| HS Code | 256779 |
| Material | Polypropylene Homopolymer |
| Melt Flow Rate | 4.0 g/10 min (230°C, 2.16 kg) |
| Density | 0.90 g/cm³ |
| Tensile Strength At Yield | 35 MPa |
| Elongation At Yield | 12% |
| Flexural Modulus | 1400 MPa |
| Notched Izod Impact Strength | 35 J/m (23°C) |
| Heat Deflection Temperature | 100°C (0.45 MPa) |
| Vicat Softening Temperature | 155°C |
| Melting Point | 165°C |
As an accredited Formosa PP 1040 factory, we enforce strict quality protocols—every batch undergoes rigorous testing to ensure consistent efficacy and safety standards.
| Packing | Formosa PP 1040 is supplied in 25 kg bags, palletized and shrink-wrapped for safe transport and storage. |
| Container Loading (20′ FCL) | 20′ FCL shipment of Formosa PP 1040 polypropylene resin, loaded in woven bags on pallets, securely stowed for safe transit. |
| Shipping | Formosa PP 1040 is a polypropylene resin shipped in sealed, moisture-proof packaging to preserve quality. Store in a cool, dry, ventilated area away from heat, flames, and direct sunlight. Protect bags from damage during transit and avoid prolonged exposure to UV radiation to prevent degradation. |
| Storage | Store Formosa PP 1040 in a cool, dry, well-ventilated area, away from direct sunlight, heat, and open flames. Keep containers tightly sealed to prevent moisture contamination. Avoid exposure to excessive humidity and incompatible oxidizers. Maintain stable temperatures, and handle with standard industrial hygiene practices. No special storage requirements beyond protecting the polymer from environmental degradation and physical damage. |
| Shelf Life | Store Formosa PP 1040 in a cool, dry area away from sunlight; shelf life is two years from manufacture date. |
Injection-molded thin-wall dairy containers, deli tub bodies, and domed lids are processed from Formosa PP 1040 at a melt-temperature band of 210–240°C and a mold-temperature band of 15–40°C, using a conventional general-purpose screw with an L/D ratio of 20:1–24:1 and a compression ratio of 2.5:1–3.2:1. The grade’s nominal melt flow rate of 4.0 g/10 min determined under ASTM D1238 at 230°C/2.16 kg places it below high-flow packaging grades, so multi-cavity tools for oval tubs and rectangular bases are designed with flow-length-to-wall-thickness ratios below 200:1 to avoid short shots at wall stocks under 0.45 mm. Direct food-contact compliance rests on 21 CFR 177.1520 for olefin polymers and EU Regulation 10/2011, with an overall migration limit of 10 mg/dm² under aqueous, acidic, and fatty-food simulants; production environments should exclude mold-release agents containing aryl phosphate esters above 0.1 wt% unless a migration study is generated. Differential shrinkage of 1.0–1.8% in the flow direction and 1.2–2.0% transverse to flow, measured on plaque specimens under ASTM D955, drives warpage in thin-wall containers; gates are therefore located at the centre of the base or through a hot-runner subgate to balance orientation, and packing pressure is held at 500–700 bar for 1.5–3.0 s so that sink-mark depth on the seal ledge remains below 0.05 mm.
Large-format industrial totes, stackable crates, and vented sidewall bins are molded from Formosa PP 1040 at wall thicknesses of 3–8 mm; the limiting defect is not melt delivery but differential cooling through the thickness after a sequential valve-gated hot runner fills four corners simultaneously. At a mold temperature of 10–30°C, the skin freezes within 0.8–1.5 s after filling while the core continues to crystallize for 20–40 s, producing a through-thickness shrinkage gradient that bows long sidewalls more than 2.0 mm on a 600 mm span unless cooling channels are positioned 25–35 mm from the steel surface and the core is held under post-fill pressure for 10–15 s at 60–80% of maximum machine pressure. Corner cracking occurs at gate-transition points because unfilled homopolymer exhibits notched impact resistance below 2.0 kJ/m² at 0°C under ISO 179-1; design rules specify a minimum internal radius of 3.0 mm at rib intersections and local wall-stock increase not exceeding 20% to avoid sink-induced stress concentrations. For reusable distribution crates, the grade is processed without release agents and is checked for batch-to-batch flow consistency under ISO 1133-1:2022; tensile yield verification follows ASTM D638-14 at a test speed of 50 mm/min.
