Lotte Chemical HDPE HIVOREX FL7000 is a high-molecular-weight high-density polyethylene blown-film resin intended for thin-gauge flexible packaging applications such as T-shirt grocery sacks, high-strength refuse sacks, and industrial liners. Manufacturer-published data list a nominal density of 0.949 g/cm³ determined by ASTM D1505 and a melt flow rate of 0.04 g/10 min at 190 °C under a 2.16 kg load determined by ASTM D1238 or ISO 1133-1:2022. The combination of low melt flow rate and density places the product in the high-molecular-weight HDPE film class rather than in medium-molecular-weight HDPE grades with melt flow rates near 0.7 g/10 min, which are more typical of thick-sheet or low-melt-strength extrusion. The product is distinguished from LLDPE film resins by higher stiffness and higher melting temperature, and from conventional monomodal HDPE film grades by a broader molecular weight distribution that contributes to high-stalk bubble stability. Published data for this specific configuration is limited where the application involves coextruded layers with high melt-index polyolefins; qualification is therefore required on the production line.
The resin is processed almost exclusively in high-stalk blown film lines equipped with grooved-feed extruders and die heads designed for high-molecular-weight polyolefins. In such lines, the molten stalk above the die is intentionally elongated before expansion; this configuration requires sufficient melt strength to prevent stalk sag and bubble instability. The low melt flow rate of HIVOREX FL7000 provides that melt strength, while the 0.949 g/cm³ density reduces film stiffness relative to 0.952 g/cm³ HDPE film grades. That density difference is small but measurable in low-gauge sacks where machine-direction secant modulus and bag-opening behavior of stacked merchandise are evaluated. On production lines using grooved-feed extruders, the feed zone is typically not cooled, because the grooved barrel section uses forced conveying and does not rely on frictional heat generation in the feed pocket. Screw designs with a barrier melting section and a Maddock mixing element are commonly specified for high-molecular-weight HDPE. Output stability is controlled by melt-pressure instrumentation; pressure excursions can occur if the screen pack becomes blinded, and a final screen-pack configuration is normally selected to hold die pressure within the limits specified by the die manufacturer.
What Melt Fracture and Bubble Stability Phenomena Distinguish HMW-HDPE Film Grades?
High-molecular-weight HDPE film grades such as HIVOREX FL7000 exhibit a narrower processing window for sharkskin and melt fracture on conventional blown film dies, but a wider stable-stalk window, because the long-chain fraction increases melt relaxation time and zero-shear viscosity. On a grooved-feed extruder with a screw diameter of 60 mm and a length-to-diameter ratio of 30:1, melt temperature is typically held between 204 °C and 232 °C at the die. Lower melt temperatures increase back pressure and can generate sharkskin on the inner bubble surface, while higher temperatures reduce melt strength and destabilize the stalk. The onset of gross melt fracture in an annular die is influenced by output rate, die gap, and melt temperature. For this grade, die gaps below 1.0 mm are generally avoided because the high melt viscosity elevates die-head pressure; specific pressure limits must be confirmed with the die manufacturer.
Blow-up ratios above 5:1 can produce asymmetric thickness profiles and bubble flapping unless an internal bubble cooling control system is used. Blow-up ratios below 3:1 reduce transverse orientation and may lower dart impact resistance. The recommended window therefore reflects a compromise between melt fracture limits at the die and bubble stability limits above the frost line. Capillary rheometry according to ISO 11443 is used to characterize the shear-rate dependence of the melt; however, resin-specific viscosity curves are not always published. Converters generally establish the acceptable temperature and die-gap window through production-scale bubble stability trials and gauge variation mapping.
