Polypropylene

What is Polypropylene?

Polypropylene (PP) is the first stereoregular polymer to have reached industrial

importance. It is a thermoplastic, meaning that it becomes pliable or moldable at a
certain elevated temperature and solidifies upon cooling. Polypropylene is
processed into film for packaging and into fibres for carpets and clothing.
PP belongs to the group of polyolefins and is partially crystalline and non-polar. It
has similar properties as polyethylene, but it is harder and more heat resistant. It is
a white rugged material with a high chemical resistance. Poly propylene is the
second-most widely produced commodity plastic (after polyethylene) and it is often
used for product packaging and labeling.

Polypropylene is manufactured from propylene gas in presence of a catalyst such

as titanium chloride. Polypropylene is a by-product of petroleum.
Technology of Polypropylene Fibers

• Polypropylene fibers are industrially prepared by spinning from the melt by the
conventional low oriented yarn (LOY) or partially oriented yarn (POY) methods,
further by aerodynamic procedures, such as spun bonded yarn or using the
melt-blown technology.

• The polymer is melted exclusively in extruders placed vertically or horizontally

and having a screw diameter of Φ= 60-150 mm. In standard extruders, the ratio
 of the length and diameter (LID) of the screw is 28-30. The melt temperature
varies from 220- 240°C (for resins of MFI 25-35 g/10 min) to 290-300°C (for
resins of MFI 6-8 g/10 min).

• The mass coloration is usually connected with spinning process. During melting
of the polymer, its molecular weight decreases by about 20% on the average
without consequences for its fiber-forming properties.

• The first melt filtration of the PP occurs at the head of the extruder and the last
one at the spinning head.
Melt Flow Index

The melt flow index (MFI) or melt flow rate (MFR) is a measure for the ease of flow of melted plastics.
It is often used in the plastic industry for quality control of thermoplastics. The method is described in
the standards ASTM D1238 and ISO 1133. A small sample of about 5 grams is heated above its
melting or softening point and forced to flow through a capillary using a piston actuated by a specified
weight, usually 2.16 kg or 5 kg. The weight of melt in grams flowing through the capillary in 10 minutes
is the melt flow index.
Melt Flow Indexer
Spinning and Drawing.
• The polymer from which low molecular weight material has been dissolved out is melted, and
spun by gear pump pressure through spinnerets.

• Melt spinning is usual, partly because it is cheap, mainly because polypropylene of high D.P.
is diffcult to dissolve.

• The polymer before spinning is about 50 per cent crystalline; after having been spun, the fibre
 has a 33 per cent crystalline content.

• It is stretched or drawn and this increases the crystallinity to 47 per cent; then it is annealed,
i.e., given a final heat treatment in which the higher temperature increases the mobility of
the polymer molecules and gives them an opportunity to re-arrange themselves a bit and
pack together better; this increases the crystallinity to 68 per cent.

• During the spinning the polymer becomes birefringent as would be expected from the
orientation induced by the traction of the jet, and the degree of birefringence is increased by
the drawing process, but the highest value obtained is 0.035, whereas " theoretically " it
could be 0.067.

• This discrepancy is interpreted as indicating that the molecules never open out completely
but exist in a stable helical form.
Main phases of the production process:

Metering: One or more spinning gear pumps receives the molten polymer and sends it
through the spinning pack to homogenize the product, feed the spinning pack at a constant rate,
and prevent fluctuation due to screw extruder. Polymer, in the form of pellets or granules, is fed
into an extruder, where it is melted and pumped via a positive displacement pump to the melt
spin pack.
 Spinning: The spin pack consists of filters and channels that supply molten polymer to a
multifilament spinneret. The distributor distributes the molten polymer over to die surface. The
diameter of the die varies from 0.5 to 1.5 mm, depending on the denier required.
Quenching: Newly extruded molten filaments that exit the spinneret are cooled, usually by
cool air, without damaging the filaments, and solidified. The cooling zone can be as simple as a
region in which quenching air is blown across the filaments, or it may be an elaborate chamber
constructed so the cooling environment can be strictly controlled.
Finishing: In order to improve antistatic and reduce abrasion.
Hot Stretching: Process of enhancement of the physico-mechanical properties.
Crimping: Improving the bulk.
Thermosetting: Treatment in hot air or steam that removes the internal stresses and relaxes
fibers. The resultant fibers are heat-set with increased denier.
Cutting: The fibers are cut into 20 to 120 mm length, depending on whether they are intended
for cotton or woolen system.
PP has the following properties:

