| HS Code | 151459 |
| Grade | PP S2040 |
| Polymertype | Polypropylene homopolymer |
| Physicalform | Pellets |
| Fibergrade | Yes |
| Meltflowrate | 38 g/10 min (230 °C/2.16 kg) |
| Density | 0.90 g/cm³ |
| Meltingpoint | 165 °C |
| Vicatsofteningtemperature | 152 °C |
| Heatdeflectiontemperature | 100 °C at 0.45 MPa |
| Tensilestrengthatyield | 34 MPa |
| Elongationatyield | 10% |
| Flexuralmodulus | 1500 MPa |
| Notchedizodimpactstrength | 20 J/m |
| Ashcontent | ≤0.03% |
| Moisturecontent | ≤0.05% |
| Isotacticity | ≥96% |
As an accredited Polypropylene Fiber Grade PP S2040 factory, we enforce strict quality protocols—every batch undergoes rigorous testing to ensure consistent efficacy and safety standards.
| Packing | Polypropylene Fiber Grade PP S2040 packed in 25 kg PP woven bags, 40 bags per pallet, totaling 1,000 kg per pallet. |
| Container Loading (20′ FCL) | 20′ FCL loading: Polypropylene Fiber Grade PP S2040 in 25 kg bags, palletized, approximately 17–18 MT net per container. |
| Shipping | Polypropylene Fiber Grade PP S2040 is shipped as non-hazardous polymer pellets in moisture-proof 25 kg bags or jumbo bags. Store in a cool, dry, ventilated area away from direct sunlight, heat, and contamination. Handle with care to avoid bag damage; no special dangerous-goods labeling required. |
| Storage | Store Polypropylene Fiber Grade PP S2040 in a cool, dry, well-ventilated area away from direct sunlight, heat, sparks, flames, and strong oxidizing agents. Keep containers tightly closed and protected from moisture and contamination. Avoid prolonged high-temperature exposure and prevent static buildup. Maintain good housekeeping, use first-in, first-out stock rotation, and follow local regulations and the manufacturer’s SDS. |
| Shelf Life | Polypropylene Fiber Grade PP S2040 typically has a 24-month shelf life when stored dry, cool, and protected from sunlight. |
For hygiene absorbent articles, S2040 with a melt flow rate reported between 32 g/10 min and 36 g/10 min under ISO 1133-1:2022 at 230°C/2.16 kg is processed on single-screw extruders with L/D ratios of 30:1–36:1 and melt filtration units using screen packs of 60/100/60 mesh. The resin is compounded with a titanium dioxide masterbatch at 2.0–4.0 wt% to reach specified opacity and whiteness, a slip/antistat masterbatch at 0.5–1.0 wt% to reduce web-to-metal friction on draw frames, and, for topsheet constructions requiring controlled liquid strike-through, a hydrophilic surfactant masterbatch at 1.0–2.0 wt%. Melt temperature at the spin beam is held between 225°C and 240°C; excursions above 250°C initiate thermo-oxidative chain scission, observed on production lines as reduced filament tenacity and increased spherulite formation in bonded web. The spunbond process routes the melt through spinnerets with hole diameters of 0.3–0.6 mm, quench air at 12–18°C, and aerodynamic slot drawing to filament speeds producing final fiber diameters of 15–25 μm. Thermal bonding on a heated calender with a bonding temperature range of 135–150°C produces point-bonded nonwovens with basis weights from 10–25 g/m². The lower calender threshold near 133°C is a processing boundary because bond strength becomes insufficient and surface abrasion releases loose fibers; above 150°C, film-like over-bonding reduces air permeability and conformability. If storage relative humidity exceeds 60%, pre-drying at 80°C for 2–4 h is required to prevent surface moisture-induced bubble formation. Polyethylene contamination above 2 wt% must be rejected before extrusion because it forms gel particles at processing temperature and clogs screen packs. Compliance for disposable diaper and adult incontinence components is governed by ISO 9092:2019 for nonwoven construction, ISO 9073-3 for tensile strength, ISO 9073-6 for liquid absorption behavior, and OEKO-TEX Standard 100 Class I for skin-contact textiles. Terminal products include spunbond topsheets, backsheet support layers, leg cuffs, waistband laminates, and acquisition/distribution layer carriers in baby diapers, feminine hygiene pads, and adult incontinence briefs.
