. The coefficient of friction is tested according to ISO 8295 or ASTM D1894-14, but the required value depends on the converting process. A coefficient of friction that is too low can cause roll telescoping; a value that is too high can cause blocking. The additive package is not a substitute for proper winding tension, and production lines must maintain a taper tension profile to avoid gauge bands. For food contact applications, the specific migration of processing aids and slip additives must be verified under EU No 10/2011 or the applicable national regulation.