low physical properties

low heat resistance
excellent chemical resistance
 translucent to opaque
low price
easy to process

Polypropylene chips can be converted to fiber/filament by traditional

melt spinning process.

The first fibres from polypropylene were introduced to the textile

industry in the 1970s and have become an important member on
the synthetic fibres market.
Polypropylene fiber displays good heat insulating properties and is highly resistant
to acids, alkalies, and organic solvents. The fiber is sensitive to heat and light, but
the resistance to these agents can be influenced by added stabilizers. Filaments
and monofilaments are used in the manufacture of cables, nets, filter fabrics and
upholstery. In staple form, the fiber is used in carpeting, blankets, outerwear fabrics,
knitwear, and filter fabrics. Textured polypropylene fiber is mostly used for carpet
manufacturing.
Growth in demand of PP is very high, and it is mainly due to its distinct technical
features:

light weight
strong
hydrophobic
flexible
has low thermal conductivity etc.

Because of all this, it is widely used to make undergarments, jackets for outerwear,
swimming suits, filters, bags and diapers.
Some of the main PP fiber characteristics:

⮚ Gives good bulk and cover

⮚ Resistant to abrasion, deterioriation from chemicals, mildew, perspiration, rot,
stain, soil and weather conditions
⮚ Resistant to bacteria and micro-organisms
⮚ Colorfast
⮚ Quick drying
⮚ Anti-static behavior
⮚ Thermally bondable
⮚ Strong
⮚ Dry hand
⮚ Comfortable and lightweight
Mechanical Properties

Polypropylene fibers are produced in a variety of types with different tenacities in order to suit varying
market requirements. Fibers for general textile uses have tenacities in the range of 4.5-6.0 g/den.
High tenacity yarns up to 9.0 g/den are produced for the use in ropes, nets and other similar
products. High performance PP fibers have been made with high strength and high modulus.

The techniques include ultra-drawing, solid state extrusion and crystal surface growth. It is possible
to make the filaments with tenacities over 13.0 g/den.

Table of Mechanical Properties of PP Fibres

Tensile strength (gf/den) 3.5 to 5.5
 Elongation (%) 40 to 100
Abrasion resistance good
Moisture absorption (%) 0 to 0.05
Softening point (ºC) 140
Melting point (ºC) 165
Chemical resistance generally excellent
Relative density 0.91
Thermal conductivity 6.0 (with air as 1.0)
Electric insulation excellent
Resistance to mildew and moth excellent
The degree of orientation achieved by drawing has influence on the mechanical properties of polypropylene
filaments. The higher the degree of stretch, the higher the tensile strength and the lower the elongation.
Commercial monofilaments have an elongation at break in the region of 12-25%. Multifilaments and staple
fibers are in the range of 20-30% and 20-35%.
How Is Polypropylene Fibre Used?

Polypropylene fibre can be used in a wide range of applications. These are

only some examples:

❑ Automotive industry
❑ Carpeting
❑ Packaging
❑ Fiber, filament, film, pipes
❑ Upholstery fabrics and bed covers
❑ Toys, bottle caps, disposables
❑ Hygiene
❑ Apparel
❑ Technical filters
❑ Woven bags
❑ Ropes and twins
❑ Tapes
❑ Construction fabrics
❑ Absorbent products (diapers)
❑ Furniture industry
❑ Agriculture