Because medical protective apparel is qualified by barrier performance rather than aesthetic hand feel, the S2040 spunbond layer is specified in 25–45 g/m² fabric weights and is processed with a formulation consisting of 100 phr S2040, 1.5–3.0 wt% titanium dioxide masterbatch for opacity, 0.5–1.0 wt% antistat masterbatch to control static discharge during lamination, and 0.2–0.5 wt% nucleating/clarifying masterbatch to reduce post-extrusion shrinkage. The spunbond process uses melt temperature of 230–245°C, quench air at 10–15°C, and calender bonding at 138–148°C. Published processing bulletins recommend that line speed not exceed 400 m/min for lightweight medical webs because draw resonance and edge neck-in produce basis-weight variation greater than ±8%. The finished fabric or composite must satisfy EN 13795-1:2019 for surgical gowns and drapes, AAMI PB70:2022 for liquid barrier performance classes, ISO 16604:2004 for resistance to blood-borne pathogen penetration, and ISO 10993-5 for in vitro cytotoxicity when used in direct skin contact. Terminal product forms include single-use isolation gowns, surgical drapes, scrub suit reinforcement panels, shoe covers, and protective aprons. A documented operational boundary is that fabric converters must not exceed 5 wt% post-industrial regrind in the outer spunbond layer where barrier consistency is critical; published data for the exact influence of higher regrind fractions on hydrostatic head in S2040-based medical webs is limited.
Thermal stabilization of S2040 during staple fiber extrusion for needlepunched geotextiles requires melt temperature at 235–250°C and spinneret hole diameters of 0.4–0.8 mm to produce continuous filaments that are quenched and then drawn at ratios of 3.0:1–4.5:1. Draw ratio stability in this configuration is limited by the moderately broad molecular weight distribution of fiber-grade homopolymer; when draw ratio exceeds 4.5:1, the filament breaks at the draw stand and generates waste coils. The formulation consists of 100 phr S2040, 2.0–4.0 wt% carbon black masterbatch for UV resistance, 0.2–0.5 wt% phenolic/phosphate antioxidant masterbatch to suppress chain degradation, and 0.05–0.15 wt% calcium stearate as acid scavenger. After drawing, filaments are crimped, cut into staple lengths of 50–90 mm, and carded into webs with basis weights of 150–500 g/m². Needlepunching on a needleboard density of 2,500–4,000 needles/m and punch density of 120–300 punches/cm² entangles the staple to produce geotextiles with grab tensile strengths from 8–25 kN/m depending on web weight. Compliance is anchored to the standards matrix shown below. Terminal products include separation geotextiles, drainage composites, erosion control blankets, silt fence, and protection layers for geomembranes.
| Standard designation | Function | Property assessed |
|---|---|---|
| ISO 10318-1 | Geosynthetics terminology and classification | Material class |
| EN 13249:2016 | Road construction geotextile functions | Separation and filtration |
| ASTM D4632/D4632M-15a | Grab tensile test method | Tensile strength |
| ISO 13433 | Dynamic puncture test method | Puncture resistance |
| ASTM D4355-21 | Xenon-arc UV degradation test | Retained strength after exposure |
In automotive needlepunch carpet converting, coarse-denier polypropylene staple derived from S2040 is formulated with 100 phr S2040, 3.0–6.0 wt% automotive color masterbatch, 1.5–3.0 wt% hindered amine light stabilizer masterbatch, and 4.0–7.0 wt% halogen-free flame retardant masterbatch to meet interior flammability requirements. The staple fiber process operates at melt temperature of 230–245°C, draw ratio of 3.0:1–4.0:1, and cut length of 60–120 mm. Carded webs are needlepunched to 200–600 g/m² and then back-coated with latex to reduce fiber shedding. Compliance is governed by FMVSS 302, ISO 3795:1989 for burning behavior, VDA 278:2011 for VOC and FOG emission limits, and IATF 16949 as the production quality management framework. Terminal products include vehicle floor carpet, trunk liners, wheel arch liners, and parcel shelf covers.
