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Plastics & Elastomers

Comprehensive Guide on Polyethylene (PE)

Polyethylene (PE) is one of the most popular thermoplastic materials. It is available

in different crystalline structures, referred to as HDPE, LDPE, and LLDPE. This com‐
modity plastic is produced by addition or radical polymerization. It is used in a large
array of applications: plastic containers, bottles, bags, plastic toys, etc.

Overview

What is Polyethylene?

Molecular Structure of Polyethylene

Polyethylene is a type of polyolefins. This is a lightweight, durable plastic that is often used for
frozen food bags, bottles, cereal liners, yogurt containers, etc. Look around you, all plastics with
recycling codes 2 and 4 are made of polyethylene. PE plastics comes with different crystalline
structures. We will review subfamilies (HDPE, LDPE, LLDPE, etc.) in a minute.

How is PE made?

PE is made from the polymerization of ethylene (or ethene) monomer. Polyethylene chemical for‐
mula is (C2H4)n.

Polyethylene chains are produced by addition or radical polymerization. Both Ziegler-Natta and
Metallocene catalysts are possible synthesis methods.

Ziegler-Natta
Polymerization
Or Metallocene
Structure of Polyethylene
Structure of PE Monomer Catalysis
(C2H4)n
C 2H 4
A great variety of crystalline structure can be achieved. We will review how it impacts the final per‐
formance.

Common Types of Polyethylene (PE)

Depending on its density and branching, different polyethylene grades can have very different
performance from one another.
PE grades are therefore classified as follows.
(click on the polymer name to learn about them in detail)

Branched Versions
Low-density polyethylene (LDPE)
Linear low-density polyethylene (LLDPE)

Linear Versions
High-density polyethylene (HDPE)
Ultra-high-molecular-weight polyethylene (UHMWPE)

Cross-linked polyethylene (PEX or XLPE)

In addition, PE is also available in other types, such as but not limited to:

Medium-density polyethylene (MDPE)

Ultra low-density polyethylene (ULDPE)
High-molecular-weight polyethylene (HMWPE)
Metallocene polyethylene (mPE)
Chlorinated polyethylene (CPE)

At the moment, the later ones aren't discussed in this guide, but a detailed list of commercial available
grades is just a click away!

Comparison Between Main Types of Polyethylene

  LDPE LLDPE HDPE

Low Density Linear Low Density High Density

Polymer Full Name Polyethylene Polyethylene
 Polyethylene

High Degree of short Linear (or Low degree

High Degree of short
Structure chain branching + of short chain
chain branching
long chain branching branching)

Ziegler-Natta catalyst
in:
Using radical polymer‐
Using Ziegler-Natta - Single-stage poly‐
ization using tubular
Catalyst and process catalyst or metal‐ merization
method or auto clave
locene catalyst - Multi-stage polymer‐
method
ization or a Cr or
Phillips-type catalyst

Density 0.910-0.925 g/cm3 0.91-0.94 g/cm3 0.941-0.965 g/cm3

Low crystalline and

High crystalline and
high amorphous (less Semi-crytalline, level
Crystallinity low amorphous (>90%
than 50-60% between 35 to 60%
crystalline)
crystalline)

Flexible and good

transparency Excellent Chemi‐
Good moisture As compared to cal Resistance
barrier properties LDPE, it has: High tensile
High impact higher tensile strength
Characteristics strength at low strength Excellent mois‐
temperature higher impact ture barrier
Excellent resis‐ and puncture properties
tance to acids, resistance Hard to semi-
bases and veg‐ flexible
etable oils

Recycling Code

High performance
bags, cushioning
Shrink wrap, films,
films, tire separator
squeezable bottles
films, industrial liners,
General Applications garbage bags, extru‐
elastic films, ice bags,
sion moldings, and
bags for supplemental
 laminates packaging and Molecular weight
garbage bags distribution is rel‐
atively narrow,
has applications
in injection mold‐
ings or flat yarns,
and the latter
type

Molecular weight
distribution is
wide, is used to
make film prod‐
ucts, hollow plas‐
tic products and
pipes

Commercial
LDPE Grades LLDPE Grades HDPE Grades
Products

Now when the basic distinction is clear, find out in detail about these 3 types of poly‐
ethylene and see which one matches the best with your final application needs.
Back to Top

High density polyethylene (HDPE)

High Density Polyethylene (HDPE) is a cost-effective thermoplastic with linear structure and no or
low degree of branching. It is manufactured at low temperature (70-300°C) and pressure (10-80
bar) & derived from either modifying natural gas (a methane, ethane, propane mix) or catalytic
cracking of crude oil into gasoline.