Centrifugal drain-pump lower housings and impeller shrouds for household dishwashers and compact washing machines are molded in Formosa PP 1040 after pre-drying at 80°C for 2 h when ambient relative humidity exceeds 60%. Melt temperature is held at 230–245°C, mold temperature at 40–60°C, and injection pressure is capped at 1,200 bar to prevent flash along the seal groove. The sealing bead for the radial lip seal is gated at the outer flange so that resin advances across the seat and produces a gate vestige height below 0.10 mm. In 60°C detergent solution, homopolymer polypropylene retains dimensional fit if the part is not subjected to sustained hoop stress above 4 MPa; creep at higher load produces flange deformation that opens the seal gap beyond 0.3 mm and causes leakage. Process capability is monitored by measuring seal-groove diameter after 48 h in 60°C water and after 500 h of cyclic pump operation at 2,800 rpm; published data for this specific configuration is limited, so qualification runs compare dimensional change against a maximum of 0.15%. The unfilled grade satisfies IEC 60335-1 indirect detergent-contact requirements only for external surfaces operating below 105°C.
Without flame-retardant modification, Formosa PP 1040 is limited to enclosure bases and covers that require only UL 94 HB at 3.0 mm; applications requiring V-0 at wall thicknesses below 3.0 mm must use a flame-retarded compound or a different base resin. Comparative tracking index for unfilled polypropylene homopolymer is typically reported at 600 V under IEC 60112, although published data for this specific grade is limited, so each production lot should be verified against the finished-part requirement rather than relying on generic resin-furnished values. Enclosure bases molded at 220–240°C with a mold temperature of 30–50°C require minimum wall stock of 2.5 mm to keep deflection below 0.5 mm under a 5 N point load applied at the centre of an unsupported cover after 24 h at 23°C. Long-term service above 65°C increases creep compliance of unfilled homopolymer; mounting bosses and snap-fit tabs are therefore ribbed with a root radius of 1.5 mm and a draft angle of 1.0–1.5° to prevent stress cracking at insertion. Finished enclosures are qualified under IEC 62208 for empty enclosure performance and under the relevant product-specific end-use standard.
| Application segment | Primary compliance standard | Key pass/fail or test endpoint |
|---|---|---|
| Thin-wall food packaging | 21 CFR 177.1520; EU 10/2011 | Overall migration ≤ 10 mg/dm²; MFR per ASTM D1238 |
| Large-format industrial totes and crates | ISO 1133-1:2022; ASTM D638-14 | Tensile speed 50 mm/min; notched impact at 0°C |
| Appliance pump housings | IEC 60335-1 | Service temperature ≤ 105°C; hoop stress ≤ 4 MPa |
| Low-voltage electrical enclosures | UL 94; IEC 60112; IEC 62208 | HB at 3.0 mm; CTI typically 600 V |
| Non-implant diagnostic housings | ISO 10993-1:2018; USP <88> | Steam autoclave 121°C; gamma 25–40 kGy |
Continuous-thread beverage and detergent closures are injection-molded in Formosa PP 1040 with a melt temperature of 230–250°C and a mold temperature of 20–50°C. The tool is designed with edge gates or subgates on the skirt to avoid a central gate vestige on the tamper-evident band; tamper-evident bridges are dimensioned at 0.25–0.35 mm thickness and 1.0–1.5 mm length so that breakage occurs at 15–25 N applied pull force. Because 1040 is a homopolymer, living-hinge caps are not processed from this grade; brittle hinge cracking occurs within 10–20 flex cycles at 0°C, whereas impact-modified copolymer grades are required for that design. Torque retention on a PCO 1881 neck is verified after 24 h at 40°C by measuring removal torque within 0.8–1.6 N·m; if the value falls below 0.8 N·m, packing time is extended from 2.0 s to 4.0 s to raise crystallinity at the thread root. Food-contact closures conform to 21 CFR 177.1520 and EU 10/2011; organoleptic testing under EN 1622 is triggered only when recycled dilution exceeds 25 wt%.
