Extrusion blow moulding of automotive fuel tanks from Tosoh HDPE HMS100 is executed on an accumulator-head machine with a 120 mm grooved-feed single-screw extruder at a 24:1 to 30:1 L/D ratio, because the resin’s high molecular weight provides parison stability during hang times exceeding 60 s. The melt temperature at the die bushing is held between 200°C and 220°C; the die gap is opened from 2.0 mm to 6.0 mm during parison extrusion to compensate for swell. HMS100 is dosed as the continuous matrix at 100 phr of the olefinic polymer phase for the outer and inner layers of six-layer barrier tanks; carbon black masterbatch is added at 0.5–2.0 phr and a hindered phenolic/phosphite stabilizer package at 0.05–0.15 phr. In tanks requiring hydrocarbon permeation resistance, a middle ethylene-vinyl alcohol copolymer barrier layer is coextruded at 2.0–4.0% of total wall thickness, with maleic anhydride-grafted polyethylene tie layers at 0.5–1.5% on either side. Compliance is demonstrated under UN ECE R34, including the fire resistance test of Annex 5, supplemented by ASTM D638-22 tensile yield and ASTM D256-23 notched Izod impact tests on cut plaques. Production-scale bottlenecks include chime-wall thinning below 2.5 mm at the joint transition and pin-flash tearing when the mould temperature falls below 12°C; the preferred mould shell temperature is 12–18°C with cooling water at 6–10°C. Blow air pressure is set to 0.6–1.0 MPa, clamp force between 150 and 400 tons, and total cycle time for a 60 L tank ranges from 120 to 200 s. The unit fails as a monolayer barrier under LEV III/China 6 evaporative emission limits if coextrusion is omitted. Terminal parts include 55–100 L gasoline and diesel fuel tanks, SCR urea reservoirs, and integrated fuel-filler spout bodies.

For UN 1H1/Y1.9/250 tight-head drums, the HMS100 fraction is introduced as the virgin resin stream at 100 phr, with carbon black masterbatch at 2.0–2.5 phr for ultraviolet stabilization and zinc stearate internal release at 0.05–0.10 phr; regrind from flash and rejected drums is reintroduced at up to 30 phr only after passing melt filtration through a 120/80/60 mesh pack. The process uses a 90 mm single-screw extruder with a 30:1 L/D barrier screw and an accumulator-head blow moulder; melt temperature is maintained at 190–210°C, while the parison programmer deploys 15–30 position points to increase wall thickness at the top chime and bottom chime to 4.0–5.0 mm and keep mid-sidewall at 1.8–2.2 mm. Blow pressure is 0.7–1.0 MPa, mould temperature is 8–15°C, and post-extrusion cooling is extended until the pinch weld reaches 60°C before demoulding. Type approval requires drop testing from 1.2 m at -18°C onto the side seam, chime, and closure in accordance with Chapter 6.1.5 of the UN Model Regulations, plus stacking tests at 50°C to verify no deformation beyond specified limits. ASTM D2463-23 establishes puncture resistance under static load, while ASTM D256-23 notched Izod provides quality assurance on specimens cut from the sidewall. A recurrent production failure mode is seal-area thinning at the flash line when the accumulator head is operated beyond a 70% shot capacity; limiting shot utilisation to 55–70% of the head volume preserves wall uniformity. Terminal products include 120 L, 200 L, and 220 L open-head and tight-head drums for liquid chemicals, viscous resins, and hazardous preparations requiring UN packaging certification.

Flat-die sheet extrusion of HDPE geomembrane with HMS100 as the primary binder is carried out on a 150 mm single-screw extruder with a 30:1 L/D barrier screw and a continuous belt screen changer; melt temperature entering the die is held at 215–235°C to limit gel-phase defects from the high molecular weight tail. The formulation adds carbon black masterbatch at 2.0–3.0% total carbon black by mass, a hindered phenolic/phosphite antioxidant package at 0.05–0.2 phr, and a polymer processing aid at 0.01–0.05 phr; recycled resin is excluded when GRI GM13 conformance is specified. The melt exits a flat die with restricted tees and a choker bar into a three-roll calendering stack heated to 60–90°C; thickness is controlled from 0.75 mm to 3.0 mm by beta-gauge feedback and bolt-adjustable die lips. Draw ratio is held at 1.05–1.15 between die exit and cooling roll to minimise frozen-in orientation that would otherwise lower stress-crack resistance. Quality assurance uses ASTM D1505-18 for density, ASTM D1238-23 for melt flow ratio stability, ASTM D6693-22 for wide-width tensile, ASTM D5397-20 for single-point notched constant tensile load, and ASTM D4218-20 for carbon black content. A known processing boundary is the tendency for the high molecular weight resin to form sharkskin at melt temperatures below 210°C; increasing the die-lip temperature to 225°C and maintaining a 1.15:1 draw ratio suppresses the defect. Terminal products are single-ply HDPE geomembranes in 1.0 mm, 1.5 mm, 2.0 mm, and 3.0 mm thicknesses for municipal solid waste landfill basal and capping liners, mining heap-leach pads, evaporation ponds, and coal-ash impoundment liners.