Selection of S2040 for agricultural spunbond crop cover requires long-duration outdoor exposure to be addressed through the HALS masterbatch loading rather than through post-fabrication treatment. The formulation uses 100 phr S2040, 3.0–6.0 wt% hindered amine light stabilizer masterbatch based on a 10% active concentrate, 0.2–0.5 wt% phenolic antioxidant masterbatch, and 0.5–1.0 wt% slip agent to stabilize web handling during winding. Melt temperature is maintained at 225–240°C, quench air at 14–20°C, and calender bonding at 130–145°C; typical web weight is 17–30 g/m². The HALS addition ratio is the critical variable: below 3 wt%, surface embrittlement has been observed after 800–1,200 h of accelerated weathering under ASTM G154-23; above 6 wt%, melt viscosity inhomogeneity and die lip accumulation reduce filament denier consistency. Published data for the exact field lifetime of this specific S2040/HALS configuration is limited. Compliance standards include ISO 9092:2019 for nonwoven crop cover construction and EN 13206:2017 where applicable to flexible agricultural cover sheets. Terminal products include floating row covers, insect barriers, frost protection blankets, and weed control mats.
In SMS face mask and surgical mask production, S2040 is restricted to the outer and inner spunbond layers, not the meltblown core. A standard 30 g/m² SMS structure comprises approximately 10 g/m² S2040 spunbond top layer, 10 g/m² meltblown polypropylene middle layer, and 10 g/m² S2040 spunbond bottom layer. The S2040 layer formulation uses 100 phr S2040, 1.0–2.0 wt% titanium dioxide masterbatch for opacity, and 0.5–1.0 wt% antistat masterbatch to reduce electrostatic charge during high-speed converting. The spunbond layer process is operated at 228–240°C melt temperature with calender bonding at 132–145°C. Compliance for finished masks includes ASTM F2100-21 for medical face mask performance, EN 14683:2019 for bacterial filtration efficiency and differential pressure, and ISO 10993-1:2018 for biocompatibility evaluation. Terminal products include Type IIR surgical masks, particulate respirator prefilter layers, and FFP2/FFP3 respirator outer layers. The operational limitation is clear: S2040 is unsuitable for the meltblown layer because its 32–36 g/10 min MFR falls far below the 800–1,500 g/10 min melt flow range required for conventional meltblown polypropylene grades.
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Polypropylene Fiber Grade PP S2040 is an isotactic homopolymer formulated for continuous-filament spunbond nonwoven production and staple-fiber extrusion. The grade is controlled-rheology, meaning that post-reactor degradation has shifted the molecular weight distribution toward a lower average chain length and a narrower dispersity. A representative melt flow rate is 38 g/10 min when measured under ISO 1133-1:2022 conditions of 230°C and 2.16 kg. Density is 0.90 g/cm³ under ISO 1183-1:2019 at 23°C. The resin is supplied as pellets with low residual catalyst and low ash to limit screen-pack pressure rise during high-output extrusion. Table 1 lists representative physical properties that appear in producer technical bulletins; these values are lot averages and should not be treated as guaranteed sales specifications.
| Property | Standard method | Unit | Representative value |
|---|---|---|---|
| Melt flow rate | ISO 1133-1:2022 | g/10 min | 38 |
| Density | ISO 1183-1:2019 | g/cm³ | 0.90 |
| Tensile stress at yield | ISO 527-2:2012 | MPa | 33 |
| Tensile strain at yield | ISO 527-2:2012 | % | 12 |
| Flexural modulus | ISO 178:2019 | MPa | 1300 |
| Charpy notched impact strength, 23°C | ISO 179-1:2010 | kJ/m² | 4.0 |
| Vicat softening temperature | ISO 306:2022 A50 | °C | 95 |
| Melting temperature, DSC | ISO 11357-3:2018 | °C | 163 |
| Ash | ISO 3451-1:2019 | % | ≤0.02 |
| Moisture content | ASTM D6980-19 | % | ≤0.05 |
The method codes in Table 1 are the version designations current at the time of publication. Lot certificates should be checked for the exact test method revision and for any property modifications made by the producer. For fiber processing, the two controlling properties are the melt flow rate and the ash content, because they affect die pressure and spin pack life. The tensile and flexural data are less relevant to nonwoven performance than downstream bonding conditions, but they provide a baseline for comparing lot-to-lot consistency.