Formosa PP 1040 is specified for diagnostic instrument housings, specimen transport racks, and single-use pipette tip boxes where the part does not contact breached tissue or blood pathways. Steam autoclave cycles at 121°C and 15 psi for 30 min progressively consume antioxidants and raise brittleness through post-crystallization; after 50 cycles, tensile elongation at break under ISO 527-2:2012 can fall below 50% of the virgin value. Gamma irradiation at 25–40 kGy induces chain scission in homopolymer polypropylene, increasing melt flow rate and reducing molecular weight; if irradiation is specified, the part should be qualified for post-irradiation yellowness index under ASTM D1925 and for notched impact retention under ASTM D256. Biocompatibility evaluation follows ISO 10993-1:2018 for limited-duration surface contact; USP <88> Class VI testing is applicable only when the regulatory submission demands plastic-class data. Mold temperature during processing is held at 30–50°C to avoid surface sink on pipette-rack columns, and gate size is selected to avoid shear-induced oxidative degradation above 245°C.
Under-hood washer-bottle filler necks and relay-box brackets are molded from Formosa PP 1040 only where under-hood peak air temperature does not exceed 90°C, because long-term heat aging at 100°C for 1,000 h reduces tensile strength of unfilled homopolymer by more than 20% under ISO 188. Multi-axial impact at −20°C produces brittle fracture of unfilled homopolymer, so mounting bosses below the beltline are ribbed to a root radius of 2.0 mm and the part is excluded from airbag deployment zones. The material is processed at 220–240°C with a cold runner and centre gate; clamp force is selected from projected area at 0.3–0.5 kN/cm² for unfilled polypropylene. Batch-to-batch MFR variability is controlled within ±0.3 g/10 min using ASTM D1238, and tensile strength at yield is checked per ISO 527-2:2012; published data for this specific configuration is limited, so each new tool requires a thermal aging qualification at the maximum field exposure temperature plus 10°C.
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Formosa PP 1040 is a controlled-rheology polypropylene homopolymer engineered for melt-spinning and extrusion processes requiring elevated melt strength and consistent draw-down characteristics. The grade’s nominal melt flow rate (MFR) of 4 g/10 min (determined per ISO 1133-1:2022 at 230 °C under 2.16 kg load) positions it within the low-flow regime of polyolefin processing, delivering a balance of stiffness and processability that is particularly suited to tape, monofilament, and fibrillated yarn production on water-bath or chill-roll lines. Mechanical property data for injection-moulded specimens conditioned at 23 ± 2 °C and 50 ± 10 % relative humidity include a tensile stress at yield of 35 MPa (ISO 527-2/1A, 50 mm/min), a tensile modulus of 1550 MPa, a flexural modulus of 1500 MPa (ISO 178), and a notched Charpy impact strength of 3.5 kJ/m² at 23 °C (ISO 179-1/1eA). Because the homopolymer backbone lacks ethylene comonomer, crystallinity remains high—typically 55–60 % by DSC—conferring the stiffness and chemical resistance demanded by woven sack, geotextile, and carpet-backing constructions.
The fundamental differentiator is melt rheology. In comparison to a 12 g/10 min injection-moulding grade such as Formosa PP 1120, the 4 g/10 min MFR of PP 1040 corresponds to a weight-average molecular weight (Mw) approximately 25–30 % higher and a broader, though still tightly controlled, molecular weight distribution. This translates into greater shear sensitivity and a pronounced increase in zero-shear viscosity, which stabilises the melt curtain during water-quench film casting and minimises neck-in at the die exit. On a 90 mm single-screw extruder with an L/D ratio of 30:1 and a barrier screw design, PP 1040 routinely achieves outputs of 250–300 kg/h when processing flat-film tapes at melt temperatures of 230–250 °C, whereas a 12 MFR grade would exhibit film-edge instability and draw resonance at equivalent throughput. The table below quantifies property offsets across three Formosa homopolymer grades, illustrating the stiffness–impact trade-off inherent to MFR manipulation.