Heavy-gauge thermoforming of HMS100 begins with sheet extrusion at 8–15 mm thickness on a 120 mm single-screw extruder with a 30:1 L/D screw and a vertically adjustable flexible-lip sheet die; melt temperature is 200–220°C and roll-stack temperature is 70–90°C to eliminate internal vacuum voids. The formulation is 100 phr HMS100 with regrind at 10–30 phr, an external lubricant package at 0.05–0.1 phr, and 0.5–1.0 phr colour masterbatch if opaque black or grey sheet is specified. Sheet surface temperature at the thermoformer is monitored by infrared pyrometer and must fall within 165–190°C before vacuum is applied; top and bottom quartz ovens are set to 210°C and 190°C respectively, and sheet sag is limited to 5–10% of the clamp-frame span to prevent excessive wall thinning. The mould is aluminium, temperature-controlled at 35–55°C, and the vacuum system is pulled to 0.05–0.08 MPa within 1.5 s; draw ratios are constrained to 1.2:1–2.0:1 for reusable load-bearing parts. Test data are generated under ASTM D638-22 for tensile yield, ISO 6603-2:2018 for multi-axial impact puncture, and ASTM D2582-21 for puncture-propagation tear. When deep pockets exceed 150 mm, plug-assisted pre-stretch is required to bring the minimum corner thickness above 2.0 mm; otherwise corner puncture under cyclic returnable-packaging handling occurs. Terminal product forms include automated automotive body-in-white dunnage trays, returnable separator pallets for camshaft and battery modules, and heavy-gauge tote liners used in sequenced parts delivery.

In agricultural chemical storage, large horizontal tanks are converted from HMS100 on accumulator-head blow moulders with a 150 mm grooved-feed extruder at a 30:1 L/D ratio and a first-in, first-out accumulator head sized for 10–30 kg shots. HMS100 is charged at 100 phr as the structural resin, with carbon black masterbatch at 2.0–2.5 phr for outdoor service and a hindered amine light stabilizer at 0.10–0.25 phr; filler, plasticizer, and recycled post-consumer resin are excluded from the wall compound for ASTM D1998-21 conformance. The melt temperature at the die is 190–210°C, parison programming uses 20–40 points to maintain a 3.0–4.0 mm bottom wall and 2.5–3.0 mm sidewall, mould temperature is 8–15°C, and clamp force for a 1,200 L horizontal tank is 400–800 tons. Internal blow pressure is 0.6–1.0 MPa, with an internal air-cooling sequence that begins at 60°C wall temperature and reduces tank bowing after demoulding; total cycle time ranges from 300 to 600 s depending on shot mass. The production-scale limitation is the risk of pinch-off tail weld cracking when the flash is trimmed below 15°C; trimming at 20–25°C after a 10-minute cooling rest reduces this. Terminal products are 600–1,500 L agricultural sprayer tanks, fertiliser injection tanks, seed-treatment mix tanks, and fresh water transport tanks mounted on trailed or skid platforms.

When rectangular chemical process tanks are fabricated from extruded HMS100 sheets instead of rotomoulded polyethylene, the resin is first extruded into 10–25 mm thick sheets on a single-screw extruder with a 30:1 L/D barrier screw, at a melt temperature of 200–220°C, then rough-planed with a carbide-tipped router to remove surface oxidation before welding. The sheet formulation is 100 phr HMS100, with 0.05–0.1 phr processing stabilizer and no mineral filler; welding rod is produced from the same resin batch to avoid melt-flow mismatch at the fusion interface. Panel joining is performed by hot-gas extrusion welding at 210–230°C with a 4–5 mm weld shoe at a travel speed of 250–400 mm/min, and by heated-tool butt fusion at 200–220°C with a bead-up pressure of 0.15 ± 0.03 MPa. Weld tensile performance is validated by ISO 13953:2001, and the finished tank undergoes a 24-hour hydrostatic test at 110% of service pressure. Compliance for stationary welded tanks refers to DVS 2207-1 for hot-gas welding and DVS 2203-4 for penetrant testing; chemical resistance is confirmed by immersion testing per ISO 175:2010 against the stored electrolyte or etchant. A notable fabrication boundary is that weld protrusion above 3 mm on the internal wall creates crevices where chloride solutions accumulate; grinding the weld bead flush is mandatory for electroplating service. Terminal product forms include rectangular electroplating process tanks, chemical etch tanks for aluminium conversion coating, secondary containment trays, and axial ventilation ductwork for acid-exhaust systems.