Thin-gauge T-shirt sack production at 12–15 µm thickness uses dart impact resistance tested by ASTM D1709 Condition A, Elmendorf tear tested by ASTM D1922, and tensile properties tested by ASTM D882. In commercial blown film operations, the grade is typically run at die gaps of 1.2–1.8 mm and blow-up ratios of 3.5:1 to 4.5:1; the high-stalk bubble is maintained with the frost line height between 8 and 12 die diameters. These conditions promote balanced orientation, reduce gauge variation, and permit downgauging from 18 µm to 12 µm in selected bag styles. Published data for this specific configuration is limited for online gauge variability; however, extrusion equipment builders specify the same parameter window for similar high-molecular-weight HDPE film resins.
Molecular Weight Distribution and Its Impact on Down-Gauging Versus LLDPE
Compared with linear low-density polyethylene film grades, HIVOREX FL7000 provides higher 1% secant modulus and tensile yield strength but lower Elmendorf tear and puncture resistance at equivalent thickness. Typical high-molecular-weight HDPE film of this density class exhibits machine-direction 1% secant modulus values above 600 MPa, while a butene LLDPE film with a density of 0.918 g/cm³ generally falls below 250 MPa when measured according to ASTM D882. This stiffness difference allows HDPE film to be downgauged in applications where bag-opening force, inherent stand-up, and yield strength are the controlling performance measures. The trade-off is lower extensibility; LLDPE typically exhibits higher elongation at break and better resistance to slow puncture.
| Variable | HIVOREX FL7000 | Medium-MW HDPE film resin | Butene LLDPE film resin |
|---|---|---|---|
| Nominal density | 0.949 g/cm³ | 0.952 g/cm³ | 0.918 g/cm³ |
| Melt flow rate, 190 °C/2.16 kg | 0.04 g/10 min | 0.7 g/10 min | 1.0 g/10 min |
| Typical blown film die gap | 1.2–1.8 mm | 0.8–1.5 mm | 1.0–2.5 mm |
| High-stalk blow-up ratio | 3.5:1–4.5:1 | Not typical | 2.0:1–3.0:1 |
The choice between HIVOREX FL7000 and an LLDPE-rich blend is therefore governed by the desired film stiffness, heat resistance, and downgauging potential. In refuse sacks requiring higher tear propagation resistance, converters may blend FL7000 with LLDPE at 10–30 wt%; the blend retains stiffness while increasing machine-direction Elmendorf tear according to ASTM D1922. Higher LLDPE addition levels beyond 50 wt% shift the bubble toward a low-stalk configuration and reduce the benefit of the high melt strength of the HDPE fraction.
In practice, the replacement of a medium-molecular-weight HDPE film resin with HIVOREX FL7000 on an existing low-stalk line is not straightforward. The low MFR increases extruder torque at the same screw speed, and the die gap must be opened from 0.8 mm to at least 1.2 mm to prevent die-lip deposits and melt fracture. If a converter attempts to run this grade on a conventional low-stalk bubble configuration with a short frost line, the bubble may become unstable because the high-molecular-weight fraction requires a longer relaxation distance. A transition to a high-stalk configuration with the frost line height moved to 8–12 die diameters is usually required. These equipment differences are among the main operational distinctions between this product and lower-viscosity HDPE film grades.
When Coextruded Layer Ratios Are Shifted Below 20 wt% in Blown Film Lines
In multi-layer coextruded sack films, HIVOREX FL7000 is commonly assigned to the core layer to provide gauge control, stiffness, and melt strength. When the core layer is reduced below 20 wt%, the blown bubble may lose dimensional stability if the skin layers are high-melt-index LLDPE grades. The interfacial viscosity ratio between a 0.04 g/10 min HDPE core and a 1.0 g/10 min LLDPE skin can induce interfacial waviness, particularly in spiral mandrel dies with long flow paths. Layer ratios between 40 wt% and 70 wt% for the HDPE core are therefore more common in commercial production.