Modifying natural gas (a methane, ethane, propane mix) or

The catalytic cracking of crude oil into gasoline 

HDPE is produced majorly using two techniques: Slurry Polymerization or Gas Phase Polymeriza‐
tion.

High Density Polyethylene Molecular Structure

High density polyethylene is flexible, translucent/waxy, weather resistant, and displays toughness
at very low temperatures.

Properties of High Density Polyethylene

1. HDPE Melting point: 120-140°C

2. Density of HDPE: 0.93 to 0.97 g/cm3
3. High Density Polyethylene Chemical resistance:
Excellent resistance to most solvents
Very good resistance to alcohols, dilute acids and alkalis
Moderate resistance to oils and greases
Poor resistance to hydrocarbons (aliphatic, aromatic, halogenated)
4. Continuous temperature: -50°C to +60°C, relatively stiff material with useful temperature
capabilities
5. Higher tensile strength compared to other forms of polyethylene
6. Low cost polymer with good processability
7. Good low temperature resistance
8. Excellent electrical insulating properties
9. Very low water absorption
10. FDA compliant

Feels like HDPE is matching your needs? Check out the list of producers »

Disadvantages of HDPE

Susceptible to stress cracking

Lower stiffness than polypropylene
High mold shrinkage
Poor UV- and low heat resistance
High-frequency welding and joining impossible

However, some grades have been smartly upgraded and offer some improved performance pro‐
files.

Check out grades specifically designed for environmental stress cracking resistance (ESCR), high
stiffness, low shrinkage, UV stabilized…

TIP: In case you have specific requirements, try using the “key feature” facet to narrow down your
search.

Applications of High Density Polyethylene (HDPE)

Excellent combination of properties makes HDPE an ideal material in diverse applications across
industries. Some of the major uses of high density polyethylene include:
 1. Packaging Applications – High Density Polyethylene is used in several packaging ap‐
plications including crates, trays, bottles for milk and fruit juices, caps for food packaging,
jerry cans, drums, industrial bulk containers etc. In such applications HDPE provides the
end product a reasonable impact strength.

Choose HDPE Grade Suitable for Packaging »

2. Consumer Goods – Low cost and easy processability make HDPE a material of choice in
several household/ consumer goods like garbage containers, housewares, ice boxes, toys
etc.

3. Fibers and Textiles – Thanks to its high tensile strength, HDPE is widely used for agricul‐
tural applications, such as in ropes, fishing and sport nets, nets as well as industrial and
decorative fabrics.

Other applications of HDPE include pipes and fittings (pipes for gas, water, sewage, drainage,
sea outfalls, industrial application, cable protection, steel pipe coating, large inspection chambers
and manholes for pipe sewage etc.) due to its excellent resistance to chemical and hydrolysis,
automotive – fuel tanks, wiring & cables – sheeting of energy, telecommunication cables.

Overall, as compared to other variations (LDPE, LLDPE), HDPE is more rigid due to high crys‐
tallinity (> 90%) but this also means it is less transparent.

Low density polyethylene (LDPE)

Low-density Polyethylene (LDPE) is a semi-rigid polymer with low crystallinity (~50-60%). Com‐
pared to HDPE, it has a higher degree of short and long side-chain branching. The LDPE is com‐
posed of 4,000-40,000 carbon atoms, with many short branches.

It is produced at high pressure (1000-3000 bar; 80-300°C) via free radical polymerization process.

Two basic processes used for the production of low-density polyethylene: stirred autoclave or
tubular routes. The tubular reactor has been gaining preference over the autoclave route due to
its higher ethylene conversion rates.