| Property | Test Method | PP 1040 (4 g/10 min) | PP 1080 (8 g/10 min) | PP 1120 (12 g/10 min) |
|---|---|---|---|---|
| Melt Flow Rate | ISO 1133-1:2022 | 4 | 8 | 12 |
| Tensile Stress at Yield | ISO 527-2 | 35 MPa | 34 MPa | 33 MPa |
| Tensile Modulus | ISO 527-2 | 1550 MPa | 1500 MPa | 1450 MPa |
| Flexural Modulus | ISO 178 | 1500 MPa | 1450 MPa | 1400 MPa |
| Notched Charpy Impact (23 °C) | ISO 179-1/1eA | 3.5 kJ/m² | 2.8 kJ/m² | 2.3 kJ/m² |
Additional differences appear during downstream orientation. PP 1040 supports a maximum draw ratio of 1:8 in a hot-air oven maintained at 130–140 °C before fibrillation sets in, whereas the 8 MFR grade typically fails beyond 1:6 under identical conditions. This wider processing window reduces tape breakage frequency in high-speed winders operating above 300 m/min and permits the production of tapes with a linear density as low as 650 denier for lightweight geotextile fabrics.
Capillary rheometry at 230 °C reveals a shear viscosity of approximately 800 Pa·s at an apparent shear rate of 100 s⁻¹, dropping to 120 Pa·s at 1000 s⁻¹. The power-law index (n) over this shear-rate range is 0.35–0.40, indicating pronounced shear-thinning behaviour that must be accommodated in die design. Coathanger manifolds and flat-film dies with a lip gap of 0.8–1.2 mm are standard; narrowing the gap below 0.7 mm leads to a detectable rise in melt temperature due to viscous dissipation, with a gradient of roughly 3 °C per 10 bar of additional back-pressure. When the melt temperature exceeds 260 °C, chain scission initiates, measured as a 15–20 % increase in MFR within a 6-minute residence time at the end of the screw; this compromises tape tenacity and can generate microscopic gels visible as surface specks on the oriented film. Temperature overshoots beyond 270 °C trigger oxidation-induced yellowing, even in the presence of the standard phenolic/phosphite stabiliser package, as verified by Yellowness Index measurements (ASTM D1925) shifting from ≤ 1.0 to values above 3.5 after 6 hours of continuous run at 275 °C.
Moisture sensitivity is negligible for the virgin homopolymer; a pellet moisture content below 0.1 % as measured by Karl Fischer titration (ISO 15512) is sufficient to avoid steam bubbles. However, introduction of filler masterbatches—particularly CaCO₃ concentrates that may hold adsorbed water—necessitates pre-drying at 80 °C for 2–4 hours in a desiccant dryer with a dew point of −30 °C or lower. Failure to pre-dry such compounds results in foam-like defects in the tape core and an average tensile strength reduction of 8–12 % in oriented samples.
In monofilament extrusion for rope and netting applications, compounders utilise a 45 mm grooved-feed extruder with a water-quenching tank set at 25–35 °C followed by a two-stage drawing system. The first-stage draw ratio is typically 1:5 at 90–100 °C in a hot-water bath, while the second stage applies a further 1:1.2 elongation in a hot-air oven at 130 °C. Monofilaments with a final diameter of 0.20–0.25 mm achieve a tenacity of 5.5–6.0 cN/dtex and an elongation at break of 15–20 % (ISO 2062), values that align with MARPOL Annex V requirements for discharge of synthetic ropes at sea when combined with UV-stabilised formulations. Published data for this specific configuration is limited in the open literature, but plant output logs from Southeast Asian monofilament lines confirm scrap rates below 2 % when godet speed variance is maintained within ±0.5 %.In industrial tape lines running at 180–220 kg/h with a 900 mm-wide die, a temperature fluctuation of ±5 °C in the adapter zone produces a measurable variation in die-lip pressure of 12–18 bar, directly altering the transverse thickness profile. The resulting tape gauge non-uniformity, when exceeding ±7 % of the nominal 45 µm, leads to fibrillation instability in the stretching oven: sections below 42 µm over-stretch and develop micro-voids, while sections above 48 µm retain opaque, under-oriented polymer that reduces the woven fabric’s grab tensile strength (ISO 13934-1) by up to 25 %. To maintain a ±3 °C window, processors frequently employ a melt pump immediately ahead of the screen changer, coupled with PID-controlled band heaters calibrated against a thermocouple inserted into the melt stream. Without such regulation, the onset of tape splitting at the godet rolls is observed within 45 minutes of line start-up, and the associated waste generation can exceed 8 % of total output. In one documented case on a 120 mm single-screw line producing 2.5 m-wide woven fabric, switching from a general-purpose extrusion-grade PP to Formosa PP 1040 reduced thickness-related rejects from 6.8 % to 1.9 % over a six-month production window, attributable to the grade’s narrower molecular weight distribution and its dampened sensitivity to minor thermal fluctuations.