When the core layer is used at lower loadings, die design becomes more important. Spiral mandrel geometries with a barrier length selected for high-viscosity melts reduce layer non-uniformity; melt-temperature differences between extruders should be maintained below 10 °C to avoid interfacial instability. In five-layer lines, placing LDPE-rich skins next to the core can reduce melt strength mismatch because LDPE has a broader molecular weight distribution and lower viscosity than LLDPE. However, LDPE skin layers also reduce film stiffness and may require an increase in HDPE core thickness to maintain the targeted 1% secant modulus measured by ASTM D882.
Interfacial instabilities are often first visible as narrow bands of haze at the boundary between the core and skin layers. This is not an inherent resin defect; it is a flow instability caused by viscosity mismatch and layer ratio. When the viscosity ratio exceeds 3:1 between adjacent melts, layer thickness uniformity can deteriorate even though the individual resins are within specification. Therefore, coextrusion trials should include cross-direction thickness mapping at 10° intervals around the bubble and haze measurement according to ASTM D1003 to detect incipient waviness before commercial production.
For food-contact packaging and other regulated markets, converters must verify the finished film against the relevant olefin polymer specifications. The base polyethylene may meet the general requirements of FDA 21 CFR 177.1520(c) for high-density polyethylene intended for food contact, but compliance of the final article depends on the additive masterbatches and processing aids used. In the European Union, migration testing under Regulation (EU) No 10/2011 and overall compliance with Regulation (EC) No 1935/2004 are required before use in food-contact bags. REACH substance registration is governed by Regulation (EC) No 1907/2006.
| Regulation/Standard | Designation | Scope |
|---|---|---|
| US food contact | 21 CFR 177.1520(c) | Olefin polymer specifications for high-density polyethylene |
| EU food contact | Regulation (EU) No 10/2011 | Plastic materials and articles intended to come into contact with food |
| REACH | Regulation (EC) No 1907/2006 | Substance registration, evaluation, and authorisation |
| US packaging heavy metals | CONEG TPCH | Heavy metals limits in packaging |
Drying is not normally required for this high-density polyethylene under closed silo storage at ambient relative humidity below 60%. Pellets that have been exposed to refrigeration or cold-weather transport should be brought to ambient temperature before conveying to prevent surface condensation and slip-agent migration issues. The resin is not recommended for continuous immersion in strong oxidizing acids, aromatic or chlorinated hydrocarbons, or for long-term outdoor exposure without carbon black or UV stabilizer. In service, the upper continuous-use temperature is limited by the same oxidative degradation pathways common to all HDPE grades; extended exposure above 100 °C in air is not recommended unless the article is tested under the relevant end-use standard.
The Density Difference Between 0.949 g/cm³ and 0.952 g/cm³ Is Not the Only Variable in Heavy-Duty Sack Design
High-strength refuse sacks and heavy-duty industrial liners produced from HIVOREX FL7000 are often specified at thicknesses from 60 µm to 150 µm, where the lower density of 0.949 g/cm³ provides a slight reduction in stiffness relative to 0.952 g/cm³ HDPE. More important for sack integrity are the molecular weight, molecular weight distribution, and orientation induced during blown film extrusion. Environmental stress crack resistance is evaluated according to ASTM D1693 Condition B in a 10% Igepal CO-630 solution; high-molecular-weight HDPE grades of this class typically exhibit F50 values above 100 h, although resin-specific values require confirmation from the supplier.
Puncture resistance is often measured by ASTM D5748 for stretch-wrap-film-like loading, or by a slow puncture probe method according to DIN 53369 for sacks and liners. Heavy-gauge film containing 2.0–2.5 wt% carbon black masterbatch is commonly used for refuse sacks and agricultural-grade liners; the carbon black loading provides ultraviolet stabilization when the film is dispersed outdoors. The addition of carbon black also reduces gloss and increases heat absorption, which must be considered in hot-climate warehouse storage. Published data for this specific configuration is limited for long-term outdoor performance, so qualification under ASTM D2565 xenon-arc exposure or ISO 4892-2 is recommended for UV-stabilized products.