Low-Density Polyethylene Structure

If you need more elasticity but limited strength, then look out for LDPE material. See this exhaus‐
tive list of commercial grades to find the suitable product »

Properties of Low-Density Polyethylene

1. LDPE Melting point: 105 to 115°C

2. Density of LDPE: 0.910–0.940 g/cm3
3. Chemical resistance of LDPE:
Good resistance to alcohols, dilute alkalis and acids
Limited resistance to aliphatic and aromatic hydrocarbons, mineral oils, oxidizing
agents and halogenated hydrocarbons
4. Temperature resistance up to 80°C continuously and 95°C for shorter times.
5. Low cost polymer with good processability
6. High impact strength at low temperature, good weatherability
7. Excellent electrical insulating properties
8. Very low water absorption
9. FDA compliant
10. Transparent in thin film form

Disadvantages of LDPE

The presence of more branching in polymer chain brings certain drawbacks to LDPE perfor‐
mance. Such as:

Susceptible to stress cracking

Low strength, stiffness and maximum service temperature. This limits its usage in ap‐
plications requiring extreme temperatures.
High gas permeability, particularly carbon dioxide
Poor UV resistance
Highly flammable
High-frequency welding and joining impossible
To overcome these challenges, several LDPE grades have been developed with improved proper‐
ties such as UV stabilized, high strength, antiblocking, etc.

Tip: Do not forget to use “Key Features” filter to explore other optimized grades of LDPE

Applications of Low-Density Polyethylene (LDPE)

Low-Density Polyethylene (LDPE) uses majorly revolve around manufacturing containers, dis‐
pensing bottles, wash bottles, tubing, plastic bags for computer components, and various molded
laboratory equipments. The most popular application of low-density polyethylene is plastic bags.

LDPE Applications

1. Packaging – Thanks to its low cost and good flexibility, LDPE is used in packaging industry
for pharmaceutical and squeeze bottles, caps and closures, tamper evident, liners, trash
bags, films for food packaging (frozen, dry goods, etc.), laminations etc.
2. Pipes and Fittings – Low-Density Polyethylene is used to manufacture water pipes and
hoses for the pipes and fittings industry due to Its plasticity and low water absorption.

Other applications include consumer goods - housewares, flexible toys, agricultural films, wiring

& cables - sub-conductor insulators, cable jacketing.

Exploring LDPE grade options for food, medical or cosmetics packaging? We have exhaustive list
for you here »

Linear low density polyethylene (LLDPE)

LLDPE is produced by polymerization of ethylene (or ethane monomer) with 1-butene and smaller
amounts of 1-hexene and 1-octene, using Ziegler-Natta or metallocene catalysts. It is structurally
similar to LDPE.

The structure of LLDPE has a linear backbone with short, uniform branches (unlike longer branch‐
es of LDPE). These short branches are able slide against each other upon elongation without be‐
coming entangled like LPDE.

In the present-day scenario, linear low-density polyethylene (LLDPE) has been quite successful in
replacing Low Density Polyethylene thanks to below mentioned properties.

Properties of LLDPE

Very flexible with high impact strength

Translucent and natural milky color
Excellent for mild and strong buffers, good chemical resistance
Good water vapor and alcohol barrier properties
Good stress crack and impact resistance

Applications of LLDPE: Suitable for a variety of film application such as general-purpose film,
stretch film, garment packaging, agricultural film, etc.

While LLDPE can compete HDPE and LDPE in variety of applications, the below mentioned table
can be useful to ease down your selection process among three PE types.

LLDPE Rela‐ LLDPE Rela‐

Property LDPE HDPE
tive to LDPE tive to HDPE

Tensile Strength
6.9-15.9 21.4-38 Higher Lower
(MN/m2)

Elongation (%) 90-650 50-800 Higher Higher

Impact strength
No break 1.02-8.15 Better Similar
(J/12.7mm)

Environmental stress
- - Better Same
cracking resistance

Heat distortion tem‐

40-50 60-82 15°C higher Lower
perature (°C)

Stiffness (4.5MN/m2) 1.18-2.42 5.53-10.4 Higher Lower

Warpage - - Less Similar

Processability Excellent Good - Easier

Haze (%) 40 - Worse Better

Gloss (45° %) 83 - Worse Better

Near transpar‐ Translucent to

Clarity Worse Better
ent to opaque opaque

Melt strength - - Lower Lower

 Softening point range 85-87 120-130 Narrower Narrower
(°C) Permeability (ml
cm-2 g-1 mil-1 cm) Hg-1
at 25°C X 10-8
H2O vapor 420 55 Better Worse
CO2 60 13 Better Worse

Source: Mukherjee, A. K. et al., Popular Plastics: 15 October, 1985.