Spinnability in PP S2040 is governed by shear viscosity, melt elasticity, and oxidative stability rather than by solid-state tensile properties. At the spinneret, the resin is processed in the melt-temperature range of 230°C to 260°C. Below 225°C, spinline stress rises and filament breaks become frequent at commercial draw ratios above 200:1. Above 270°C, thermo-oxidative chain scission accelerates, lowering melt viscosity beyond the intended controlled-rheology target and producing die drool, shot, and uneven web formation. The stabilizer package in PP S2040 includes a primary phenolic antioxidant and a secondary phosphite process stabilizer; the phosphite reacts with hydroperoxides during extrusion and is consumed as a function of residence time and melt temperature. Prolonged residence above 15 minutes in the barrel reduces stabilizer reserves and shifts the melt flow rate upward, which can alter filament denier control.
Gel-count control is achieved by filtration through the spin pack rather than by resin specification alone. Commercial spunbond lines commonly use screen packs of 25 µm to 40 µm aperture. A resin with uncontrolled gel content will increase pressure drop across the pack and shorten screen life. PP S2040 is manufactured with a low-gel formulation, but no ISO method defines a universal gel threshold for nonwoven PP; buyers usually include a pressure-rise target in incoming inspection protocols. The melt flow rate of 38 g/10 min corresponds to a controlled-rheology resin with low extensional viscosity. In capillary rheometry, polypropylene with this melt flow rate typically shows shear-thinning behavior at shear rates above 100 s⁻¹, but the producer of S2040 does not guarantee a single-point apparent viscosity. Spinline tension is proportional to the ratio of elongation rate to melt strength. A narrow molecular weight distribution reduces the high-molecular-weight fraction that contributes to strain hardening; this is the primary reason PP S2040 can be drawn to fine filaments without frequent melt fracture.
On a typical spunbond line, PP S2040 is gravity-fed into a single-screw extruder with an L/D 30:1 barrier screw and a downstream melt gear pump. Barrel set points from feed to metering zones are commonly 200°C, 220°C, 230°C, 240°C, and 250°C, with spin-beam melt temperature held at 245°C. The gear pump stabilizes melt pressure between 8 MPa and 12 MPa before the spin pack. Quench air at 12°C to 20°C and a relative humidity below 80% stabilizes filament attenuation. Throughput on spunbond lines varies from 200 kg/h on narrow laboratory beams to above 500 kg/h on wide production beams. The extruder barrel diameter is typically 90 mm to 150 mm, with L/D ratio 30:1 to 36:1. A barrier screw with a Maddock mixing section improves melt homogeneity. The melt gear pump should be sized to maintain inlet pressure between 3 MPa and 8 MPa; if the inlet pressure drops below 3 MPa, feeding instability can produce denier variation. Quench air velocity between 0.3 m/s and 0.8 m/s is typical for polypropylene spunbond.
The resin is used in hygiene coverstock, medical barrier fabrics, filtration media, geotextiles, agricultural crop covers, and furniture upholstery. Nonwoven mechanical performance is then determined by fabric construction, calendar bonding temperature, and bonding pressure; relevant test methods include EN ISO 9073-1 for mass per unit area and EN ISO 9073-3 for tensile properties. PP S2040 itself does not confer high durability in long-term outdoor exposure without UV stabilization additives; geotextile and agricultural applications require additional UV masterbatch.
When a plant switches from a lower-MFR fibre grade such as PP S2025 or from a general-purpose homopolymer, the differences are rheological and thermal, not merely a change in setpoint. PP S2040 typically has a melt flow rate of 38 g/10 min, while a lower-MFR fibre grade may be near 25 g/10 min and a general-purpose homopolymer may be 3 g/10 min. The higher MFR reduces melt pressure at the die, permits lower melt temperature, and allows higher line speed for finer filament counts. The lower melt strength of PP S2040 also reduces die swell and delays melt fracture, which is advantageous in high-velocity air attenuation but limits sag resistance in processes such as thick sheet extrusion or blow moulding.