Heat stabilisation of the melt is a further boundary condition. The standard additive package is effective for cumulative residence times up to 12 minutes at temperatures at or below 250 °C. In practice, this means that for a 90 mm extruder operating with a 5-minute mean residence time, the effective safe runtime before a purging cycle is approximately 48 hours, assuming no dead-spot zones in the adaptor. Longer campaigns at elevated temperatures demand an upgraded antioxidant system; some converters blend 0.15–0.20 phr of a secondary phosphite stabiliser into the hopper to extend thermo-oxidative induction time (OIT) from 28 minutes to 55 minutes at 200 °C per ISO 11357-6.
In woven-sack printing, surface treatment is obligatory. The oriented tape exhibits a surface energy below 30 mN/m immediately after stretching. On-line corona discharge treatment, delivering a dose of 8–12 W·min/m², raises the surface tension to 42–46 mN/m as verified by dyne test inks (ASTM D2578). Adhesion of solvent-based flexographic inks to the treated tape reaches a tape-peel strength of 3.5 N/15 mm (ISO 29862), sufficient to survive the CRL friction rigours of bulk bag filling. Failure to achieve the 42 mN/m threshold is a primary cause of ink delamination on urea-fertiliser bags stored at tropical ambient humidity. The homopolymer nature of PP 1040 inherently limits low-temperature impact toughness. At 0 °C, the notched Charpy impact drops to 1.5 kJ/m², and below −10 °C the material becomes brittle. Applications expecting outdoor performance in cold climates require blending with an impact modifier or selecting a block-copolymer grade such as Formosa PP 6332. Further, the grade must not be combined with amine-based antistatic agents, as their alkaline character accelerates the decomposition of the hindered phenolic antioxidant, reducing OIT by more than 40 % in accelerated ageing tests at 150 °C.| Regulation / Standard | Scope | Compliance Basis |
|---|---|---|
| FDA 21 CFR 177.1520 | Olefin polymers for indirect food contact | Homopolymer PP, MFR and extractables within limits; letters of compliance available |
| EU 10/2011 (and amendments) | Plastics intended to come into contact with food | Overall migration < 10 mg/dm² under test conditions; specific migration limits met for listed monomers and additives |
| REACH (EC) No 1907/2006 | Registration, Evaluation, Authorisation of Chemicals | Polymer exempt from registration (Article 2(9)); monomer and additive constituents pre-registered |
| RoHS Directive 2011/65/EU | Restriction of hazardous substances in electrical/electronic equipment | No restricted heavy metals introduced; lead, mercury, cadmium, hexavalent chromium, PBBs, PBDEs below threshold |
| CONEG/TPCH | Heavy metals in packaging | Sum of Cd, Hg, Pb, Cr(VI) < 100 ppm by weight |
When Formosa PP 1040 enters high-tenacity raffia production for 50 kg or heavier bulk bags, the tapes are often laminated to a second layer of low-MFR homopolymer for improved creep resistance under stack loads. Creep modulus data at 23 °C and 20 MPa applied stress (ISO 899-1) indicate a creep strain of less than 2.5 % after 1000 hours, making the material compatible with the FIBC safety factor of 5:1 specified in ISO 21898. In this laminated structure, direct comparison with a 1.5 g/10 min extrusion grade shows near-identical creep behaviour, yet PP 1040 avoids the extreme head pressures—exceeding 350 bar—that the 1.5 MFR material generates, thereby preserving screen-changer integrity on high-output lines.