Ultrahigh-Molecular-Weight Polyethylene (UHMWPE)

Ultrahigh-molecular-weight polyethylene or UHMWPE has a molecular weight about 10 times

higher (usually between 3.5 and 7.5 million amu) than High Density Polyethylene (HDPE) resins.

When it comes to HDPE vs UHMWPE, they both have a similar appearance, but UHMWPE is an
extremely tough, abrasion-resistant, low-cost plastic thus better suited for industrial or manufac‐
turing applications where friction or wear may be a concern. Find out more about UHMWPE prop‐
erties below.

UHMWPE is synthesized using metallocene catalysts and ethane units resulting is structure
where ethane units are bonded together resulting in UHMWPE structure typically having 100,000
to 250,000 monomer units per molecule.

It has excellent mechanical properties such as high abrasion resistance, impact strength and
low coefficient of friction. 
The material is almost totally inert, therefore it is used in the most corrosive or aggressive en‐
vironments at moderate temperatures. 
Even at high temperatures, it is resistant to several solvents, except aromatic, halogenated
hydrocarbons and strong oxidizing materials, such as nitric acid.
These special properties allow the product to be used in several high-performance
applications.
UHMWPE is suitable for high wear applications such as tubes, liners, silos, containers and
other equipment.

View All UHMWPE High Impact Resistance Grades »

Cross-linked Polyethylene (PEX or XLPE)

High-density crosslinked polyethylene, or XLPE, is a form of polyethylene with crosslinked struc‐

ture specifically designed for critical applications.
Cross linked polyethylene is produced from polyethylene under high
pressure with organic peroxides which creates a free radical. The free
radical generates the crosslinking of the polymer which results in a
resin that is specifically designed for critical applications like chemical
storage pipework systems, hydronic radiant heating and cooling sys‐
tems, and insulation for high voltage electrical cables.

Key Features of XLPE

High and low temperature

Hydrolysis resistance
High electrical and insulation properties
High abrasion resistance
Potable water approved
High extrusion speed on standard lines
Lower cost
Mechanically tougher 

Key Features of XLPE

XLPE cables are by far the most popular and XLPE offer unlimited benefits in several electrical
applications thanks to its moisture-resistance, stress resistance and higher protection against heat
deformation vs other comparable power cables. Especially when comparing XLPE vs PVC cables,
XLPE power cable has:

Much longer service life

Better heat resistance, XLPE power cable can typically stand up to 260°
Has better tensile strength and impact resistance
Higher eligibility for higher rated current applications

Here is the list of all XLPE grades suited for wires and cables »

How to Process PE Plastic?

Various forms of Polyethylene can be used in processes like injection molding, blow molding, ex‐
trusion and various film creation processes such as calendaring or blown film extrusion.
High density polyethylene can be easily processed by injection molding, extrusion (tubes,
blow and cast films, cables, etc.), blow molding and rotomolding. Being and ideal material for
injection molding process, it is majorly used for batch and continuous production.

The most common processing technique used for Low Density Polyethylene is extrusion
(tubes, blow and cast films, cables...). Low Density Polyethylene can be processed by injec‐
tion molding or rotomolding also.

Easily Avoid Disruptions in Your Injection Molding or Extrusion Production Line

Watch Free Video Today!

UHMWPE is processed variously by compression molding, ram extrusion, gel spinning, and
sintering. It conventional methods such as injection, blow or extrusion molding, because this
material does not flow even at temperatures above its melting point.

PE (mainly HDPE) is gradually gaining popularity as a 3D Printing material. Its strength, low
density, and non-toxicity make it ideal for a wide range of 3D printed objects. Additionally, re‐
cycled polyethylene grades and bio-based PE are also used for processing by 3D Printing.
The sheer availability of PE is encouraging efforts to apply this material for additive manufac‐
turing.