| Parameter | PP S2040 fibre grade | Lower-MFR fibre PP | General-purpose PP homopolymer |
|---|---|---|---|
| Melt flow rate, ISO 1133-1 | 38 g/10 min | 25 g/10 min | 3 g/10 min |
| Melt strength | Lower, controlled-rheology | Moderate | Higher, broad molecular weight distribution |
| Typical die melt temperature | 230°C–260°C | 240°C–270°C | 250°C–280°C |
| Spunbond draw behaviour | Fine denier at high line speed | Coarser denier, lower speed | Unsuitable above 150 m/min |
| Gel/filter pressure risk | Low, specified by screen-pack rise | Low to moderate | Not controlled for spin pack life |
| Primary application | Spunbond nonwoven, staple fibre | Staple fibre, low-speed spunbond | Cast film, strapping, injection |
The difference in melt flow rate alone does not capture molecular architecture. PP S2040 is produced by controlled visbreaking with an organic peroxide, yielding a narrower molecular weight distribution and a reduced high-molecular-weight tail. A general-purpose homopolymer retains a broader distribution and higher melt elasticity, which promotes draw resonance and spinline tension at high attenuation speeds. Published data for the polydispersity index of S2040 is limited because producers rarely disclose molecular weight distribution, but the processing differences are consistently observed in equipment trials. Operators should monitor extruder motor load, die pressure, and spinline tension during transition; these variables respond before web defects become visible.
Resin drying is not normally required because polypropylene equilibrium moisture uptake is below 0.01 wt% at 23°C and 50% RH. However, cold pellets moved into a warm plant can carry surface condensation. A dehumidified-air hopper dryer set at 80°C for 2 hours removes surface moisture; drying beyond 4 hours provides no benefit and may increase energy cost. Barrel zone temperatures above 260°C should be limited to startup purges; continuous operation above 270°C accelerates oxidative chain scission and can shift the melt flow rate uncontrollably. PP S2040 is not recommended for direct food-contact use unless the specific lot and its antioxidant package are cleared under FDA 21 CFR 177.1520 or equivalent. The resin contains a stabilization package that is consumed during processing; reprocessing repeated regrind or incorporating high fractions of recycled material can alter the melt flow rate and ash content. Avoid direct contact with copper alloys above 250°C because copper ions catalyze thermo-oxidative degradation of polypropylene. The grade is also not intended for long-term hot-water pressure service above 80°C.
Process control in PP S2040 spinning is best judged by die pressure, melt temperature at the spin beam, and quench air stability. A sudden die-pressure rise while extruder speed and melt temperature remain constant indicates gel accumulation or additive fouling; the spin pack should be inspected at a pressure increase of 10% to 15% over baseline. Filament breaks that concentrate near the spinneret edge suggest uneven quench air distribution rather than resin deficiency. Web defects known as shot, drips, and un-bonded filaments are common markers of melt-temperature excursions above 270°C, while weak calendar bonding may indicate excessive quench cooling or an incorrect bonding temperature. During startup and grade transitions, purging with a lower-MFR commodity polypropylene is standard practice; this removes degraded resin from hot barrel surfaces. A gear pump inlet pressure below 3 MPa indicates insufficient extruder feeding or bridging in the feed throat, while a pressure above 15 MPa signals excessive screen pack resistance or a blocked filtration medium. These operational boundaries are equipment-specific, and published data for this exact configuration is limited; plant trials with the installed die width and throughput determine the final process window.
Compared with PP S2025, PP S2040 provides higher throughput at equivalent extruder speed and lower pressure drop across the spin pack, but it produces filaments with lower melt strength. This trade-off makes PP S2040 more suitable for fine-denier spunbond fabrics where high line speed and uniformity dominate, and less suitable for processes requiring high melt extensional strength such as open-staple spinning with long cooling zones. Compared with metallocene-catalyzed polypropylene, PP S2040 may have lower impact strength and lower clarity; metallocene grades are selected when fabric softness, elasticity, or ductile performance requires a more uniform comonomer distribution. In high-speed spunbond, PP S2040 is selected over PP S2025 when target filament denier is below 2.0 dpf and line speed exceeds 150 m/min. At lower line speeds or for coarser nonwoven, a lower-MFR grade may offer higher web loft and higher tear resistance because the higher melt strength produces larger filament attenuation diameter. These are operational trade-offs, not evidence of absolute superiority.