HDPE LDPE

Injection Molding

Melt temperature: 200-300°C Melt temperature: 160-260°C

Mold temperature: 10-80°C Post mold shrinkage lies between 1.5 and
Drying is not necessary if stored properly 3.5% 
High mold temperature will improve bril‐ Material Injection Pressure: Up to 150
liance and appearance of the part MPa
Mold shrinkage lies between 1.5 and 3%,
depending on processing conditions, rhe‐
ology of the polymer and thickness of the
final piece

Extrusion
 Melt temperature: 200-300°C Melt temperature: 180-240°C
Compression Ratio: 3:1 Higher melt temperatures are needed for
Cylinder Temperatures: 180-205°C extrusion-coating (280-310°C)
Pre-Drying: No, 3 hours at 105-110 C A three zone screw with an L/D ratio of
(221-230°F) for regrind around 25 is recommended
Melt temperature: 160-260°C
Post mold shrinkage lies between 1.5 and
3.5%

Key Applications of Polyethylene

Polyethylene is the most common plastic produced in the world and manufactured in three differ‐
ent forms - HDPE, LDPE, LLDPE. So, what are the typical applications where you will find PE?.

From electrical insulation, household containers, packaging and films to buckets and bottles, each
form of polyethylene has a wide range of applications as discussed below.

There is no doubt that the excellent combination of properties makes polyethylene an ideal mater‐
ial in diverse applications across industries. Further, it can be engineered according to the end
use requirements.

Among more than 6800 Polyethylene grades available today in the market, you can find PE uses
in the following applications.

Packaging bottles & films - HDPE is widely used to manufacture crates, trays, bottles caps,
drums, etc. While LDPE is majorly used in films, plastic bags, trash bags, and other food
packaging material.

Medical and healthcare - Used to create medical products such as patches, personal pro‐
tective equipment, packaging films, containers, lidstock, and bag headers, etc.

Pipes, Hoses & Fittings - PE parts are used in gas pipes, water pipes, sewer pipes, hoses,
etc. thus offering excellent resistance to chemicals and hydrolysis.

Household products/ Consumer Goods - Garbage containers, kitchenware, housewares,

ice boxes, bowls, buckets, ketchup bottles, etc.

Agriculture - PE films are used widely for greenhouse, walk-in tunnel and low tunnel covers,
and mulching.

Wiring & Cable - Crosslinked polyethylene or polyethylene copolymer resins are useful for
wire and cable insulation and jacketing.
(To see several material options available today, click on application)

Polyethylene Recycling and Toxicity

Resin Identification Code for two main forms of polyethylene are:

LDPE and HDPE are non-biodegradable in nature and contribute significantly to the world’s plas‐
tic waste products. Both the forms of polyethylene are recyclable and used to produce bottles for
non-food items, plastics for outdoor applications, compost bins, etc.

In solid form, Polyethylene is safe and non-toxic in nature but could be toxic if inhaled and/or ab‐
sorbed as a vapor or liquid (i.e., during manufacturing processes).

View several recycled polyethylene grade options available today »

PE (HDPE and XLPE) is widely used for water-related applications. Cross-linked polyethylene has
become popular for potable water in recent years, but PEX requires special fittings and is not re‐
cyclable. High-Density Polyethylene (HDPE) pipes are used for non-potable water applications.
For potable water, HDPE can be used for both hot water and cold-water service applications.

Drive your R&D efforts faster and in the right direction with a clearer view on plastics recycling ma‐
terial advances (volume resins, upcycling additives, recyclate compounds…) and applications
(packaging, consumer goods, automotive…). Take this exclusive course by Industry Expert Don‐
ald Rosato.

Plastic Recycling Innovation: Materials, Technologies, Applications Update

Is polyethylene an ideal plastic for your case?

PE has a broad-application spectrum. It is used for plastic containers, bottles, bags, plastic toys,
films, tubes, plastic parts, laminates, etc.
Basically, if you’re application does not call for extreme performance, PE could be a material of
choice. Under certain circumstances, polyethylene can also compete with engineering plastics. As
you can imagine, given its cost and wide availability, industry has found smart ways to push its
performance limit.

If you’re still hesitating between PE and PP, PET, PVC… let’s review the main reason to choose
PE over other types of plastics; and when it may not be the best choice.

Key Applications

Key Properties

Suppliers

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Rate this Content Publish

GOURDON B Apr 28, 2022

Bon article de synthèse sur LES LES POLYETHYLENES. On aurait peut-être essayé
de mieux
différencier les structures en fonction de la catalyse ZIEGLER/ NATTA et les MELTAL-
LOCENES
et aussi face à la radicalaire. MERCI
[email protected]

macdenis e Feb 27, 2022

GOOD EVENING
PLEASE, I NEED TO KNOW WHO AUTHORED THIS-Advanced Guide for A to Z In-
formation on PE-so that I will cite it correctly and appropriately in my write-up

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